Komatsu PC200-6 Page 390 Shop Manual Download

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Summary of Contents for PC200-6

Page 1: ...c l a s s i c ma c h i n e r y n e t...

Page 2: ...CONTENTS 01 GENERAL 01 I IO STRUCTURE AND FUNCTION IO I 20 TESTING AND ADJUSTMENT 20 I 30 DISASSEMBLY AND ASSEMBLY 30 I 40 MAINTENANCE STANDARD 40 I 00 2 c l a s s i c ma c h i n e r y n e t...

Page 3: ...00 2 01 l 1o 2 1O 27 l 00 2 I 0 01 2 1o 3 1O 28 l 00 2 2 0 01 3 1o 4 1o 29 l 00 2 3 0 01 4 1o 5 1O 30 l 00 2 4 0 01 5 1O 6 1o 31 l 00 2 5 0 01 6 1o 7 1O 32 l 00 2 6 0 01 7 1O 8 1o 33 l 00 2 7 0 01 8...

Page 4: ...O 126 lo 158 IO 63 10 95 IO 127 IO 159 IO 64 IO 96 IO 128 IO 160 IO 65 IO 97 10 129 lo 161 IO 66 IO 98 IO 130 IO 162 IO 67 IO 99 IO 131 lo 163 IO 68 10 100 IO 132 IO 164 IO 69 10 101 10 133 IO 165 IO...

Page 5: ...20 43 20 44 20 45 20 46 20 47 20 48 20 49 20 50 20 51 20 52 20 53 MARK PAGE REV 20 54 20 55 20 56 20 57 20 58 20 59 20 60 20 61 20 62 20 63 20 64 20 65 20 66 20 67 20 68 20 69 20 70 20 71 20 72 20 73...

Page 6: ...7 20 168 20 169 20 170 20 171 20 172 20 173 20 174 20 175 20 176 20 177 JAND REVISED PAGES MARK PAGE REV MARK PAGE REV 20 178 20 179 20 180 20 181 20 182 20 183 20 184 20 185 20 186 20 187 20 188 20 1...

Page 7: ...ARK PAGE REV MARK PAGE REV 0 30 27 0 0 30 58 0 0 30 28 0 0 30 59 0 0 30 29 0 0 30 60 0 0 30 30 0 0 30 61 0 0 30 31 0 0 30 62 0 0 30 32 0 0 30 63 0 0 30 33 0 0 30 64 0 0 30 34 0 0 30 65 0 0 30 35 0 0 3...

Page 8: ...0 30 100 0 0 30 131 0 0 30 162 0 40 30 0 30 101 0 0 30 132 0 40 31 0 30 102 0 0 30 133 0 40 I 40 32 0 30 103 0 0 30 134 0 40 2 40 33 0 30 104 0 0 30 135 0 40 3 40 34 0 30 105 0 0 30 136 0 40 4 40 35 0...

Page 9: ...LIST OF ORIGINAL NEW AND REVISED PAGES MARK PAGE REV MARK PAGE REV MARK PAGE REV 40 51 I 40 53 40 54 MARK PAGE REV 00 2 7 0 c l a s s i c ma c h i n e r y n e t...

Page 10: ...other clothes suited for Melding work JVhen carrying out any operation with two or more Norkers always agree on the operating procedure oefore starting Always inform your fellow workers Before adding...

Page 11: ...ou to slip or can even start fires As a general rule do not use gasoline to wash parts In particular use only the minimum of gasoline when 19 20 21 22 23 24 washing electrical parts Be sure to assembl...

Page 12: ...CTURE AND FUNCTION This section explains the structure and function of each component It serves not only to give an understanding of the structure but also serves as reference material for troubleshoo...

Page 13: ...r distributors Get the most up to date information before you start any work A Safety Special safety precautions are nec essary when performing the work FILING METHOD Caution Special technical precaut...

Page 14: ...ope to slip off the hook during hoisting and a serious accident can result Hooks have maximum strength at the middle portion 100 88 79 71 41 FSO064 3 Do not sling a heavy load with one rope alone but...

Page 15: ...and packing of power train case etc Can l Features Resistance to heat l Used as sealant for flange surfaces and bolts at high temperature locations used to prevent seizure l Used as sealant for heat r...

Page 16: ...13 2 I 4 8 13 3 20 kO 3 31 4 2 9 10 17 6 70 0 7 65 7 56 8 12 19 11 5 I o 112 kg 8 14 22 18 k2 0 177 I9 16 24 28 5 3 279 29 18 27 39 4 383 39 20 30 56 6 549 i58 22 32 76 8 745 78 24 36 94 5 iI0 927 98...

Page 17: ...7 k6 8 11 5 I o 112 k9 8 28 5 k3 279 29 TIGHTENING TORQUE FOR FLAIRED NUTS Use these torques for flaired part of nut cm483 Thread diameter of bolt Width across flat I Tightening torque mm mm kgm Nm 1...

Page 18: ...nal Starting Glow plug 15 1 1 0 45 84 13 36 I 159 7 0 40 1 1 0 80 85 42 73 I 1 35 11 4 Starting 60 1 1 0 80 127 63 84 I 1178 13 6 Starting 100 1 217 I 0 80 109 1 17 6 230 Starting CLASSIFICATION BY CO...

Page 19: ...ecimal 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 IO so multiply 2 165 inches by I...

Page 20: ...504 90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogramto Pound 1 kg 2 2046 lb T kg 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 2...

Page 21: ...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 LitertoU K Gallon le 0 21997 U K Gal Q 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...

Page 22: ...36 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...

Page 23: ...1 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 1...

Page 24: ...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...

Page 25: ...cations PC200 6 PC2OOLC 6 Specifications PC21 OLC 6 Specifications PC220LC 6 Specifications PC25OLC 6 Weight table PC200 6 PC200LC 6 Weight table PC21 OLC 6 Weight table PC22OLC 6 PC25OLC 6 Fuel coola...

Page 26: ...PC200 6 PC200LC 6 PC21 OLC 6 XOlAD024 Unit mm c l a s s i c ma c h i n e r y n e t...

Page 27: ...th 5 980 I 7 075 I E Maximum digging depth of 5 160 5 840 6 435 7 590 cut for 8 level F Maximum digging reach 8 915 9 395 9 875 10 880 G Maximum digging reach at 8 720 9 205 9 700 10 705 ground H Mini...

Page 28: ...PC22OLC 6 PC25OLC 6 GENERAL ASSEMBLY DRAWING F XOlAD024 Q Machine cab height 2 020 2 140 R Engine compartment height 2 255 2 375 S Operator s cab height 2 905 3 020 01 4 c l a s s i c ma c h i n e r...

Page 29: ...220 6 770 7 220 4 955 5 455 6 005 6 455 E Maximum digging depth of 5 550 6 170 6 440 7 210 cut for 8 level F G Maximum digging reach 9 285 9 655 10 180 10 625 Maximum digging reach at 9 090 9 470 10...

Page 30: ...930 5 055 5 860 6 165 digging depth Maximum digging depth of 5 380 5 895 6 475 6 950 cut for 8 level F Maximum digging reach 9 285 9 655 10 180 10 625 G Maximum digging reach at 9 035 9 445 9 980 10 3...

Page 31: ...o top of cab Ground clearance of counterweight Minimum ground clearance Tail swing radius Minimum swing radius of work equipment Height of work equipment at minimum swing radius Length of track on gro...

Page 32: ...motor Swing motor Hydraulic cylinder Hydraulic tank Hydraulic filter Hydraulic cooler PC200 6 PC2OOLC 6 A82001 and up A82001 and up S6D102 1 Ccycle water cooled in line vertical direct injection with...

Page 33: ...l length for transport Overall width Overall width of track Overall height for transport Overall height to top of cab Ground clearance of countenveight Minimum ground clearance Tail swing radius Minim...

Page 34: ...0 60 1066 60 210 155 24 V 5 5 kW 24V 45A 12V 150Ahx2 cwx 4 2 on each side Track roller 9 on each side Track shoe Assembly type triple grouser Variable displacement piston type x 2 gear type x 1 Type n...

Page 35: ...cm Overall length for transport Overall width Overall width of track Overall height for transport Overall height to top of cab Ground clearance of counterweight Minimum ground clearance Tail swing rad...

Page 36: ...7 63 7 I 1 500 2300 f 60 1066 60 212 156 24 V 5 5 kW 24V 45A 12V 150Ahx2 cwx 4 2 on each side Track roller 10 on each side Track shoe Assembly type triple grouser Variable displacement piston type x...

Page 37: ...port Overall width Overall width of track Overall height for transport Overall height to top of cab Ground clearance of counterweight Minimum ground clearance Tail swing radius Minimum swing radius of...

Page 38: ...number Travel motor Swing motor Hydraulic cylinder Hydraulic tank Hydraulic filter Hydraulic cooler f PC25OLC 6 A82001 and up SAGDI 02 I Ccycle water cooled in line vertical direct injection with tur...

Page 39: ...ler cushion l Carrier roller l Track roller l Travel motor l final drive Track shoe assembly Standard triple grouser shoe 600 mm Standard triple grouser shoe 700 mm Wide triple grouser shoe 800 mm Wid...

Page 40: ...nk large assembly Link small assembly Boom pin Arm pin Bucket pin Link pin Machine model Serial number Unit kg PC200 6 PC2OOLC 6 A82001 and up A82001 and up 1 334 1 334 620 620 623 623 187x2 187x2 251...

Page 41: ...unterweight I 290 I 29 I 4 730 Swing machinery I 205 Control valve Swing motor Travel motor I 230 I 9 I 123x2 Track frame assembly l Track frame 0 Swing circle l Idler l Idler cushion 0 Carrier roller...

Page 42: ...assembly Arm assembly Bucket assembly Boom cylinder assembly 753 187x2 Arm cylinder assembly Bucket cylinder assembly 251 155 Link large assembly 78 Link small assembly 22x2 Boom pin 43 10x2 32 10 26...

Page 43: ...l Idler cushion 0 Carrier roller l Track roller l Travel motor l final drive Track shoe assembly Standard triple grouser shoe 600 mm Standard triple grouser shoe 700 mm Wide triple grouser shoe 800 m...

Page 44: ...mblv I 710 I 710 Bucket assembly Boom cvlinder assemblv 747 747 215x2 215x2 Arm cylinder assembly 296 296 Bucket cylinder assembly 183 183 Link large assembly Link small assembly 80 80 22x2 22x2 Boom...

Page 45: ...system PC22O PC250 22 8 SPECIFIED CAPACITY Total amount of oil including oil for components and oil in piping REFILL CAPACITY Amount of oil needed to refill system during normal inspection and mainten...

Page 46: ...ade l Oil viscosity recommendations are as follows The use of multi graded lubricating oil has been found to improve oil consumption control and improve engine cranking in cold temperatures while main...

Page 47: ...determine if local water supplies meet these standards water samples can be tested by water treatment laboratories Softened water that is prepared using common salt sodium chloride contains excessive...

Page 48: ...int 10 95 Travelmotor 10 96 Valvecontrol IO 107 Work Equipment Swing PPC valve 1O l 08 TravelPPCvalve IO 112 ServicePPCvalve IO 116 Safetylockvalve IO 119 PPCaccumulator IO 119 PPC shuttle Travel junc...

Page 49: ...D E E 1 Drive plate 2 Torsion spring 3 Stopper pin 4 Friction plate 5 Damper assembly 6 Air cleaner 7 Intake connector 8 Muffler 9 Rear engine mount 10 Front engine mount OUTLINE l The damper assembly...

Page 50: ...ER RADIATOR OIL COOLER AFTERCOOLER 5 6 1 Reservoir tank 2 Oil cooler 3 Radiator 4 Fan 5 Radiator inlet hose 6 Radiator outlet hose 7 Radiator cap 8 Net 9 Shroud SPECIFICATIONS Radiator CWX4 Oil cooler...

Page 51: ...7 Engine 2 Center swivel joint 8 Travel speed solenoid valve 3 Control valve 9 Swing brake solenoid valve 4 Final drive 10 Swing motor 5 Travel motor 11 Swing machinery 6 Hydraulic pump 12 Swing circ...

Page 52: ...1 sun 21 teeth gear 5 No 1 planetary carrier 6 Cover 7 No 2 planetary carrier 8 Sprocket 9 Floating seal 10 Travel motor 11 Hub 12 No 2 planetary 36 teeth gear 13 Ring gear 84 teeth 14 No 1 planetary...

Page 53: ...No 2 planet 30 teeth gear 7 No 2 ring 80 teeth gear 8 Spacer 9 No 1 ring 80 teeth gear 10 No 1 planet 33 teeth gear 11 Sprocket 12 Floating seal 13 Travel motor 14 Hub 15 Retainer 16 No 1 planetary ca...

Page 54: ...wing circle outer race 115 teeth a Inner race soft zone S position b Outer race soft zone S position 2 8 I w _ d 3 L_ _ _J I I B 8 X09DD022 PC200 6 PC2OOLC 6 PC25OLC 6 SPECIFICATIONS PC21 OLC 6 PC220L...

Page 55: ...eth gear 6 No 2 ring 72 teeth gear 7 Case 8 No 1 ring 72 teeth gear 9 No 1 sun 21 teeth gear 10 Oil level gauge 12 Cover 13 No 1 planetary 25 teeth gear 14 No 1 planetary carrier 15 Coupling 16 No 2 p...

Page 56: ...ller 6 Track shoe 7 Center guard 8 Recoil spring 9 Front guard X14AH022 l The dimensions and number of track rollers may differ according to the model but the basic struc ture is the same l No of trac...

Page 57: ...Select the most suitable track shoe from the following table Standard PC2004 PC220LC 6 PC21 OLC 6 PC22OLC 6 PC25OLC 6 Specifications Category Specifications Category Specifications Category Specificat...

Page 58: ...ers and fallen trees l Travel in Hi speed only on flat ground and when it is impossible to avoid traveling obstacles lower the travel speed to approx half of Lo speed Categories B and C are wide shoes...

Page 59: ...e 13 Oil cooler 14 L H travel motor 15 Arm holding valve 16 Boom holding valve 17 PPC safety valve 18 L H PPC valve 19 R H PPC valve 20 Center swivel joint Travel PPC valve L I 22 23 24 Service PPC va...

Page 60: ...______ __ ___ ___ _ _____ p _E_ lp __________________________ ___ _ __ ____________ qgL p LLFT I c j _______ ___ __ ______ 4 g _ p _c_ PIG D XG 8 4 160 8 cc rev 021xt3 2 r i t r MY ___ ______ _ _ _ _...

Page 61: ...HYDRAULIC CIRCUIT DIAGRAM 2 2 PC250LC 6 TRAVEL MOTOR 150 3 280 0 cc rev JOINT i I i i k B i I I go3 j O L ________ ______ A L _ _ _ s w I t P B 10 14 I c l a s s i c ma c h i n e r y n e t...

Page 62: ...Suction strainer 7 Filter element 6 7 X10BV049 SPECIFICATIONS Tank capacity 230 P Amount of oil inside tank 166 P Pressure valve Relief cracking pressure 0 017 f 0 004 MPa 0 17 f 0 04 kg cm Suction c...

Page 63: ...ntrol pump delivery port PGA f Front LS pressure port PLSF g Rear LS pressure port PLSR h LS control EPC pressure port PSIGR i Main pump suction port PS j LS control EPC pressure port PSIGF b d 5 i i...

Page 64: ...port PDF b Front delivery port PAF c Rear delivery port PAR d Front control pressure port PANF e Rear delivery pressure port PAZR f Front delivery pressure port PAZF g Rear delivery pressure port PA1...

Page 65: ...inside of cylinder block 7 so a difference between volume 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 bloc...

Page 66: ...he cylindrical surface in direction X10AV245 With servo piston 12 the area receiving the pres sure is different on the left and right so main pump discharge pressure self pressure PP is al ways connec...

Page 67: ...HYDRAULIC PUMP 1 Front shaft 2 Cradle 3 Front case 4 Rocker cam 5 Shoe 6 Piston A A B B 7 Cylinder block 8 Valve plate 9 End cap 10 Rear shaft 11 Rear case 12 Servo piston XlOAV246 1O 20 c l a s s i c...

Page 68: ...s designed so that the oil pressure bal ance is maintained at a suitable level The oil inside each cylinder chamber of cylinder block 7 is sucked in and discharged through Cylinder block 7 is supporte...

Page 69: ...delivery pressure inlet port b Port PEN n C l LS valve signal pressure outlet port C Port PA1 Pump delivery pressure inlet port d Port PLS Control valve LS pressure inlet port e Port PSIG LS control...

Page 70: ...P LS VALVE 1 Locknut 2 Plug 3 Spring 4 Spool 5 Sleeve 6 Piston 7 Plug A A 1 2 3 4 5 6 7 B B TVC VALUE 8 Solenoid 9 Piston 10 Sleeve 11 Spring 12 Spring 13 Piston 14 Lever 15 Valve body XlOAV249 IO 23...

Page 71: ...sure PPI self pressure and PP2 other pump pressure are high the NC valve controls the pump so that no more oil that the constant flow in accordance with the dis charge pressure flows even if the strok...

Page 72: ...EPC valve for the LS valve entering port e also changes the pos ition of spool 4 The set pressure of the spring changes Before the engine is started servo piston 1 is pushed l to the right by the spr...

Page 73: ...is connected to the drain port so circuit c h becomes drain pressure PT The operation of the n C valve is explained later l For this reason the pressure at the large piston diameter end of the servo...

Page 74: ...pressure PP rises pump pres sure PP pushes spool 4 to the left When spool 4 moves main pump pressure PP l flows from port d to port c and from port h it enters the large piston diameter end XlOAV255 M...

Page 75: ...of the throttle from port b to port c and from port d to port c of spool 4 is approximately the same At this point the pressure of port c is approximately pump pressure PP XlOAV255 l At this point the...

Page 76: ...ng set pressure of springs 3 and 4 and pump pressure PPI and other pump see pressure PP2 Piston 2 stops at a position where the combined force pushing piston 2 is balanced and the pressure pressure of...

Page 77: ...ssures PPI and PP2 are small piston 2 is on the right At this point port c and port d are connected and the pressure entering the LS valve becomes drain pressure PT If port h and port e of the LS valv...

Page 78: ...ure from port f enters the large piston diameter end of servo piston 9 and servo piston 9 stops XlOAV259 XlOAV258 l If main pump pressures PPl and PP2 increase further and piston 2 moves further to th...

Page 79: ...nd voltage X sent to solenoid 1 in creases further the relationship between pump pressures PPI and PP2 and pump discharge amount Q is proportional to the pushing force of the solenoid and moves in par...

Page 80: ...one the current becomes constant so the force pushing on solenoid push pin 11 is also constant l If main pump pressures PPI and PP2 are low the combined force of the pump pressure and the force of sol...

Page 81: ...is light and is balanced at a position towards the left In this case the pressure from port b flows to port c so servo piston 9 moves to the left to make the discharge amount smaller by the same mecha...

Page 82: ...1 Body 2 Driven gear 3 Housing 4 Drive gear 5 Relief valve 6 Filter 0 b A A SPECIFICATIONS Type BAR 01 6 Theoretical delivery 16 0 cc rev Max delivery pressure 3 23 MPa 33 kg cm XlOBH152 a Suction po...

Page 83: ...ng operations XlOBH142 OPERATION l Chamber A is the pump circuit and chamber C is the drain circuit The oil passes through the ori face in the main valve and fills chamber B l If any abnormal pressure...

Page 84: ...lement x2 3 Case 4 Plug C u A XlOBV050 OUTLINE l One line oil filter is installed to discharge side of the main pump to prevent the entry of dirt and dust and to protect the circuit and equipment A Fr...

Page 85: ...STRUCTURE AND FUNCTION CONTROL VALVE CONTROL VALVE 9 SPOOL VALVE STANDARD 3 SERVICE VALVE hh U pi pii fi h g s p j Y X r i W a b V XlOBH144 IO 38 c l a s s i c ma c h i n e r y n e t...

Page 86: ...valve are installed to this l Each valve forms one unit with the connection bolt and the passages are internally connected so the structure is compact and is very easy to service l This control valve...

Page 87: ...6 Spool bucket 7 Spool service 1 8 Spool service 2 K K 14 XlOBH145 9 Spool service 3 10 Spool return spring 11 Main unload l LS relief valve 12 Main relief valve bucket end group 13 Sub unload valve...

Page 88: ...VALVE J J 4 s EE EE X10BH146 1 LS shuttle valve 2 LS select valve 3 Pump merge divider valve for main 4 Return spring 5 Pump merge divider valve for LS 6 Return spring 7 LS bypass valve 1o 41 c l a s...

Page 89: ...E i H H 1 F F 2 1 1 N N XlOBH147 1 Pressure compensation valve 2 Safety suction valve 3 Check valve for arm regeneration circuit 4 Arm counterbalance valve 5 Suction valve 6 Check valve for boom regen...

Page 90: ...ONTROL VALVE B SPOOL VALVE STANDARD For details of the names of the ports and the main structure see 9 SPOOL VALVE T T T ps pi pi C e i m dd i ii 3 bb e 5 Y m A ee W a b v XlOBH148 IO 43 c l a s s i c...

Page 91: ...TANDARD 1 SERVICE VALVE For details of the names of the ports and the main structure see 9 SPOOL VALVE c e 9 e k 7 O I II pb pd 4 Pf Pih pj PI Pn ee Y bb 5 W a b v XlOBH149 1o 44 c l a s s i c ma c h...

Page 92: ...CONTROL VALVE 8 SPOOL VALVE STANDARD 2 SERVICE VALVE j For details of the names of the ports and the main structure see 9 SPOOL VALVE dd i i d i Ii j i n 6 p 7 r Y X bb a XlOBHlSO 1o 45 c l a s s i c...

Page 93: ...7 9 9 19 XlOBHlBl 1 Suction valve 2 Main valve 3 Piston 4 Piston spring 5 Poppet 6 Poppet spring 7 Suction valve spring 8 Sleeve 9 Adjustment screw 10 Locknut Part No Set Pressure Use 709 70 74600 24...

Page 94: ...System and has the following features 1 Fine control not influenced by load 2 Control enabling digging even with fine control 3 Ease of compound operation ensured by flow divider function using area...

Page 95: ...LS differential pressure APLS becomes lower than the set pressure of the LS valve when the actuator load pressure is high the pump swash plate moves toward the maximum position if it becomes higher t...

Page 96: ...d together this valve acts to make the pressure difference AP between the upstream inlet port and downstream outlet port of the spool of each valve the same regardless of the size of the load pressure...

Page 97: ...ACH FUNCTION OF CLSS Hydraulic circuit diagram for system 1P r_ _I__ ___ I 1 Tc________ P ____ II _ __ ______ _ __ I _I I ____T __ y P 1 ________ 7 II II A 10 1 L_ 1 ___________ __ IIB 1 C I8 XlODD017...

Page 98: ...ion valve Safety suction valve LS shuttle valve R H travel spool Suction valve Boom spool Check valve for boom regeneration circuit Swing spool L H travel spool Arm spool Arm counterbalance valve Chec...

Page 99: ...power max 3A Sub unload valve 3B Sub unload valve 4 Pump merge divider valve 5A Control valve 5B Control valve 6A Actuator 6B Actuator 7A Check valve 7B Check valve 1A j j w _ 61 ij 8 Pump passage 9 L...

Page 100: ...XlODDOlS Operation l The pressure in pump passage 8 is received by area dl at the end face of the valve and area d2 at the end face of piston 13 The pressure in LS circuit 9 is drained to the tank fro...

Page 101: ...pressure x area difference A2 force F2 of spring 16 the poppet moves to the right and seat E opens As a result the pres 2 XlODD020 ssurized oil in LS circuit 9 passes through the notched groove in the...

Page 102: ...ed l When the pilot pressure is applied to port PXl piston 18 and piston 19 move to the left and poppet 15 and piston 17 are brought into close contact so poppet 15 cannot move and the LS control pres...

Page 103: ...d oil in pump passage 1 is stopp ed by valve 4 and cannot escape so the pres sure rises When this pressure becomes larger than the force of spring 5 valve 4 moves to the left ports B and C are interco...

Page 104: ...sure compensation valve 3 is introduced and goes to shuttle valve 7 as the LS pressure When this happens it is con nected to port B of the actuator through valve 4 and LS pressure E actuator load pres...

Page 105: ...b l This reduces the speed of the rise in the LS pres sure and prevents any sudden change in the oil pressure Furthermore a pressure loss is gener ated by the circuit resistance between LS shuttle va...

Page 106: ...ressure is higher than other work equipment l The pressure compensation valve acts as a load check valve Operation l If the pump pressure LS pressure is lower than the load pressure at port C shuttle...

Page 107: ...equipment the LS pressure of port D and the spool meter in at port F in the direction of closing to the right downstream pressure of port B becomes the In other words the valve upstream pressure if sa...

Page 108: ...hen holding pressure at port A LS pressure in spring chamber B l Shuttle valve 3 is pushed to the right by the pressure of port A and the circuit between ports A and C is shut off In this condition th...

Page 109: ...is used Swing The holding pressure at the swing port is low so a pressure compensation valve without a shuttle valve is used Reference When there is no shuttle valve l If there is no shuttle valve pis...

Page 110: ...ing of spool When ratio is more than 1 Spool meter in downstream pressure Max load pressure and oil flow is divided in a proportion less than the area of opening of spool When ratio is less than 1 Spo...

Page 111: ...nder head so that when the boom is lowered the return flow can be used to increase the flow of oil from the pump to the cylinder bottom 8 Regeneration circuit 1 l Operation l When the cylinder head pr...

Page 112: ...OWE XlODD032 Cylinder head pressure Cylinder bottom pres sure digging operations etc Check valve 5 in regeneration circuit 8 acts to shut off the flow from the cylinder head to the cylinder bottom IO...

Page 113: ...ttom pressure l A return flow circuit is provided from the cylinder head to the cylinder bottom so that when the arm is moved in the flow of oil to the cylinder becomes the pump discharge amount the r...

Page 114: ...pening at cylinder bottom pressure and prevents any oil the cylinder head This reduces the pressure flowing back from the cylinder bottom to the loss between the cylinder head and the hydraulic head e...

Page 115: ...port A becomes greater than the force of spring 3 piston 1 moves to the left l Spool 2 is pushed by piston 1 and also moves to the left so ports B and C are interconnected When this happens the press...

Page 116: ...IG are operated simultaneously good simultaneous operation is achieved by restriction of boom spool max stroke Operation 1 When no arm operation When boom raises spool 1 goes to the left c by stroke S...

Page 117: ...o avoid pressure drop of pump F pump flow goes to L H travel motor through travel junction valve Operation 1 With no travel operation When arm digs spool 1 goes to the left by stroke St0 to touch pist...

Page 118: ...ODD039 Function Reduce arm PPC pressure to M V for simultaneous operation of arm dig and boom up Operation 1 Simple operation of arm dig PPC pressure goes to port PI and pushes spool 1 to the right ag...

Page 119: ...to its own l control valve group oil flows Pl and P2 of pressurized oil discharged from the two pumps l At the same time it also carries out merging and dividing of LS circuit pressure l Therefore pr...

Page 120: ...ore the pressurized oil discharged from each pump is sent to its own control valve group Pressure PI To bucket R H travel boom group Pressure P2 To swing L H travel arm group l In the same way LS spoo...

Page 121: ...ure BP is OFF l Pilot pressure BP is OFF so piston 3 is pushed to the left by spring 2 If the swing is then oper ated swing LS pressure PI passes through swing spool 5 and enters port A It pushes valv...

Page 122: ...tion when all work equipment is at neutral Ir The valves and circuits that are not connected with the explanation of the operation of the CLSS hydraulic system have been omitted PLSl 33A I 8 Connectio...

Page 123: ...valve L H travel LS shuttle valve arm Check valve for boom regeneration circuit Check valve for arm regeneration circuit Arm counterbalance valve Main unload valve LS relief valve Main relief valve bu...

Page 124: ...other side neutral li The diagram shows the independent bucket DUMP operation with pump merge 281 f l l Connection of ports when pump flow is divided Connected ports B D Disconnected ports A C TS I 1...

Page 125: ...ad valve is closed Arm group When the pump flow is merged all spools are at neutral so the oil flow from the minimum swash plate angle of main pump 2A is all drained from sub unload valve 30B of the a...

Page 126: ...f cut off control Ir The diagram shows the arm DUMP and standard mode relief with the pump flow merged II II W 1 lift II I l l I 288 205FO6070 l Connection of ports when pump flow is merged Connected...

Page 127: ...trolled by LS relief valve 288 When the difference a PLS between the pump pressure and LS pressure becomes large main unload valve 28A is actuated to suppress the rise in the main circuit pres sure an...

Page 128: ...wer max relief Ir The diagram shows bucket DUMP relief with the pump flow divided t PLSl I L I I 1 I l Connection of ports when pump flow is divided Connected ports B D Disconnected ports A C IO 82 20...

Page 129: ...relief valve 28B so the LS relief valve is not actuated 2 When the bucket DUMP is operated and the load pressure becomes greater pump pres sure PI and LS pressure PLSI both rise Pi lot pressure PB is...

Page 130: ...ump flow merged boom RAISE Ir The diagram shows the boom RAISE with the pump flow merged PLSl Pl I 1 n 28A 288 205FO6072 l Connection of ports when pump flow is merged TS 1O 84 c l a s s i c ma c h i...

Page 131: ...l 8 even if both pumps are at the maximum swash plate angle the LS dif ferential pressure is set to be smaller than the pump LS control pressure In other words LS differential pressure a PLS is a PLS...

Page 132: ...e diagram shows the swing operated independently with the pump flow divided PLSI 1 I I I I I L I I II rln 28 l Connection of ports when pump flow is divided Connected ports B D Disconnected ports A C...

Page 133: ...swash plate angle the LS differential pressure is set to be smaller than the pump LS control pressure In other words LS differential pressure n PLS is a PLS c pump LS control pressure so the pump swa...

Page 134: ...ndependently The diagram shows the travel operated independently with the pump flow divided 28 TS I 58 l Connection of ports when pump flow is divided Connected ports B D Disconnected ports A C 1O 88...

Page 135: ...Flow of oil from main pump 2B To R H travel spool 7 bucket group The straight travel is compensated by the travel junction valve From the condition in 1 above if the lever on the side being steered is...

Page 136: ...rged compound operation Ir The diagram shows boom RAISE arm IN with the pump flow merged PLSl a Connection of ports when pump I 1O 90 205FO6075 flow is merged Connected ports A D B C I dL c l a s s i...

Page 137: ...s to increase the set pressure of the pressure compensation valve Because of this the pressure between port H or arm spool 11 and port I or pressure compensation valve 17 rises and spool meter in LS d...

Page 138: ...ank e Port B from swing brake solenoid valve XlOAV265 Model item Type Theoretical delivery Safety valve set pressure PC200 6 PC200LC 6 PC22OLC 6 PC21 OLC 6 PC25OLC 6 KMFgOAB 2 87 8 cc rev 27 44 MPa 28...

Page 139: ...Drive shaft 3 Cover 4 Case 5 Disc 6 Plate 7 Brake piston 6 End cover 9 Piston 10 Cylinder 11 Valve plate 12 Air bleed plug 13 Center shaft 14 Center spring 15 Safety valve 16 Check valve 17 Check valv...

Page 140: ...and plate 6 are pushed together and the brake is applied 2 When swing brake solenoid is excited When the swing brake solenoid valve is excited the valve is switched and the pressurized oil from the c...

Page 141: ...From control valve to port B5 Al Cl El A I T2 D2 82 A2 c2 x10zz020 82 To L H travel motor port PA Cl From control valve port A2 C2 To R H travel motor port PA Dl From control valve port A5 D2 To L H...

Page 142: ...enoid valve SPECIFICATIONS Model Item Type Theoretical delivery E Rated speed Brake releasing pressure Travel speed switching pressure Differential pressure D4 xo7zzoo1 PC200 6 PC2OOLC 6 PC21 OLC 6 PC...

Page 143: ...all 11 Brake spring 4 Rocker cam 12 Brake piston 5 Piston 13 Plate 6 Cylinder 14 Disc 7 Valve plate 15 Regulator piston 8 End cover 16 Spring XO7ZZOO2 17 Check valve spring 18 Check valve 19 Counterba...

Page 144: ...x0722003 a T port To tank b PB port From control valve c P port From travel speed solenoid valve d PA port From control valve e T port To tank SPECIFICATIONS Item Model PC25OLC 6 Rated speed Min MaX 8...

Page 145: ...7 Valve plate 8 End cover 9 Regulator valve 10 Spring 11 Brake spring 12 Brake piston 13 Plate 14 Disc 15 Regulator piston 16 Spring D D 1 0 il x0722004 17 Check valve spring 18 Check valve 19 Counter...

Page 146: ...o end cover 8 is shut off by regulator valve 9 Fulcrum a of rocker cam 4 is eccentric to point of force b of the combined force of the propul sion force of cylinder 6 so the combined force of the pist...

Page 147: ...or valve 9 to the left in the direction of the arrow Because of this the main pressure oil from the control valve passes through passage d in regu lator valve 9 enters regulator piston 15 at the botto...

Page 148: ...g travel When the travel lever is placed in neutral coun terbalance valve spool 19 returns to the neutral posrtron and crrcurt to the parking brake IS closed The pressurized oil in chamber A of brake...

Page 149: ...to the engine speed pump discharge amount Operation when pressure oil is supplied l When the travel lever is operated the pressu rized oil from the control valve is supplied to port PA It pushes open...

Page 150: ...n 24age set safety valve Function l When travel is stopped or when traveling down hill the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve but the motor is r...

Page 151: ...ows to chamber MB in the circuit on the opposite side Fig 8 Operation of mechanism for varying set pressure 1 When starting travel high pressure setting When the travel lever is operated the pressuriz...

Page 152: ...r J passes through passage H and escapes to chamber PA from chamber G The piston moves to the left in the direction of the arrow and the set load becomes smaller Be cause of this the set pressure of t...

Page 153: ...travel lever 14 L H work equipment R H PPC valve lever R H work equipment 15 Safety lock valve lever 16 L H PPC valve LS control EPC valve 17 Safety lock lever Hydraulic pump 18 Timing valve i 16 17 L...

Page 154: ...PC2OOLC 6 PC21 OLC 6 PC22OLC 6 PC25OLC 6 XOQDH025 a Port P from control pump b Port T to tank c Port P2 L H Arm IN R H Boom RAISE d Port P4 L H Swing LEFT R H Bucket DUMP e Port PI L H Arm OUT R H Boo...

Page 155: ...TION WORK EQUIPMENT SWING PPC VALVE 6 I a 9 10 1 Spool 2 Metering spring 3 Piston 4 Disc 5 Nut for connecting lever D D X09DH026 7 Joint 8 Plate 9 Retainer 10 Body 11 Filter 1o 109 c l a s s i c ma c...

Page 156: ...is shut off from pump pressure chamber P At almost the same time it is connected to drain chamber D to release the pressure at port P When this happens spool 1 moves up or down so that the force of m...

Page 157: ...essure that corresponds to the lever position When the spool of the control valve returns oil in drain chamber D flows in from fine control hole f in the valve on the side that is not working The oil...

Page 158: ...VEL PPC VALVE a C D 1 D b C e XlOBH155 a Port P from control pump b Port T to tank c Port PI L H travel REVERSE d Port P3 R H travel REVERSE e Port P2 L H travel FORWARD f Port P4 R H travel FORWARD I...

Page 159: ...STRUCTURE AND FUNCTION TRAVEL PPC VALVE 6 5 A A c c 1 Piston 5 Valve 2 Plate 6 Metering spring 3 Collar 7 Centering spring 4 Body 8 Bolt D D XlOBH156 IO 113 c l a s s i c ma c h i n e r y n e t...

Page 160: ...pressure chamber PP At almost the same time it is connected to drain chamber D so the pres sure at port PI escapes As a result spool 1 moves up and down until the force of metering spring 2 is balanc...

Page 161: ...ssure equivalent to the position of the lever When the control valve returns oil in drain cham ber D flows in from fine control hole f of the valve on the side that is not moving It passes through por...

Page 162: ...VE 1 Pin 2 Cam 3 Ball 4 Piston 5 Cover 6 Sleeve 7 Centering spring 8 Metering spring 9 Spool 10 Body a Port T to tank b Port P from control pump c Port A to service valve P d Port B to service valve P...

Page 163: ...port T through fine control hole X of spool 9 When operated l When cam 2 is moved metering spring 8 is pushed by ball 3 piston 4 and sleeve 6 and spool 9 is also pushed down by this l As a result fin...

Page 164: ...at port a and the force at metering spring 8 Therefore metering spring 8 is compressed in proportion to the amount the control lever is moved The spring force becomes larger so the pressure at port a...

Page 165: ...C ACCUMULATOR SAFETY LOCK VALVE PPC ACCUMULATOR 1 Lever 2 Body 3 Seat 4 Ball 5 End cap XlOBH165 6 XlOBH166 1 Gas plug 2 Shell 3 Poppet 4 Holder 5 Bladder 6 Oil port SPECIFICATIONS Gas capacity 400 cc...

Page 166: ...RAVEL JUNCTION VALVE PPC SHUTTLE TRAVEL JUNCTION VALVE 1 PPC shuttle valve 2 Travel junction valve XlOBH167 OUTLINE l The PPC shuttle valve and travel junction valve form a combined structure 1O l 20...

Page 167: ...W X ba cb ee XlOBH168 FUNCTION This sends the PPC valve output pressure or EPC valve output pressure to the control valve and travel junction valve It is provided with a mount port for the pressure sw...

Page 168: ...42 to control valve bucket r Port P52 to control valve boom s Port P62 to control valve arm t Port P72 to control valve arm u Port P82 to control valve boom v Port PA2 to control valve R H travel w Po...

Page 169: ...UCTURE AND FUNCTION PPC SHUTTLE TRAVEL JUNCTION VALVE 3 3 2 2 F F A A G G B B J J 2PLACES K K 2PLACES L__ ___J N N L L E E AA AA XlOBH169 1 Body 2 Plug 3 Ball IO 123 c l a s s i c ma c h i n e r y n e...

Page 170: ...pring 4 Spool d A A XlOBH170 a Port Tl from R H travel control valve b Port T2 from L H travel control valve c Port T3 from R H travel control valve d Pot t T4 from L H travel control valve e Port PF...

Page 171: ...in a straight line Because of this the flow of oil to the left and right travel motors when traveling in a straight line is almost the same so there is no travel deviation The travel junction valve in...

Page 172: ...d or reverse l When the steering is operated in forward or re verse if the difference in the pilot pressure from the PPC shuttle valve becomes greater than the switching pressure spring force the spoo...

Page 173: ...stage relief solenoid valve 3 Pump merge divider solenoid valve 4 Travel speed solenoid valve 5 Swing brake solenoid valve a b e f 9 h i j To tank From control pump To PPCYEPC valve From PPC shuttle v...

Page 174: ...pump does not flow to the actuator At the same time the pressurized oil from the actuator flows from port A to port T and is then drained to the tank X10DD048 When solenoid is excited l When the signa...

Page 175: ...NOID VALVE LS CONTROL EPC VALVE 1 a 2 3 4 5 6 b 1 Body 5 Coil 2 Spool 6 Plunger 3 Spring 7 Connector 4 Push pin i XlOBH173 a Port C to LS valve b Port T to tank c Port P from control pump 1O l29 c l a...

Page 176: ...s no signal current flowing from the con troller to coil 5 coil 5 is deactivated l For this reason spool 2 is pushed to the right in the direction of the arrow by spring 3 l As a result port P closes...

Page 177: ...ted As a result spool 2 is moved to the left or right until the propulsion force of plunger 6 is balanced with the load of spring 3 pressure of port C Therefore the circuit pressure between the EPC va...

Page 178: ...ed with arm holding valve the structure and function of the arm holding valve is the same as this valve B B 4 5 I 1 1 I I I 1 A A 0 0 0 0 H 0 0 0 00 XlOBH174 1 Safety suction valve 2 Pilot spring 3 Pi...

Page 179: ...rough the valve and flows to the bottom end of the boom cylinder 2 Boom lever at NEUTRAL When the boom is raised and the control lever is returned to NEUTRAL the circuit for the holding pressure at th...

Page 180: ...zed oil from the bottom end of the boom cylinder the pressure of the pressurized oil in chamber b is lowered by orifice a If the pressure in chamber b drops below the pres sure at port V poppet 5 open...

Page 181: ...C200 6 PC200LC 6 PC22OLC 6 I PC21 OLC 6 PC25OLC 6 130 I 140 Inside diameter of cylinder Stroke 90 100 95 100 80 90 I 1 285 1 285 Max stroke Min stroke Width across flats of piston nut 95 95 135 I 140...

Page 182: ...H BREAKER I Head cover 2 Element 3 Case 4 Drain plug 5 Valve 6 Spring 7 Spring set plug XlOBV051 SPECIFICATIONS Rated pressure 6 86 MPa 70 kg cm Flow 107Plmin Relief valve cracking pressure 0 34 0 049...

Page 183: ...ed as a crane STRUCTURE l When an excessive weight is lifted the oil pressure goes up at the bottom side of the boom cylinders When this happens the pressure switch senses the rising pressure turns th...

Page 184: ...STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE Control panel Overload warning pilot lamp i I 4 r 8Bs88 XllAH003 1O l 38 c l a s s i c ma c h i n e r y n e t...

Page 185: ...the highest points the operating pressure of switch 3 will be somewhere between 60 kg cm and 360 kg cm based on the boom position For instance when the boom is in a certain position between the lowes...

Page 186: ...ft makes the pres sure range wider l Screw E Zero point adjustment screw Turning to the right one complete turn raises the pressure by 57 kg cm Each complete turn to the left lowers the pressure by 57...

Page 187: ...t FUNCTION l This valve prevents sudden uncontrolled lowering of the boom when lifting due to the burst of a hose in the boom cylinder line In such a condition this valve will hold the load until the...

Page 188: ...of the cylinder raising the boom BOOM LOWER l During boom lowering the pilot signal reverses the front through the control valve spool High pressure oil flows to the head side of the cylinder Oil in t...

Page 189: ...peration to lower safety l The sudden loss of pressure at port V will cause check valve 4 to re seat and so the valve is locked l The boom can be lowered in a controlled way by operating the wrist con...

Page 190: ...STRUCTURE AND FUNCTION WORK EQUIPMENT WORK EQUIPMENT X1722023 1 Arm 2 Bucket cylinder 3 Arm cylinder 4 Boom 5 Boom cylinder 6 Bucket IO 144 c l a s s i c ma c h i n e r y n e t...

Page 191: ...ELECTRICAL CIRCUIT DIAGRAM 112 TO 2 2 I 2 2 2 2 2 2 2 BLUE CNWHOI LTO FOLDOUT 24 EN HO TO 2 2 2 1 2 2 IO 145 0 c l a s s i c ma c h i n e r y n e t...

Page 192: ...ELECTRICAL CIRCUIT DIAGRAM 2 2 Z TO l 2 TO l 2 TO 1 21 TO l 2 t _ _ ___ _________ I 1 I IO 146 0 c l a s s i c ma c h i n e r y n e t...

Page 193: ...ELECTRICAL WIRING DIAGRAM FOLDOUT 11 PC200 6 PC200LC 6 PC21 OLC 6 PC22OLC 6 PC25OLG6 i P i _ l9 26 12 13 14 15 16 IO 147 c l a s s i c ma c h i n e r y n e t...

Page 194: ...36 Fuse box 37 Caution buzzer 38 Starting switch 39 Fuel control dial 40 Cigarette lighter 41 Swing lick switch 42 Wiper switch 43 Light switch 44 Buzzer cancel switch 45 Service meter 46 Speaker 47 K...

Page 195: ...ed simply by using the starting switch l A dial type engine control is used to control the engine speed The engine throttle controller receives the control signal from the fuel control dial sends a dr...

Page 196: ...tle controller calculates the angle of the governor motor according to this signal and send a signal to drive the governor motor so that it is at that angle When this happens the operating angle of th...

Page 197: ...ned it rotates the potentiometer shaft When the shaft rotates the resistance of the vari able resistor inside the potentiometer changes and the desired throttle signal is sent to the engine throttle c...

Page 198: ...ed to allow observation of the operation of the motor l The rotation of the motor is transmitted to the potentiometer through a gear 1 Potentiometer 2 Cover 3 Shaft 4 Dust seal 5 Bearing 6 Motor 7 Gea...

Page 199: ...l Fuel control dial Input Input Model selection 1 Model selection 3 Input Input Governor motor drive A Governor motor drive B output output No Name of signal Input output 12 GND Input 13 Battery relay...

Page 200: ...n I Power maximizing function 3 Swift slow down function 4 Auto deceleration function 5 Engine automatic warming up overheat prevention function Swing priority function 7 Swing control system 8 Travel...

Page 201: ...rake r Travel lever Monitor panel I I _ G7 i iEE 1 _1 01 0 0 010 H r 3uzzer cancel switc L H knob I Caution buzzer I iwing lock switch L 1 IPump controller Model selection connector Engine throttle co...

Page 202: ...is possible to select the most suitable engine torque and pump absorption torque to match the nature of the work l The pump controller detects the actual engine speed and the speed set by the engine g...

Page 203: ...tial output point By re peating this control the engine can always be used at near the 96 partial output point Engine speed N Pump discharge amount Q X12BV091 l Matching point in general operation fin...

Page 204: ...ed out in the same way as for the general operation finishing opera tion and breaker operation modes to match the load in the pump In this way the fuel consumption is reduced and the fine control abil...

Page 205: ...nd engine speed are kept as they are and the pump absorption torque is increased Control function when WC prolix switch is ON P ON Prolix N OFF Normal _ _ I ____ l Even if any abnormality should occur...

Page 206: ...p merge divider valv Pump controller Y i Monitor panel X12BV097 FUNCTION l The following two functions are available to provide the optimum matching under various working conditions a 2 stage relief f...

Page 207: ...f function For details of the operation see CLSS S stage relief function The relief pressure for normal operation is 31 85 MPa 325 kg cm but when the 2 stage relief function is actuated the relief pre...

Page 208: ...pump discharge amount for independent operation Actuator Mode Heavy duty operation H O General operation G O Finishing operation F O Lifting operation UO Breaker operation B O Boom Arm Bucket RAISE L...

Page 209: ...for a certain time or switches the working mode to the lifting operation L O and reduces the speed It is operated using the L H knob switch to momentarily match the operating conditions The power max...

Page 210: ...n is automatically set as follows Working mode Engine pump control 2 stage relief function Actuating time 2 Swift slow down function l During normal operations if it is desired to carry out lifting op...

Page 211: ...1L H travel OTravel lever I I pressure i switch I I n Pump controller 1 1 X12BVlOO FUNCTION l If all the control levers are at neutral when waiting for work or waiting for a dump truck the engine spee...

Page 212: ...diately to approx 100 rpm below the set speed to the No 1 deceleration pos tion If another 4 seconds passes the engine speed is reduced to the No 2 deceleration position approx 1400 rpm and is kept at...

Page 213: ...A c a 3 G Network signal Engine throttle c controller Pump controller Network signal c uu X12BV102 FUNCTION l If the coolant temperature is low this automatically raises the engine speed to warm up t...

Page 214: ...the engine is started if the engine coolant temperature is low the engine speed is auto matically raised to warm up the engine Conditions for actuation both are necessary Conditions for cancellation a...

Page 215: ...remedy Coolant temperature Between 102 C and Coolant temperature gauge Red range Working Pc2Cro e PC22oLC e mode kwckw general finishing breaker Mode kept as it is output reduced Lifting Lifting oper...

Page 216: ...ion mode OFF 90 swing and loading of dump truck Boom swing priority selection mode ON 180 swing and loading of dump truck X12BV106 STD Swing priority 0 90 180 Swing angle o X12BV105 l The change in th...

Page 217: ...r Control valve Pump merge 1 I J divider valve h nn mr n n aI T Control pump Swing lock switch signal Drive signal Pump controller Swing lever signal I 1 I X12BV109 FUNCTION l The system is provided w...

Page 218: ...ON the swing lock switch stays ON and the swing brake is not canceled When the swing brake is canceled the swing has only a hydraulic brake operated by the safety valve so if the swing is stopped on a...

Page 219: ...I 1 00 P 00 1 c L _ A Pressure sensor Drive signal1 00000 Drive signal1 Engine throttle 00 controller Throttle signal Pump controller IPressure sensor signal1 C Switch signal 6 A I 4 c XlZBVlll Monito...

Page 220: ...ection according to pump discharge pressure If the machine is traveling with the travel speed switch at Hi and the load increases such as when traveling up a steep hill if the travel pressure con tinu...

Page 221: ...results to the pump controller l This detection is carried out by a magnet and an electric current is generated every time the gear tooth passes in front of the magnet 1 Plug 2 Switch 3 Connector SPEC...

Page 222: ...hragm of the pressure detection portion the diaphragm deflects and changes shape A gauge layer is installed to the face opposite the diaphragm and the resistance of the gauge layer converts the deflec...

Page 223: ...tion Ioutput I 26 Speed sensor Input 27 INetwork circuit monitor _ 6 Travel speed solenoid 7 LC control EPC Outpui Outpui 1 Outpui 8 I Bucket DUMP switch I Input I 28 I Monitor circuit engine I I Cont...

Page 224: ...STEM NC VALVE See HYDRAULIC PUMP XlZBVllS FUNCTION l This resistor acts to allow a suitable current to flow to the TVC solenoid when the TVC prolix switch is ON l No current flows when the NC prolix s...

Page 225: ...tion This always displays the coolant tempera ture and fuel level 3 Time display 1 This normally displays the time 2 If this is set to the machine data moni toring mode internal data from each control...

Page 226: ...l It has a built in CPU Central Processing Unit and processes displays and outputs the data from the sensors and controllers l The time display and monitor display panels use a liquid crystal display...

Page 227: ...c l a s s i c ma c h i n e r y n e t...

Page 228: ...e mode selection switches and the condition of the machine changes each time that any switch is pressed The LED above the switch lights up to display the present Symbol item Action condition of the ma...

Page 229: ...When abnormal Coolant level I Contact type I ON close OFF open Engine oil level Contact type I ON close OFF open Hydraulic oil level Contact type ON close OFF open Engine oil pressure Contact type OFF...

Page 230: ...LEVEL SENSOR ls Z XllAJlOS 4 ENGINE OIL PRESSURE SENSOR COMMON FOR BOTH Lo AND Hi 1 Connector 2 Plug 3 Switch 4 Float 1 Plug 2 Contact ring 3 Contact 4 Diaphragm 5 Spring 6 Terminal Composition of cir...

Page 231: ...rmistor XllAJlll 6 FUEL LEVEL SENSOR l L _ T _ _ _ c c fk Composition of circuit 1 Float 2 Connector 3 Cover 4 Variable resistor 7 AIR CLEANER CLOGGING SENSOR EMPTY XllAJ112 Actuation OFF pressure 7 4...

Page 232: ...justing LS valve output pressure servo pistion input pressure and LS differential pressure 20 44 Testing and adjusting control pump circuit oil pressure 20 47 Testing EPC valve solenoid valve output p...

Page 233: ...e model Item Measurment Conditions I Unit Low idle in H O mode Engine speeds Engine rating Rated gross power J rated speed kWJrpm intake manifold pressure At rated speed j I mm Hg Intake air restricti...

Page 234: ...thin operating range B2 pump relief Arm relief BArm relief Travel lever operated in small movements Engine at high idle 4 4 4 4 4 4 4 4 2 100 f 100 2 250 f 100 DFuel control dial at MAX DControl lever...

Page 235: ...used reference l Pump outlet port pressure I For travel measure oil pressure for relief on one side 2 For swing measure oil pressure with swing lock switch on 3 The boom pressure is the oil pressure a...

Page 236: ...gh idling l Hydraulic oil temp 45 55 C l In H O mode l Swing on turn and measure time taken to swing next 5 turns l Engine stopped l Hydraulic oil temp 45 55 C l Set machine on 15 slope and set upper...

Page 237: ...vel peed 1 rravel speed 2 B Engine at high idling B Hydraulic oil temp 45 55 C B In H O mode B Raise track on one side at a time rotate one turn then measure time taken for 5 turns with no load STD 27...

Page 238: ...measure time taken for 5 turns with no load 36 2 34 40 30 39 33 3 17 2 14 2 Travel speed 2 15 5 21 5 l Engine at high idling l Hydraulic oil temp 45 55 C l In H O mode l Run up for at least 10 m and...

Page 239: ...ne moves in 5 min Lock Din PoD1W l Engine at high idling l Hydraulic oil temp 45 55 C l Lock shoes and relieve travel circuit Posture for measurement l Place in above posture and measure extension or...

Page 240: ...3 1 f 0 3 3 8 f 0 4 Max 4 5 Max 4 7 3 8 0 4 3 1 0 3 P Engine at high idling B Hydraulic oil temp 45 55 c b In HI0 mode Max 3 5 Max 3 6 Max 3 7 3 0 f 0 3 bucket ylinder ully etracted I _rlly ended Max...

Page 241: ...dling l Relieve circuit to be measured 20 4 5 50 10 l Engine at high idling l Hydraulic oil temp 45 55 C f Use a hard horizontal surface PC200 C200LC C21OLC C22OLC PC200 C2OOLC C21OLC C22OLC C250LC C2...

Page 242: ...MPa Q Urnin limit Q Umin kg cm P P P P See graph See graph 2 As far as possible bring pump discharge pressure P and P as close as possible to the average pressure when measuring The error is large nea...

Page 243: ...limit Q Umin kg cm As desired P P P P 2 See graph See graph Sr As far as possible bring pump discharge pressure P and P as close as possible to the average pressure when measuring The error is large n...

Page 244: ...ory Item Time taken for swing for boom RAISE and starting swing PC00246 l Engine at high idling l Hydraulic oil temp 45 55 C l In H O mode l Load the bucket with the rated load and measure the time ta...

Page 245: ...7 k n 2 Disconnect connector E04 z Between 2 3 0 25 7 k f2 8 2 Between 1 3 4 6kQ If the condition is as shown in the table below it is 1 Turn starting switch OFF 8 II Between 1 2 2 5 7 5 0 2 Disconnec...

Page 246: ...condition is as shown on the table below it is normal Between 13 12 20 30U Sr This is only for 2 5 set after the starting switch is operated ON OFF at other times it must be 0 U PC200 PC2OOLC PC21 OLC...

Page 247: ...curl SO6 3ucket dump so7 Swina SO8 If the condition is as shown on the table below it is normal PC oil ressure switch Between I 2 chassis Min 1 M fI If the condition is as shown on the table below it...

Page 248: ...I 03 male 1 Turn starting switch OFF 2 Disconnect connector V03 If the condition is as shown on the table below it is normal I Between 1 2 1 20 600 1 I Between 2 chassis I Min I Mf2 I 1 Turn starting...

Page 249: ...I I F O IApprox 2100 I Approx 2200 I I L O IApprox 1700 I Approx 1750 I No 2 throttle signal Monitoring code 16 lO Power Max I Approx 2420 I Approx 2530 HIO GIO I Swift slow down H O G O Approx 1700...

Page 250: ...If the condition is as shown on the table below it is normal l Working in G O mode I PC200 PC220 PC21 0 PC250 I Front between 510 80mA 410t80mA If the condition is as shown on the table below it is no...

Page 251: ...ting swtich ON Starting switch OFF Right side Dlsplay position Left side Min Max k0 0 0 646 4 119 4 681 4 456 5 063 8 III 4 820 5 744 11 34 927 Disconnection I Position of guage display Starting swtic...

Page 252: ...5 3 0 V 1 Start engine 2 Insert T adapter io7 2 a a 1 Screw in rotation sensor until it contacts the ring gear then turn back one turn 2 It must work normally when adjusted as above If the condition...

Page 253: ...he condition is as shown in the table below it is ormal Air cleaner normal I Continuity Air cleaner clogged No continuity Measurment conditions I Install oil pressure neasuring guage Remove wiring lar...

Page 254: ...d color x 1II 0 Bosch index Smoke meter l 790 261 I 311 Pressure gauge 2 45 25 5 88 60 39 2 400 58 8 600 MPa kg cm Pressure gauge 68 6 MPa 700 kg cm Hydraulic tester Digital hydraulic tester Hydraulic...

Page 255: ...the work equip ment lever but not enough to make the work equipment move When measuring at high idling with the travel power max operated operate the travel le ver but not enough to make the machine m...

Page 256: ...TESTING AND ADJUSTING MEASURING INTAKE MANIFOLD PRESSURE MEASURING INTAKE MANIFOLD PRESSURE Refer to ENGINE SHOP MANUAL for tools and proper procedure 20 25 0 c l a s s i c ma c h i n e r y n e t...

Page 257: ...TESTING AND ADJUSTING MEASURING INTAKE AIR RESTRICTION MEASURING INTAKE AIR RESTRICTION Refer to ENGINE SHOP MANUAL for tools and proper procedure 20 26 0 c l a s s i c ma c h i n e r y n e t...

Page 258: ...TESTING AND ADJUSTING MEASURING LUBRICATING OIL PRESSURE MEASURING LUBRICATING OIL PRESSURE Refer to ENGINE SHOP MANUAL for tools and proper procedure 20 27 a c l a s s i c ma c h i n e r y n e t...

Page 259: ...TING AND ADJUSTING MEASURING FUEL FILTER INLET RESTRICTION MEASURING FUEL FILTER INLET RESTRICTION Refer to ENGINE SHOP MANUAL for tools and proper procedure 20 28 a c l a s s i c ma c h i n e r y n e...

Page 260: ...TESTING AND ADJUSTING MEASURING BLOWBY PRESSURE MEASURING BLOWBY PRESSURE Refer to ENGINE SHOP MANUAL for tools and proper procedure 20 29 0 c l a s s i c ma c h i n e r y n e t...

Page 261: ...TESTING AND ADJUSTING MEASURING EINGINE BACK PRESSURE MEASURING ENGINE BACK PRESSURE Refer to ENGINE SHOP MANUAL for tools and proper procedure 20 30 0 c l a s s i c ma c h i n e r y n e t...

Page 262: ...with smoke meter G2 I 1 2 3 4 5 6 7 Insert probe 0 into the outlet port of exhaust pipe I then tighten the clip to secure it to the exhaust pipe Connect the probe hose accelerator switch plug and air...

Page 263: ...TESTING AND ADJUSTING MEASURING COOLANT TEMPERATURE MEASURING COOLANT TEMPERATURE Refer to ENGINE SHOP MANUAL for tools and proper procedure 20 32 0 c l a s s i c ma c h i n e r y n e t...

Page 264: ...TESTING AND ADJUSTING MEASURING VALVE CLEARANCE MEASURING VALVE CLEARANCE Refer to ENGINE SHOP MANUAL for tools and proper I procedure 20 33 a c l a s s i c ma c h i n e r y n e t...

Page 265: ...ING 1 2 3 4 5 6 7 Lossen two nuts and bolts 0 Carefully lever compressor housing as shown to tighten belt to tightness criteria Tighten lower bolt to hold in position Tighten upper bolt Check each pul...

Page 266: ...sensor I turn back one turn 3 Tighten locknut 3 Be particularly careful when securing the sensor wiring to ensure that no excessive force is brought to bear on the wiring Be careful not to let the tip...

Page 267: ...overnor lever 4 2 Repeat the procedure in Step 1 1 above to set to the governor adjustment mode 3 Set governor lever 4 to a postion where it contacts the full speed stopper 5 of the injection pump the...

Page 268: ...When this is done the upper structure will tilt forward so the front will go down and the rear will rise Set the dial gauge to the zero point Set the arm more or less at right angles to the ground su...

Page 269: ...C Midway between the 4th and 5th track roller from sprocket ADJUSTING If the track shoe tension is not within the standard value adjust as follows 1 When the tension is too high Loosen plug 1 graduall...

Page 270: ...easure the pressure in the pump circuit on the opposite side when the arm or bucket circuit is relieved Arm relief Load on front pump rear pump unloaded Bucket relief Load on rear pump front pump unlo...

Page 271: ...G O or H O mode with the engine at high idling and the power max function actuated relieve one of the boom arm or bucket circuits and mea sure the oil pressure ADJUSTING 1 LS relief valve 1 Loosen nut...

Page 272: ...RAVEL CIRCUIT 3 Swing motor safety valve l Loosen locknut I then turn adjustment screw 2 to adjust jl Turn the adjustment screw to adjust as follows l To INCREASE pressure turn CLOCKWISE l To DECREASE...

Page 273: ...ssure gauge Cl Install a 39 2 MPa 400 kg cm gauge to the servo valve end and a 58 8 MPa 600 kg cm gauge to the pump outlet port end 2 Set the swing lock switch ON 3 Set the working mode to H O mode 4...

Page 274: ...to the right the pump absorption torque will be reduced There is also a connection with the angle so see Note below The adjustment range for the screw is a maximum of 90 to both the left and right 2 A...

Page 275: ...is rotating under no load on one side i Set the working mode to H O mode and set the travel speed switch to Hi ii Use the work equipment to raise the track assembly on one side iii Measure the oil pr...

Page 276: ...Remove oil pressure measurement plugs 5 and 6 Thread dia 10 mm Pitch 1 5 mm and install the plug inside hydraulic tester CI ii Install oil pressure gauge CI 58 8 MPa 600 kg cm to the measurement plug...

Page 277: ...ential pressure is not within the standard value adjust as follows 1 Loosen locknut 7 and turn screw 8 to adjust the differential pressure Turn the screw to adjust the differential pres sure as follow...

Page 278: ...g the relief pressure No Section of hydraulic circuit shut off Component that can be checked 1 Control pump outlet port Control pump 2 Solenoid valve inlet port Solenoid valve 3 Travel PPC valve inlet...

Page 279: ...justment screw as follows l To INCREASE pressure turn CLOCKWISE l To DECREASE pressure turn COUNTERCLOCKWISE Amount of adjustment for one turn of adjustment screw 0 53 MPa 5 4 kg cm Locknut 63 7 f 9 8...

Page 280: ...pressure gauge kit to install oil pressure CI 5 88 MPa 60 kg cm 2 Measure the output pressure under the conditions in Table 1 Table 1 Operation and working mode All control levers at neutral Engine s...

Page 281: ...minimum Motor swash plate angle at maximum 2 stage relief Swing lock switch ON work equipment lever ooerated Pressure rise ON Min 2 74 Min 28 solenoid I I I All levers at neutral Normal pressure OFF 8...

Page 282: ...rom the PPC shuttle valve as follows 1 Disconnect the hose between the PPC valve and the shuttle block at the block end 2 Install an adapter for measuring the oil pressure to the tip of the hose then...

Page 283: ...CURL SO6 Arm OUT 603 Boom RAISE 602 D n XlOAV283 0 Circuit diagram I C_i__ _ XlOAV284 1 Swing PPC shuttle valve 2 PPC shuttle valve for LS select 3 PPC shuttle valve for OUT boom RAISE 4 PPC shuttle...

Page 284: ...ase the pressure inside the hydraulic tank Then set the safety lock lever to the LOCK position Remove the PPC valve Remove boot 1 Loosen locknut 2 then screw in disc 3 until it con tacts the 4 heads o...

Page 285: ...d right travel levers 3 forward and backwards and check that the levers are fitted securely in the stopper bolt head of the PPC valve Check also that cover 3 is not contacting portion If it is contact...

Page 286: ...avel for 1Om then measure the deviation when traveling for the next 20m Set to H O mode and measure with the engine at high idling Ir Install the hydraulic pressure gauge and measure x14zzoo1 the pump...

Page 287: ...he accumulator again before operating Reference If the cause of the hydraulic drift is in the packing and the above operation is carried out the downward movement becomes faster for the following reas...

Page 288: ...boom holding valve and install a blind plug in the hose Blind plug 07376 50315 j Leave the boom holding valve end open 2 Start the engine charge the accumulator then stop the engine 3 Operate the boo...

Page 289: ...e standard value the problem is in the cylinder Fully extend the rod of the cylinder to be meas rued then stop the engine Disconnect piping 1 at the head end the block the piping at the chassis end wi...

Page 290: ...lways use signals and check when carrying out this operation 4 Continue this condition for 30 seconds then measure the oil leakage for the next minute When measuring move the motor slightly to change...

Page 291: ...only those procedures marked with a 0 for each tvoe of work I Bleeding air from pump 1 Loosen air bleed plug I and check that oil oozes from the plug 2 When oil oozes out tighten plug 1 Plug 17 15 2 4...

Page 292: ...d bucket cylinders j When the cylinder has been replaced bleed the air before connecting the piston rod Be particularly careful not to operate the cylinder to the end of its stroke when the piston rod...

Page 293: ...nel Method of using judgement table Details of troubleshooting and troubleshooting procedure Troubleshooting of engine throttle controller system E mode Troubleshooting of engine S mode Troubleshootin...

Page 294: ...rator For this reason when carrying out troubleshoot ing it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure 2 Points to a...

Page 295: ...s of maintenance etc 1 I Look at the troubleshooting sectron of the shop manual to find locations of possrble causes step 3 1 Preparation of troubleshootmg tools 1 I Look at the table of troubleshooti...

Page 296: ...es used for protecting the wiring Compared with other electrical components fitted in boxes or cases wiring harnesses are more likely to be affected by the direct effects of rain water heat or vibrati...

Page 297: ...of the water jet The connector is designed to prevent water from entering but at the same time if the water does enter it is difficult for it to be drained Therefore if water should get into the conne...

Page 298: ...it with a Lock I X08DD064 vinyl bag to prevent any dust dirt oil or water from getting in the connector portion Connecting connectors 1 Check the connector visually Check that there is no oil dirt or...

Page 299: ...er and oil has been removed Drying wiring harness If there is any oil or dirt on the wiring harness wipe it off with a dry cloth Avoid washing it in water or using steam If the connector must be washe...

Page 300: ...eful when handling the control box 2 Do not open the cover of the control box unless necessary 3 Do not place objects on top of the control box 4 Cover the control connectors with tape or a vinyl bag...

Page 301: ...ntenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the performance should be confirmed with special test equipment Sealing openings After any piping o...

Page 302: ...shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and old oil from th...

Page 303: ...m 1 2 3 4 5 6 7 a Check battery voltage engine stopped ZO 30V _ Check level of battery electrolyte Check for discolored burnt or bare wiring Check for missing wiring clamps hanging wires Checks for ge...

Page 304: ...I I I M23 M 2 Horn switch R H knob switch F2 t DO8 IKESI I 2 Heater circuit _ M26 I M I 6 I Air conditioner I R6 Dll D13 EOI E04 KESI 2 Alarm buzzer circuit M6 KESI 2 Battery relay drive circuit R8 M...

Page 305: ...itch R4 I DUMP oil rre switch I R3 I il pressure witch zsure 1 I vo2 vo3 X 2 LS select solenoid valve Nl X 2 Pump merge divider solenoid valve Nl W08 070 18 Wiper motor controller P6 WI0 M 4 Rear limi...

Page 306: ...I A I I u _i I I I I om m c l a s s i c ma c h i n e r y n e t...

Page 307: ...M46 M38 M45 R04 co5 HO2 Ml3 LUO M26 205F06389 SO8 so4 so5 i so3 so1 so2 c l a s s i c ma c h i n e r y n e t...

Page 308: ...emale refer to the pins while the terms male housing and female housing refer to the matinn nnrtinns of the housino __ _ _ _ No of X type connector pins Male female housing Female male housing X08DDO7...

Page 309: ...R CONNECTOR PIN NUMBERS No of pins Male female housing M type connector Female male housing X08DD081 X08DD082 2 7 E 9 1 X08DD083 X08DD084 3 ezl X08DD086 1 X08DD086 4 m X08DD087 4 2 X08DD088 20 79 a c...

Page 310: ...ROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No of pins M type connector Male female housing Female male housing 1 4 6 X08DD089 ES 6 3 X08DD090 20 80 0 c l a s s i c ma c h i n e r y n e...

Page 311: ...LE FOR CONNECTOR PIN NUMBERS 10 L I 5 10 1 X08DD093 X08DD094 No of pins S type connector Male female housing Female male housing I 5 5 1 8 XOSDDOSl X08DD092 16 1 XOBDD095 16 7 X08DD096 20 81 a c l a s...

Page 312: ...NECTION TABLE FOR CONNECTOR PIN NUMBERS No of pins 16 AMP040 type connector Male female housing Female male housing 6 16 16 8 X08DD097 X08DD098 20 1 11X08DD099 11 1 XO8DDlOO 20 82 0 c l a s s i c ma c...

Page 313: ...OTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No of pins AMP070 type connector Male female housing Female male housing 14 XOSDDlOl XOSDD102 18 XCr8DD103 XOSDDlO4 20 83 a c l a s s i c ma c h i n e...

Page 314: ...TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No of pins 3 l AMP250 tv connector Male female housing X08DDlOS 1 Female male housing X08DD106 20 84 0 c l a s s i c ma c h i n e r y n e t...

Page 315: ...SHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No of pins 14 SWP type connector Male female housing Female male housing 1 4 8 11 3 7 10 14 X08DD107 X08DD108 20 85 a c l a s s i c ma c h i n e r y...

Page 316: ...NECTION TABLE FOR CONNECTOR PIN NUMBERS No of pins MIC type connector Male female housing Female male housing 1 17 X08DDlOS L_ _1 X08Dqllo li 11 1 0 oao 21 21 12 21 XOSDDlll 20 86 a c l a s s i c ma c...

Page 317: ...CONNECTOR PIN NUMBERS No of pins 5 Relay connector 2 I 5 3 XOSDD113 No of pins Male male housing Simple connector Female female housing 1 XOSDD114 X08DD115 No of pins Ring connector 1 X08DD116 20 87 a...

Page 318: ...UMBERS No of pins Male female housing L type connector Female male housing ED 1 1 0 2 0 2 2 X08DDll7 XOSDDllB No of pins Male female housing PA type connector Female male housing g a B B H X08DDllS XO...

Page 319: ...LESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No of Automobile connector KESO pins Male female housing Female male housing 2 il N 1 X08DD121 1 XOSDD122 20 89 a c l a s s i c ma c h i n e r y n...

Page 320: ...FOR CONNECTOR PIN NUMBERS No of pins Automobile connector KESi Female female housing Male male housing 2 2 IiF 1 FB X08DD123 X08DD124 3 2 3 3 2 X08DD125 X08DD126 4 3 4 4 X08DD127 X08DD128 20 90 0 c l...

Page 321: ...ump absorption torque and engine outout Monitor panel Engine speed sensor N WOrt lock signal i E z m RAISE IN OUT ret CURL i l A OWER UMP Explanation of networking functions With this system a network...

Page 322: ...d at the same time depending on the nature of the abnormality it displays the user code on the time display panel to advise the operator of the action to take However in cases of abnormalities which a...

Page 323: ...Rear of monitor panel 205FO6376 I G LI I I uKJp ay y a 1 IbC b G Operation Display 1 To set to the service code display 1 Time display goes out mode keep the time switch L H On the display panel the s...

Page 324: ...ode switch 4 To finish with the service code mode Use the sam e procedure as in Item 1 4 If there is no service code in memory 0 o_ 1 1 1 1 is displayed 5 To erase the memory Keep the time switch pres...

Page 325: ...switch R H work 0 11 Wl ing mode switch T The 3rd digit is for the tens 3 To go back to the previous moni Blank so this display means 180 mA 0 18 A toring code display Press the time switch L H workin...

Page 326: ...ut signal 3 B Pump controller 23 Pump controller solenoid actuation B Pump controller 30 Fuel control dial input value IOmV Engine throttle controller 31 Governor potentiometer voltage IOmV Engine thr...

Page 327: ...tch ON 0 Travel switch ON 20 Input condition of pump controller 0 Boom LOWER switch ON PPC oil pressure switches Boom RAISE switch ON 0 Arm IN switch ON 8 Arm OUT switch ON 0 Bucket CURL switch ON 0 B...

Page 328: ...l selection 2 GND connected 0 Model selection 3 GND connected 0 Model selection 4 GND connected 0 Starting switch ON 8 Auto deceleration signal ON 0 Battery relay drived I 37 Output condition of engin...

Page 329: ...0 Engine oil pressure Lo sensor OPEN 0 Engine oil pressure Hi sensor OPEN 0 0 Alarm buzzer actuated 0 0 0 8 0 L H knob switch signal 1 ON 0 L H knob switch signal 2 ON 0 Model selection 1 GND connecte...

Page 330: ...the time adjustment mode Keep the time switch depressed for 2 5 seconds Use the L H working mode switch to advance the hour Use the R H working mode switch to advance the minute To return to the time...

Page 331: ...If a service code is displayed on the monitor panel go to the troubleshooting code at the bottom of the judgement table E 00 A l mark is put at the places where the failure mode and service code matc...

Page 332: ...troubleshooting code on the right of the judgement table H 00 l If the input signal is not displayed on the monitor panel go to the troubleshooting code at the bottom of the judgement table F 00 Exam...

Page 333: ...rding to the answer follow either the YES line or the NO line to go to the next 1 Note The number written at the top right corner of the 1 is an index number it does not indicate the order to follow l...

Page 334: ...roperly inserted Always connect any disconnected connectors before going on the next step t Check that the coolant is at the specified level before carrying out troubleshooting 2 al coolant level flas...

Page 335: ...tor system E2 OOto E2 99for pump controller system C mode Carry out troubleshooting for rnn troller system 7 I I Is service code displayed on 1 monitor panel l Operate and check service code LE3 00 to...

Page 336: ...When networking cannot be carried out for the monitor and engine throttle controller only throttle signal is recognized as FULL normal control is carried out for others l Procedure for checking monito...

Page 337: ...mp controller 1 Checking input signal 1 Check oil pressure switch i Set to the monitoring mode and display monitoring codes 20 and 21 ii Operate each work equipment lever and check how the bit pattern...

Page 338: ...ng mode and display monitoring code 23 ii Refer to Table 3 and check that the applicable bit lights up Table 3 Types of solenoid and conditions for actuation Name of solenoid Actuation condition Bit t...

Page 339: ...A phase direction for increasing engine speed and code 34 is the B phase direction for reducing engine speed ii Measure the governor motor drive current when the fuel control dial is turned in the acc...

Page 340: ...r drive system is displayed E 5 E3 01 Abnormality in network reception system is displayed E 6 E3 05 Abnormality in model code is displayed E 7 E3 06 Abnormality in governor potentiometer system is di...

Page 341: ...ON operate fuel bv hand or isfixed with control dial and __ Lng mode fi ikd i 1 0 y If engine does not stop push governor lever to STOP position and check if engine stops Defective adjustment of gover...

Page 342: ...130 v go _ 16Q_ 7 1 0 85WB 0 85G 5 0 75G II In cmrn 0 5BW AIIII I III1 I II n 5R I I ________________ _ ______ __ 2 6 7e 0 75R 8 0 75w i _ H02tMIC CO9 S8 PC200 PC220 Fusible link M14 L2 EOl MIC21 Engi...

Page 343: ...c l a s s i c ma c h i n e r y n e t...

Page 344: ...governor motor drive Takes no particular action 2 When there is a disconnection in only one of A system EOI 20 HO2 5 E05 2 phase or B phase 5 Disconnection in wiring harness between I 4 IO 21 Min 1 M...

Page 345: ...on does not work 0 E 3 E 4 6 Engine does not stop 0 0 0 0 0 0 0 0 x E 14 g Automatic warming up operation is defective 0 0 E 3 E 4 10 Exhaust gas is black s 7 11 Oil consumption isexcessive or exhaust...

Page 346: ...also does not rotate go to E l 1 I 1 Is voltage between EOl l Z and 12 normal IES I h NO l20 30V l 21 starting switc Isvoltage between EOl 6 and 12 l 20 3ov Turn starting switch ON ES 3 YES pijiij 20...

Page 347: ...emale 15 7 16 or _ I between each pin and chassis as shown in Table l Turn starting NO switch OFF Disconnect EOl YES Cause Defective engine throttle controlier Defective wiring harness in system with...

Page 348: ...engine can be started but it stays in low idling or 2 it will not stop after it is started A Stop the engine push the governor lever of the fuel injection pump to the NO INJECTION position before chec...

Page 349: ...ne can be started but it stays in low idling or 2 it will not stop after it is started A Stop the engine push the governor lever of the fuel injection pump to the NO INJECTION position before checking...

Page 350: ...ec pump controller _ tar then connect NO displayed connector again YES Is voltage between Turn starting switch ON S y CO3 7 W 8 Turn starting 15 normal switch ON Does LED of pump W o onitoring _ contr...

Page 351: ...Check for the LED display for the engine throttle controller and pump controller from the direction Engine throttle controller P of the arrow as shown in the diagram on the right Note 1 Push the oper...

Page 352: ...sistance be Turn starting tween EOl female switch ON 8 9 18 19 and Set to monitoring NO GND as shown in code 03 and 36 Table 2 Turn starting NO switch OFF Disconnect EOl ON Table 1 Monitoring display...

Page 353: ...EOl controller YES female k5 16 17 or _ 1 between each pin and chassis as shown in Is resistance Table l Defective wiring harness in system with defective betweenE06 male _ Turn starting NO resistance...

Page 354: ...ted connectors before going on to the next step Note This only occurs when the engine is stopped and the starting switch is turned OFF is displayed 2 YES Is resistance between EOl female 113 and YES_...

Page 355: ...ing check that all related connectors are properly inserted Always connect any disconnected connectors before going on to the next step Are E3 06 E3 17 Turn starting switch ON YES YES YESjeflT n Is ad...

Page 356: ...battery relay 1 NO Turn starting switch START YE Connect 1 1end of tester to battery terminal f j 20 29v Turn starting NO switch ON Approx 24V 5 YES II Is voltage between starting switch terminal C a...

Page 357: ...en battery relay terminal E and revolving frame ground connection terminal between 5 and BR Defective contact or dis connection in wrrrng harness between battery terminal t j Mll H05 6 X07 1 starting...

Page 358: ...rting switch ON EO onitoring Is E3 Ol displayed 1 2d n starting switct disconnected and motor lever is placed YE Turn starting switch ON N 4 When linkage bet ween governor motor and injection pump is...

Page 359: ...X07 17 EOl female 6 or defective starting switch See E 7 See E 2 See E 6 E 12 Related electric circuit diagram Engine throttle controller Starting switch X07 Ml C 17 Remedy eplace epair or splace EOl...

Page 360: ...op also at midway position 4 When linkage between governor motor and injection pump is adjusted does condition become normal See TESTING AND ADJUSTING Fuel control dial 5 Is voltage between EOl 7 and...

Page 361: ...ctive governor motor c jefective contact of wiring hiarness between starting S witch ACC X07 17 EOl female 6 or defective Statting switch s ice C 15 s ee E 7 S ee E 2 S eeE 6 Starting switch X07 MIC17...

Page 362: ...played Turn starting switch ON 3 Does injection L pump governor NO lever contact FULL stopper Start engine Set fuel control dial to MAX H O mode I NO YE 4 Is adjustment of linkage between governor mot...

Page 363: ...C17 FlJse Eng ne throttle controller Cause See E 5 Defective injection pump Defective governor motor Defective contact of wiring harness between starting switch ACC X07 17 EOl female 6 or defective st...

Page 364: ...n _ E01 17 and 16 When starting normal YES switch is OFF does voltage between 601 When engine is NO Start signal 4 13 and 12 change stopped _ as shown in Table 2 PC200 2 9 3 3v When starting p PC220 2...

Page 365: ...ttle controller leplace Contact with 24V wiring harness of wiring harness between starting switch ACC X07 17 EOl female 6 or defective starting switch iepair or eplace See E 6 X0 Ml C l7 k lza Startin...

Page 366: ...2 When light is connected Between wiring harness and chassis Min 1 MQ Turn starting switch OFF Disconnect EOl and battery relay BR Table 1 When ON Voltage from starting APP OX 24V 1 To battew relay BR...

Page 367: ...during operations Engine does not rotate smoothly Engine lacks output no power Exhaust gas is black incomplete combustion Oil consumption is excessive or exhaust gas is blue Oil becomes contaminated q...

Page 368: ...re sponds to the items where answers can be ob tained from the user The items in are items that can be obtained from the user depending on the user s level Check items The serviceman carries out simpl...

Page 369: ...leshooting for that item to make final confirmation of the cause r l 2 For Confirm recent repair history in the Ques tions Section ask the user and mark the Cause column with A to use as reference for...

Page 370: ...Three symptoms have causal relationship with this problem Exhaust gas slowly became black Power slowly became weak er and Dust indicator is red If we look from these three symptoms to find the cause...

Page 371: ...causes intersect 1 2 3 4 5 Clogged air cleaner element 908 Air leakage between turbocharger and head 00 Clogged seized injection nozzle 0 Defective contact of valve valve seat 0 Worn piston ring cylin...

Page 372: ...more in the above table Incold weather the specific gravity must be for the charging rate of at least 75 in the above table I Confirm recent re au histow 5 _ Engine oil must be added more frequently...

Page 373: ...r When starting switch is turned to ON there is no clicking sound u Battery terminal is loose When battery is checked battery electrolyte is found to be low Specific gravity of electrolyte voltage of...

Page 374: ...the monitor panel General causes why engine turns but no exhaust gas comes out l Supply of fuel impossible 0 Supply of fuel extremely small 0 Improper selection of fuel partucularly in winter Standar...

Page 375: ...gas comes out but engine does not start l Lack of rotating force due to defective electrical system 0 Insufficient supply of fuel l Insufficient intake of air 0 Improper selection of fuel manual star...

Page 376: ...Insufficient supply of fuel l Improper condition of fuel injection 0 Use of improper fuel When air element is inspected directly it is found to be clogged 0 When fuel filter w filter are inspected di...

Page 377: ...ply of fuel l Overheating If there is overheating and insufficient output carry out troubleshooting for overheating l Failure of power train If the engine stops because of a failure in the power train...

Page 378: ...e does not rotate smoothly hunting l Air in fuel system l Defective governor mechanism l Defective electrically controlled throttle mechanism electrically controlled throttle type If there is no hunti...

Page 379: ...ral causes why engine lacks output l Insufficient intake of air 0 Insufficient supply of fuel l Improper condition of fuel injection 0 Use of improper fuel if non specified fuel is used output drops l...

Page 380: ...l I In Power was lost Graduallv I I I I 8 I I Non specified fuel has been used I I lol I E temperature of some cylinders is low I I I IDI I a Z Match marks on fuel injection pun 2 Seal on injection pu...

Page 381: ...engine cooling water When exhaust oipe is removed inside is found to be dim with oil CT3 I lo G 0 2 Inside of turbocharger intake pipe is dirty with oil 8 Oil level in clutch or TORQFLOW transmission...

Page 382: ...erated for long period A A A g z Engine oil must be added more frequently 8 Non soecified fuel has been used 0 Ie When oil filter is inspected metal particles are found 0 ci u When exhaust pipe is rem...

Page 383: ...ve injection of fuel Illlllllj Confirm recent repair history Degree of use Operated for long period 4 A A z More than for other machines g 6 0 of same model t Condition of fuel consumption z Gradually...

Page 384: ...is in cooling water or water spurts back or water level goes down General causes why oil is in cooling water l Internal leakage in lubrication system l Internal leakage in cooling system 20 156 0 c l...

Page 385: ...General causes why oil pressure lamp lights up l Leakage clogging wear of lubricating system l Defective oil pressure control 0 Use of improper oil improper viscosity l Deterioration of oil due to ove...

Page 386: ...oling water carry out troubleshooting for Oil is in cooling water l Water in oil cloudy white l Fuel in oil diluted and smells of diesel fuel l Entry of oil from other component I Causes y en engine 1...

Page 387: ...between top and bottom radiator tanks is 0 excessive Temperature difference between top and bottom radiator tanks 1 inspected the core is found to be clogged When a function test is carried out on the...

Page 388: ...rnal noise or an external noise General causes why abnormal noise is made l Abnormality due to defective parts l Abnormal combustion noise l Air sucked in from intake system Speed of some cylinders do...

Page 389: ...s why vibration is excessive l Defective parts abnormal wear breakage 0 l Improper ignn ent Abnormal combustion I outside standard I I I I I I I I I Remove front cover and check directlv Remove head c...

Page 390: ...g brake solenoid system is displayed Short circuit in LS select solenoid system is displayed Short circuit in pump merge divider solenoid system is displayed Short circuit in 2 stage relief solenoid s...

Page 391: ...ooting of the failure and the service code is no longer displayed or if the monitor display returns to normal After completing troubleshooting always erase the user code from memory 2 Service code mem...

Page 392: ...c l a s s i c ma c h i n e r y n e t...

Page 393: ...nce of solenoid is extremely high vibration of the machine the condition will 2 In the case of 3 when the boom swing priority E2 12 Disconnection in LS 2 Disconnection in wiring harness between return...

Page 394: ...engine throttle controller 1 Working mode G O 1 I Even when travel is operated the power 2 Priority mode OFF does not increase 1 Disconnection short circuit short circuit with 3 Travel speed Lo 2 The...

Page 395: ...mp and rear pump pressure as Abnormality in pressure 1 Defective pressure sensor 0 MPa 0 kg cm when actuating 1 Voltage between CO3 3 and 9 and between When abnormality is detected it switches the 1 T...

Page 396: ...ystem t 6 z Model selection input error Network response overtime error Short circuit in LS control EPC solenoid system Disconnection in LS control EPC solenoid system Abnormality in front pump pressu...

Page 397: ...Iii I I 1 1 I I iEO1 L _ I Enqine throttle ContrOller Model selection connector Travel 2 stage Swinq Pumb merqe LS speed relief brake divider select I H knob SW i tch Rear Front i_S control TVC TVC So...

Page 398: ...connect any disconnected connectors before going on to the next step j When the starting motor rotates correctly If the starting motor also does not rotate go to E l 1 YES 1 Defective pump controller...

Page 399: ...COl Interchange wiring with other TVC solenoid Is Ju F starting switch applicable service l Disconnect CO4or NO code displayed C13 whichever is Go toA Cause Iefective pump controller Interchange wirin...

Page 400: ...Between CO4 male 1 and Between CO1 female 17 and 2 9 Between CO5 female 4 and chassis Between CO5 female 8 and 9 Min 1 MO IO 22n CL 30 Between CO4 male 2 and chassis Between CO1 female 9 and chassis...

Page 401: ...or NO code displayed C13 whichever is applicable Turn starting switch OFF V Interchange wiring NO Turn starting switch ON again Y A p Turn starting switch OFF Disconnect 05 between each pin for troubl...

Page 402: ...female 4 and chassis chassis chassis Min 1 ML E2 37 Between CO4 male 1 and 2 Between CO4 male 2 and chassis Between CO1 female 17 and 9 Between CO1 female 9 and chassis Between CO5 female 8 and 9 Betw...

Page 403: ...Dis switch OFF 11z in T le l 11 Disconnect COl rn swing lock Iitch OFF I y c GF ct vo4 NO 1 YES c NO Go to A Turn starting switch OFF Interchange wiring NO l Turn starting switch ON again 5 YES A Is r...

Page 404: ...ROUBLESHOOTING C 4 C 4 Related electric circuit diagram Pump controller Cl Swing lock prolix switch Swing lock switch GND v4 Swing brake H4 Fuse X08DD144 20 I 77 0 c l a s s i c ma c h i n e r y n e t...

Page 405: ...nnectors are properly inserted Always connect any disconnected connectors before going on to the next step Check that fuse 1 is normal Yl 1 l Turn starting switch OFF interchange wiring Turn starting...

Page 406: ...OTING c 5 C 5 Related electric circuit diagram Pump controller Cl I I Swing lock prolix switch Swing lock switch Swing brake solenoid valve Hl I H4 1 Fuse X08DD145 20 I79 a c l a s s i c ma c h i n e...

Page 407: ...r troubleshooting Turn starting NO 1 2 in the table 1 switch OFF normal Disconnect COI 1 Interchange wiring with other solenoid Is applicable service Turn starting switch OFF Interchange wiring Turn s...

Page 408: ...c circuit diagram Pump co1 controller MIC17 LS select Pump nerge divider rravel speed VB VB Z stage relief I El HO2 s LS select 1 Travel speed solenoid valve Fuse t 1 HO4 SlS II VO6 X2 X08DD146 20 181...

Page 409: ...Always connect any disconnected connectors before going on to the next step Check that fuse 1 is normal 3 Isvoltage between ya each pin for 2 troubleshooting 3 F GotoA in the table 1 _ Is resistance...

Page 410: ...other than L O Set working mode switch to L O mode Between i2 15 V05 male 1 and 2 20 60f2 Between CO1 female 14 and chassis When ON same as femate lo Turn swing lock switch ON 1Between CO1 I I Betwee...

Page 411: ...mp controller as shown in Table l 2 YES _ Isresistance Turn starting between CO2 switch ON female U3 14 Set to monitoring NO 15 16 GND as code 02 22 shown in Table 2 A Turn starting NO switch OFF Disc...

Page 412: ...Turn starting switch ON Sz o Onitoring N controller light up Turn starting switch ON When E2 18 and E3 Ol are displayed simultaneously 1 Disconnect connector PO2 then connect it agam Does service cod...

Page 413: ...8DD133 Check for the LED display for the engine throttle controller and pump controller from the direction Engine throttle controller C of the arrow as shown in the diagram on the right Note 1 Push th...

Page 414: ...connectors are properly inserted Always connect any disconnected connectors before going on to the next step 2 YES Is resistance YES between CO1 1 female 15 7 _ 7 chassis as Is resistance shown in Ta...

Page 415: ...ed connectors are properly inserted Always connect any disconnected connectors before going on to the next step 2 YES Defective controller Replace Is resistance_ II YES between CO1 1 female 15 7 7 cha...

Page 416: ...e pump controller Replace Disconnection in wiring harness between CO3 female l HO1 11 CO8 female 3 Front between CO3 female 2 HO1 13 CO7 female 3 Rear or short circuit with ground Repair or replace Ap...

Page 417: ...C l 2 C l 2 Related electric circuit diagram Pump controller RI pressure sensor 4 24vtt F pressure sensor If pressure sensor l S16 CO8tX3 F pump pressure sensor X08DD149 20 191 a c l a s s i c ma c h...

Page 418: ...splayed If it is not displayed the problem has been removed Before carrying out troubleshooting check that all the related connectors are properly inserted Always connect any disconnected connectors b...

Page 419: ...roubleshooting check that all the related connectors are properly inserted Always connect any disconnected connectors before going on to the next step Cause Remedy 2 YES Is resistance YES between CO3...

Page 420: ...re properly inserted Always connect any disconnected connectors before going on to the next step CO3 5 and chassis as shown in Table Turn starting switch ON N When CO3is disconnected is voltage betwee...

Page 421: ...re switch does not light up Bit pattern 20 4 Boom RAISE oil pressure switch does not light up Bit pattern 20 5 Arm IN oil pressure switch does not light up Bit pattern 20 6 Arm OUT oil pressure switch...

Page 422: ...ormal and IScircuit insulated from Is resistance between chassis SO8 male 1 and 2 normal and is circuit Between SO8 and NO 1insulated from C02 Max 1 Q chassis Between wiring harness and chassis Min 1...

Page 423: ...ravel Lever operated Max 1 V Start engine 3 YES l Between SO1and C02 Max 1 R l Between wiring harness and chassis Min 1 MQ l Disconnect SO1and C02 Travel lever I operated Max 1 R NO l Lever at neutral...

Page 424: ...YES disconnection in wiring Is resistance between harness between SO4 SO4 female 2 and female 1 and chassis m_ CO2 female 2 2 normal and is circuit insulated from Defective contact short Is resistance...

Page 425: ...ancebetween chassis l Boom RAISE SO2 male 11and 2 operated normal and is circuit c l Beve exSp2Cand No Max 1 V NO insulatedfrom chassis l Be een wiring harness and chassis Min 1 MD Start engine _ Disc...

Page 426: ...d is circuit Arm IN operated Max 1 V Start engine SO5 male 1 and 2 S05 Max 1 I Between wiring harness and chassis Min 1 ML l Disconnect CO2 and S05 Arm IN operated Max 1 1 Nfl iever at neutral Min 1 M...

Page 427: ...perated Max 1 V Start engine Is resistance between So3 male 1 and 2 normal and is circuit N3 insulated from chassis l rJ operated l Lever at neutral Min 1 MQ Start engine Disconnect S03 Hi l Between 0...

Page 428: ...cuit insulatedfrom Is resistancebetween chassis SO6 male 1 and 2 _ normat and is circuit _ Between CO2and No 3 insulatedfrom SO Max 1 R chassis l Between wiring harness and chassis Min 1 MR l Disconne...

Page 429: ...d is circuit NO insulatedfrom l Start engine chassis l vee xC 2Dand NO l Bet aen wiring harness and chassis Min 1 MC Disconnect CO2and S07 Bucket DUMP I ooerated Max 1 R Nn l Lever at neutral AT_ Min...

Page 430: ...isconnected connectors before going on to the next step 1 Y YES 1 I Defective pump controller I Replace Is voltage between Defective swing lock switch CO2 9 and CO1 1 Disconnection or short 2 normal 2...

Page 431: ...ed P Defective pump COntrOkr f See TESTING AND _ Is voltage between ADJUSTING NO t nd 14 Defective engine speed Measure in AC NO sensor range 0 5 3v Reference Low 1 9v Defective contact or l Start eng...

Page 432: ...ed jl Always connect any disconnected connectors before going on to the next step 1 Is voltage between 3 YES CO2 181and chassis normal Is resistance YES between terminals _ 2 l L H knob switch cUa Ob...

Page 433: ...O F O modes work equipment speed is faster that specified speed Compound operations H l 6 In compound operations work equipment with larger load is slow H 17 In swing boom RAISE boom RAISE isslow H 18...

Page 434: ...fasterthan set speed 0 0 00 H l H li v In compound operations work equipment with larger load is slow 0 5E 0 0 H l L Tij In swing boom RAISE boom is slow In swing arm OUT arm is slow 6 0 H ll s g In s...

Page 435: ...c l a s s i c ma c h i n e r y n e t...

Page 436: ...t operation of u boom Arm IN bucket CURL ai Independent operation of when condition is d arm P Arm OUT bucket DUMP ii t Independent operation of 5 B and front or rear pump o bucket 5 pressure more tha...

Page 437: ...see TESTING AND ADJUSTING See below 7yEs Does condition become normal when servo NO assembly is replaced Distribution of NO servo LS and TVC and piston pump servo piston 2 2 2 kg cm Engine at high ZZ...

Page 438: ...rvo piston Correct or replace Defective operation of LS control EPCsolenoid valve Replace Defective operation of sub Repair or unload valve replace Defective operation of main Replace relief valve Def...

Page 439: ...ective servo piston I I I See below Adjust or replace servo valve assembly Replace piston pump assembly Replace the servo valve assembly on the defective side with a new part and if the engine speed i...

Page 440: ...inkage I around pump Cause Is hydraulic tank oil level normal Are there bubbles inside hydraulic tank 3 YES KH Goto4 NO Is suction strainer External object Cloth etc Is suction strainer clogged with m...

Page 441: ...oes condition become normal _ when oil pressure switch is replaced NO H 6 Fine control ability is poor or response is poor Defective oil pressure switch Defective operation of PPC shuttle valve in app...

Page 442: ...l Engine at high idling n 5 Is relief pressure of front and rear pumps normal when boom RAISE circuit is relieved P l 31 9 1 0 MPa 325 10 kg cm l Engine at high idling normal or does pres sure compens...

Page 443: ...ve operation of pump When boom is NO merge divider solenoid valve raised 0 MPa 0 kg cm Defective boom holding valve or suction valve of control valve Defective operation of boom Repair or holding valv...

Page 444: ...of PPC vaii normal 1 l Min 2 74 MPa Min 28 kg cm Engine at high idling Yl Does control valve Y A normal or doespres surecompensation valve pistonmove l It is also possible tc interchange with other co...

Page 445: ...shuttle for L H travel boom R H travel or bucket 8YE S Defective operation of main merge divider valve or LS Repair or Is pump merge merge divider valve replace _ divider solenoid valve output pressu...

Page 446: ...ng NO Max 20 cc min Et e at high NO l w pP to other compensation valve Note After inspection do not forget to return to the original position Cause refeciive operation of ontrol valve spool refective...

Page 447: ...rchanged Isslippersealof pree e GotoA leakage of cylinder surecompensation Max 20 cc min valvefreeof damage l At relief N Or doespressure corn Engine at high idling O pensatron valvepiston movesmoothl...

Page 448: ...g approx 1306 rpm or below regardless of the working mode H 13 Lack of power when pressure rises Cause If condition is normal except when pressure rises j Carry out troubleshooting with the swing prio...

Page 449: ...replace Defective operation of main merge divider valve epair or eplace Defective operation of pump merge divider solenoid valve qepair or eplace Remedy Output pressure of LS control EPC solenoid tra...

Page 450: ...r replace Repair or replace H 18 In swing arm OUT arm OUT is slow See H 17 If the operation is normal when the swing and arm OUT are operated independently carry out trouble shooting with the swing Pr...

Page 451: ...k tip NO Cause Defective travel motor Repair or assembly Note 2 replace Defective operation of control valve spool Defective operation of travel junction valve Defective PPCshuttle Defective PPC valve...

Page 452: ...dling Travel relief NO yl 6 compensation valve normal or does pres sure compensation valve piston move It is also possibleto interchangewith other compensatronvalve N Note After inspection do not forg...

Page 453: ...e travel motor assembly Defective pressure compensation valve or defective operation of pressure compensation valve piston Defective operation of control valve spool Defective operation of travel junc...

Page 454: ...ted system is normal k Difficult to turn to both left and right when relieved on Pressure high only on side not being relieved 1 4 YES p pqj H Min 2 74 MPa NO Min 28 kg cm Engine at high idling Set sw...

Page 455: ...control valve main circuit check valve remains open iepair or eplace Defective control valve suction valve ieplace YES Defective travel motor check lepair or eplace I 8 YES Does condition become norma...

Page 456: ...I Hi PC200 2 0 f 0 2 MPa PC21 0 20 fi 2 kg cm PC220 1 8 f 0 2 MPa PC250 18 f 2 kg cm 2 0 f 0 2 MPa 20 h 2 kg cm 1 8 f 0 2 MPa 18 f 2 kg cm 0 2 f 0 2 MPa 2 2 kg cm 0 2 f 0 2 MPa 2 f 2 kg cm Remarks l E...

Page 457: ...g in one direction l Min 2 74 MPa Min 28 kg cm l CIcFte swmg l Tu sw g lock Defective swing machinew Repair or replace Defective swing holding Repair or brake or swing motor replace Defective operatio...

Page 458: ...O Go to Item 5 8 VALUE TABLE n 6 One direction only l Min 2 74 MPa Min 28 kg cm l Engine at high idling l Turn swing lock switch ON lock yes Does control valve spool move 7 smoothly Is output pressure...

Page 459: ...e interchanged It is also possible to NO measure relief pressure of motor Relief pressure 27 4 23 4 MPa 280 310 kg cm Note After inspection do not forget to return to the original position Defective s...

Page 460: ...YES when left and right 2 swmg PPCslow return valves are Is problem reversed interchanged _ _ YES when left and right Defective PPC valve outout hoses of PPC Repair or replace Does control valve smoo...

Page 461: ...ve Defective PPC valve H 29 Excessive abnormal noise when stopping swing become normal when safety valve YES 2 Does condition becomenormal _ when suction valve is cleaned 3YEs Is dirt found in NO swin...

Page 462: ...dling l At swing relief b When swing brake is applied Cause 1 Defective swing motor safety valve Defective swing motor suction valve Defective pressure compensation valve or defective operation of pre...

Page 463: ...f LS alve qeplace servo sssembly reeztive LS control EPC Repair or replace refective operation of main Terge divider valve or LS lerge divider valve Repair or replace tefective operation of pump Repai...

Page 464: ...d engine is started CAUTION items flash but when there is no abnormality in engine or CHECK items 20 254 a Engine oil pressure flashes 20 254 b Coolantlevelflashes 20 25 5 c Coolant temperature flashe...

Page 465: ...ntrol cannot be carried out switch pressed for 5 seconds to actuate clear 2 When there is abnormality in pump controller function the output is cut off so control cannot be 1 Abnormality in internal c...

Page 466: ...zzer cancel PlO KES12 w I ndow washer WiDer motor controller Puma controller Engine oil level sensor coolant temDerature Engine throttle controller Model selection connector Fuel level Engine sDeeci s...

Page 467: ...gain and keep the time switch depressed for 5 seconds to return the system to normal M 3 El 031 Short circuit in buzzer output or contact of 24V wirin harness with buzzer drive harness is displayed If...

Page 468: ...starting switch ON NO M 4 Related electric circuit diagram Monitor panel POl O4020 Power a Fuse source 1 13 a W 6 H05tM6 GND g X08DD164 b Some of lamps on monitor panel gauge display time display do...

Page 469: ...y of monitoring code 01 as shown in Table l 2 Turn starting Do bits I 2 3 switch ON _ of monitonng code Set to NO 36 light up as monitoring code shown in Table l 01 Turn starting switch ON l Set to h...

Page 470: ...n in the switch ON Is there continuity table _ between PO8 Connect ct disconnect NO _ NO female 2 and shortconnector to PO8 chassis ground female Turn starting switch OFF l Turn starting Disconnect PO...

Page 471: ...M 7 b Related electric circuit diagram EOB SWP14 or Connection with ground Continuity Connected Yes Disconnected X08DD166 cl cl 6 hydraulic oil level flashes Remedy Cause Y 1 5 When PO9 female 1 iscon...

Page 472: ...voltage between harness with wiring harness wiring of starting s between starting switch switch terminal Rl l Ov NO terminal Rl HO3 21 or and chassis ground l TurTurctaarti g between PO1 8 HO3 2 norm...

Page 473: ...ng on to the next step j Check both the alternator system and the engine oil pressure system a Alternator system Cause I I or above l 26 30V Start engine and run at half throttle NO or above Iefective...

Page 474: ...switch OFF l Disconnect wiring harness PO1 of oil pressure sensor M 9 Related electric circuit diagram Defective oil pressure sensor Replace Contact of chassis ground with wiring harness between PO1...

Page 475: ...O2 stopped Max 3 V female 13 l Turn starting switch ON l Disconnect P02 Defective alternator NO l Remove wmng harness from terminal R b Engine oil pressure sensor system When engine oil pressure is no...

Page 476: ...engine oil pressure flashes kl 1 harness at terminal sensor is removed Engine at low idling B B I i0 I Is there continuity between PO1 female 17 11 12 Turn starting switch OFF Disconnect POl NO Cause...

Page 477: ...cted to PO7 system see M 21 _ female does Is coolant display go out temperature _ Start engine NO Defective monitor panel Replace gauge in red range Start engine and run at half Defective monitor pane...

Page 478: ...Start engine and rrn lf throttle 2 YES When PO6is removed does displaygo out DisconnectP06 l Start engine NO l Wait for approx 2 minutes t The fuel level may vary so the displayisgivena time delay M l...

Page 479: ...r fuel level 1YES When PO1 female 13 and chassis are connected fioe yzer l Tz c arng NO Defective monitor panel Disconnection in wiring harness between PO1 female 13 PO4 2 buzzer or between t24V PO4 1...

Page 480: ...bulb blown or is there defective contact 2 yEsm Defective monitor panel A l Remove bulb Does bit 2 of l Check bulb monitoring code 46 visually NO light up Defective contact or disconnection in wiring...

Page 481: ...gauge 2YF S 1Isthere continuitv i 1 I between PO2 female and chassis when short l l Turn startina NO switch OFF Disconnect P02 Defective coolant temperature sensor system see M 21 Defective monitor pa...

Page 482: ...12 _ NO gducnhF Turn starting NO switch OFF k7connect P02 M l 5 Related electric circuit diagram PO2 HO3 E08 04016 516 SWP14 PO7 X2 Monitor panel Cause Remedy Defective coolant temperature sensor syst...

Page 483: ...given a switch OFF time delay l Disconnect P02 P06 M 17 Fuel level gauge does not give display Check that there is actually no fuel before carrying out troubleshooting Does display appear when PO6 fem...

Page 484: ...x01 Swing lock switch 040161 MIC21 X05 M4 1 1 2 Monitor panel 3 b 4 w 6 205CAO6540 M 19 Swing lock prolix switch is ON prolix but monitor panel parking display does not flash Carry out this troublesho...

Page 485: ...el level sensor when carrying out the troubleshooting YE resistance between connector 1 and 3 YES interference with sensor Replace Note 2 m Is there any large 2 crack chip or damage to float inside ta...

Page 486: ...r Note 1 Iisconnection in wiring larness Note 2 defective lamp external force applied 3efective sensor Remedy lean connector ir replace ensor leplace sensor leplace Note 1 If the problem occurs again...

Page 487: ...nce of mount Defective contact of connector Note 2 Disconnection in wiring harness Note 3 defective clamp external force applied Defective sensor UP lean eplace sensor Jote 4 lean connector r replace...

Page 488: ...Min 1 MD ri l Float I I I Cause Iefective movement of float dueto dirt Resonanceof mount Note 2 Defective contact of connector Note 2 Disconnection in wiring harness Note 3 defective clamp external fo...

Page 489: ...ve contact of C onnector Note 2 _ C a hsconnection in wiring larness Note 3 defective lamp external force pplied tefective sensor Cause Remedy Clean Replace sensor Note 4 Clean connector or replace Re...

Page 490: ...ween MO7 male 2 X01 3 fuse 4 etween MO7 male 1 X01 1 IO4 11 RO4 2 HO5 1 chassis Iround between RO4 3 and fuse 0 between RO4 5 HO2 10 flWfemale ll or between RO4 5 102110 MlOt11 MOS female 1 defective...

Page 491: ...arness or power source with wiring harness between MO7 male 1 X01 1 R04 1 Defective light relay DisconnectR04 NO Min 1 MR 0 M 25 Related electric circuit diagram Light switch Defective light switch LH...

Page 492: ...Between 12 15 Max 1 Q INT mode Between 1 2 Between 12 14 Between 2 4 Between 14 15 Min MR Between 1 2 Between 12 14 OFF mode Between I 4 Between 12 15 Min 1 MQ Between 2 4 Between 14 15 Between 1 2 Be...

Page 493: ...Safety circuit during operation of wiper Tsa 10 set safety function 111 Set time 10 set Item Symbol Length of pause until next actuation Tla 4 set Safety circuit during operation of wiper Tsa safety f...

Page 494: ...Table 3 l Max 1 MR l Turn starting switch OFF Disconnect W04 b Table l Between 14 15 Dek ive wiper washer Ieplace Defective contact or disconnection in wiring harness between Ml0 male1 3 4 W08 female...

Page 495: ...blade Safety circuit during operation of wiper safety function WI Symbol Set time Tla 0 13 set Tsa 10 set TIP 1 5set Tsp 10 set Item 1 Symbol 1 Set time 1 Length of pause until next actuation Tla 4se...

Page 496: ...EMBLY 30 24 REMOVAL 30 25 FINAL DRIVE 30 25 INSTALLATION 30 25 DISASSEMBLY OF FINAL DRIVE ASSEMBLY PC200 6 PC2OOLC 6 PC21OLC 6 PC22OLC 6 30 26 ASSEMBLY hi dl k tibLY PC200 6 PC2OOLC 6 PC21OLC 6 PC22OL...

Page 497: ...OR REAR PUMP 30 I 25 lN kk 30 125 REMOVAL 30 126 LS CONTROL EPC VALVE 30 126 INSTALLATION 30 126 REMOVAL 30 127 SOLENOID VALVE 30 127 INSTALLATION 30 127 REMOVAL 30 128 WORK EQUIPMENT SWING PPC VALVE...

Page 498: ...MOVAL 30 I 56 OPERATOR S CAB 30 I 56 INSTALLATION 30 I 58 REMOVAL 30 I 59 COUNTERWEIGHT 30 159 INSTALLATION 30 159 REMOVAL 30 I 60 ENGINE THROTTLE CONTROLLER 30 160 INSTALLATION 30 160 REMOVAL 30 I 61...

Page 499: ...c l a s s i c ma c h i n e r y n e t...

Page 500: ...y components tighten the forcing screws alternately Before removing any unit clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal Precautions when handlin...

Page 501: ...to prevent excessive tightening on one side When operating the hydraulic cylinders for the first time after reassembling cylinders pumps and other hydraulic equipment removed for repair always bleed t...

Page 502: ...tool I 790 l 01 2510 792 I04 3940 01580 11631 Press fitting of bearing inner race 01643 31645 Disassembly assembly of final drive assembly 790 I 05 2100 Jack 1 I 1 790 101 1102 Pump I 1 I 796 570 lII...

Page 503: ...790 101 1300 790 101 1102 790 434 I 630 Cylinder 100 ton 1 PC25OLC Pump 1 Installer 1 Installation I off Remove press fitting of master pin Toating seal 791 601 1000 Oil pump 1 Charging with oil check...

Page 504: ...C25OLC Socket width across flats 95 mm 790 302 1450 BUCKET PC200 PC2OOLC PC21 OLC Hydraulic cylinder 0 Socket width across flats 85 mm 790 302 I 350 1 790 720 I 000 Expander 1 Expansion of piston ring...

Page 505: ...1 I 640 l 790 101 5021 l 01010 50816 Push tool kit Push tool l Grip l Bolt 790 201 1500 l 790 201 I 650 l 790 I 01 5021 OlOlO 50816 Push tool kit Push tool l Grip l Bolt 790 201 I 500 0 790 201 I 660...

Page 506: ...ports 1 Don t release gas into the atmosphere Remove fan guard 2 Disconnect hoses 3 and 4 and disconnect electrical connector Loosen bolts 5 and 6 and rotate compressor about bolt 5 towards the engine...

Page 507: ...slightly and release the refrigerant RI 34a completely before disconnecting hoses and tubes Fit plugs to hoses and tubes to prevent ingress of moisture dust or dirt 4 Remove condenser assembly 5 by re...

Page 508: ...Remove motor cover 4 Remove motor rod 2 Remove governor motor assembly 3 Sr m Rotate the shaft of the governor motor and do not stop it suddenly INSTALLATION OF GOVERNOR MOTOR ASSEMBLY 0 Carry out in...

Page 509: ...side of hydraulic oil cooler assembly 4 Sling hydraulic oil cooler assembly 7 remove 2 mounting bolts each on left and right then lift off hydraulic oil cooler assembly 7 6 Hydraulic oil cooler assem...

Page 510: ...nk strainer and using tool B stop the oil l When not using tool B remove the drain plug and drain the oil from the hydraulic tank and inside the system Hydraulic tank Approx 170 P Drain engine coolant...

Page 511: ...bly When raising the radiator and hydraulic oil cooler assembly check the position carefully and do not let it hit the fan when removing it Radiator l hydraulic oil cooler assembly 125 kg INSTALLATION...

Page 512: ...hydraulic tank strainer and using tool B stop the oil l When not using tool B remove the drain plug and drain the oil from the hydraulic tank and inside the system Hydraulic tank Approx 170 P Mark al...

Page 513: ...onnect Remove the connector wiring clamps completely 6 Disconnect hoses 12 and 13 from control pump 7 Remove suction tubes 14 and 15 8 Disconnect hoses 16 and 17 installed to top of main pump assembly...

Page 514: ...h 24B Disconnect air conditioner compressor hoses 25 and 26 If fitted Loosen the sleeve nut slightly and release the refrigerant gas completely before disconnecting the hoses Fit blind plugs to preven...

Page 515: ...EMBLY 0 Carry out installation in the reverse order to removal Engine mount bolt 276 9 f 31 9 Nm I r J XlOARO25 m 28 3 f 3 3 kgm Refilling with coolant Add coolant through the water filler to specifie...

Page 516: ...ER ASSEMBLY 1 Remove main pump assembly For details see REMOVAL OF MAIN PUMP ASSEMBLY 2 Remove damper assembly 1 INSTALLATION OF DAMPER ASSEMBLY 0 Carry out installation in the reverse order to remova...

Page 517: ...r 6 Remove connector 7 from holder and disconnect it Remove the wiring from the clamp then disconnect from the fuel tank If refueling pump is fitted disconnect hose 9 from tank tube Remove mounting bo...

Page 518: ...vel joint Remove elbow 11 Disconnect drain hose 12 Disconnect hoses 13 and 14 between control valve and swivel joint Disconnect travel speed selector hose 15 Disconnect plate 16 Remove center swivel j...

Page 519: ...OINT ASSEMBLY 1 Assembly slipper seal 7 and O ring 6 to swivel rotor 2 Set swivel shaft 5 to block then using push tool tap swivel rotor 4 with a plastic hammer to install Contact surface of rotor sha...

Page 520: ...extremely careful not to damage the tool surface of the hose mount Final drive assembly 425 kg INSTALLATION OF FINAL DRIVE ASSEMBLY 0 Carry out installation in the reverse order to removal m Final dri...

Page 521: ...then remove cover 1 using eyebolts 0 X07HH037 Spacer Remove spacer 2 No 1 sun gear shaft Remove No 1 sun gear shaft 3 5 No 1 carrier assembly 1 Remove No 1 carrier assembly 4 X07HH039 2 Disassembly No...

Page 522: ...embly 1 Remove No 2 carrier assembly 15 2 Disassemble No 2 carrier assembly as follows i Push in pin 16 and pull out shaft 17 from carrier 18 After removing the shaft remove pin 16 ii Remove thrust wa...

Page 523: ...0 remove hub assembly 25 from travel motor 2 Disassemble hub assembly as follows i Remove floating seal 26 ii Remove bearings 27 and 28 from hub 2 3 Remove floating seal 30 from travel motor 31 X07HH...

Page 524: ...eck that the angle of the floating seal is within 1mm After installing the floating seal coat the sliding surface thinly with engine oil 3 4 Using tool G install floating seal 30 to travel motor 31 Th...

Page 525: ...ck plate as shown in the diagram below Casting notch X07HHOSO Thread of mounting bolt Thread tightener LT 2 Do not coat the tap portion of the nut with thread tightener LT 2 3 No 2 carrier assembly 1...

Page 526: ...oothly 2 Install No 2 carrier assembly 15 4 Thrust washer Install thrust washer 14 5 No 2 sun gear Install No 2 sun gear 13 6 No 1 carrier assembly 1 Assemble No 1 carrier assembly as follows There ar...

Page 527: ...eyebolts Q align position of bolt holes of hub and ring gear 12 and install j Remove all grease and oil from the mating surface of the ring gear and hub Do not put any gasket sealant on the mating su...

Page 528: ...t washer Remove thrust washer 2 4 No 1 sun gear shaft Remove No 1 sun gear shaft 3 5 No 1 carrier assembly 1 Remove carrier assembly 4 2 Disassemble carrier assembly as follows i Remove mounting bolts...

Page 529: ...assembly as follows I 1 0 ii iii iv Remove mounting bolts i7 then remove holder Set carrier assembly 16 in press then using push tool 0 pull out pin 18 and remove gear assembly 19 Remove bearing 21 a...

Page 530: ...AL DRIVE 13 Hub assembly 1 Using eyebolts a remove hub assembly 27 from travel motor 2 Remove floating seal 28 3 Remove cage 29 then remove floating seal 30 4 Remove bearing 31 and 32 30 35 0 c l a s...

Page 531: ...parts before installing the floating seal After installing the floating seal check that the angle of the floating seal is within 1 mm After installing the floating seal coat the sliding surface thinly...

Page 532: ...bearing clearance again Hook spring balance 0 in the tap hole for the sprocket mount bolt pull to rotate the hub on the shaft and measure the starting force j Starting force See Tightening Torques an...

Page 533: ...n be ex tremely careful of the angle of the pin and rotate the gear while press fitting After assembling the carrier assembly check that gear 19 rotates smoothly iv Fit holder and tighten with mount b...

Page 534: ...it pin 6 When press fitting the pin be ex tremely careful of the angle of the pin and rotate the gear while press fitting After assembling the carrier assembly check that gear 19 rotates smoothly iv F...

Page 535: ...til start mark on socket is aligned with end mark on cover Mounting boll Stan mark 00socket X07HH076 j When disassembling or assembling the final drive replace cover mounting bolt with bolt and tighte...

Page 536: ...pplied to the plug so push the removal tool at a right angle when loosening the plug 3 End cover assembly and valve plate XlOAV14t 1 2 3 4 5 Turn over tool A and remove safety valve assembly 5 Loosen...

Page 537: ...force of approx 441 N 45 kg applied to the plug so push the removal tool at a right angle when loosening the plug Remove plug 14 then remove spring 15 and valve 16 Remove ring 17 then remove seat 18 s...

Page 538: ...face to protect the surface Never allow the puller to scratch or damage the cylinder block sliding surface 7 Cylinder block and piston assembly 1 Rotate tool A 90 and remove cylinder block and piston...

Page 539: ...32060 x 2 Nut 01582 02016 Hold bolt of tool Q with wrench tighten nut to compress spring then remove snap ring 36 38 39 Loosen nut slowly to relieve tension of spring 39 then remove tool Q Remove spac...

Page 540: ...needed and only the oil seal is replaced replace the oil seal as follows 1 Remove snap ring 46 and spacer 47 2 Using bar 8 hit end face with hammer hit through to core of oil seal 48 then twist to re...

Page 541: ...1 2 Using tool R press fit bearing 44 to shaft 43 to make shaft assembly 42 Tool R Push tool 709 465 I 120 When press fitting the bearing push the end face of the bearing inner race with tool R and p...

Page 542: ...2 Assembly of piston assembly Assemble piston 37 to retainer shoe 36 3 Assembly of cylinder block and piston assembly i Assemble 3 preloaded pins 35 to cylinder block 32 j Coat the preload pins with g...

Page 543: ...up ring in the direction shown in the diagram 5 Adjusting end play of shaft 1 2 3 Using tool S and puller 8 press fit bearing 27 to shaft 43 Tool S Push tool 796 460 I 120 When press fitting the beari...

Page 544: ...pacer from table below XlOAV17 al b mm 1 1 70 1 79 1 1 80 1 89 1 1 90 1 99 1 2 00 2 09 Spacer to 708 8H 708 8H 708 8H 708 8H select 32220 32230 32240 32250 v Assemble selected spacer then assemble aga...

Page 545: ...6 and spring 15 in order then fit backup ring and O ring and install plug 14 Plug 137 3 f 14 7 Nm 14 1 5 kgm v Assemble spool 13 piston 12 and spring 11 in order then fit O ring and tighten plug 6 tem...

Page 546: ...spring 3 then fit O ring and install plug 2 Precautions when installing plug 1 Remove all oil and grease from the plug and male thread motor case and dry completely 2 When coating with adhesive coat...

Page 547: ...DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR 3 Assemble spacer 47 and install snap ring 46 46 47 30 52 0 c l a s s i c ma c h i n e r y n e t...

Page 548: ...h 3 Set the tool in position then paint the cylinder block with inspection paint Coat thinly with paint 4 Push the valve plate with a force of 39 2 49 0 N 4 5 kg against the cylinder block turn the va...

Page 549: ...uipment and set block 0 between track frame and track shoe 3 Lift off sprocket 1 INSTALLATION OF SPROCKET 0 Carry out installation in the reverse order to removal A Thread of sprocket mounting bolt Th...

Page 550: ...kg kg 2 3 Remove hose clamps 7 and 8 Disconnect swing motor inlet and outlet hoses 9 IO and 11 4 Remove bracket 12 5 Disconnect drain hoses 13 and 14 6 Disconnect pilot hose 15 7 Remove swing motor as...

Page 551: ...oses Swing machinery assembly 215 kg INSTALLATION OF SWING MACHINERY ASSEMBLY 0 Carry out installation in the reverse order to removal Swing machinery mounting bolt 548 8 r49 Nm 56 f 5 kgm Refilling w...

Page 552: ...8 e 2 Cover Remove mounting bolts then remove cover 1 3 No 1 ring gear Remove No 1 ring gear 2 2 Disassemble No 1 carrier assembly as follows i Remove snap ring 5 then remove thrust washer 6 gear 7 be...

Page 553: ...upling Remove coupling 14 Cover Remove mounting bolts then using eyebolts 0 remove cover 15 8 No 2 ring gear Remove No 2 ring gear 16 9 No 2 sun gear Remove No 2 sun gear 17 10 Bolt Remove holder moun...

Page 554: ...e plate 27 12 Shaft assembly 1 Remove mounting bolts 28 2 Set shaft and case assembly to press then using push tool 0 remove shaft assembly 29 from case assembly 30 21 23 24 25 26 2j 20 XOSDH050 3 Dis...

Page 555: ...ce of oil seal Gasket sealant LG 6 Be careful not to let the gasket sealant LG 6 get on the oil seal lip when press fitting 2 Fit cover assembly 31 to case 37 and tighten mounting bolts 28 Cover mount...

Page 556: ...the caulked metal from the inside diameter of the hole before starting to assemble Assemble plate 27 to carrier 22 Assemble bearing 25 to gear 24 fit top and bottom thrust washers 23 and 26 and set g...

Page 557: ...for oil filler port as shown in diagram then install Cover mounting sealant LG 6 surface Gasket Mounting bolt 276 s31 9 Nm 28 25 3 25 kgm 10 Coupling Install coupling 14 11 No 1 carrier assembly 1 Ass...

Page 558: ...ly 4 12 No 1 sun gear Install No 1 sun gear 3 13 14 15 No 1 ring gear Align position of holes for oil filler port of No 1 ring gear 2 with cover 15 then install Ring gear mounting surface Gasket A sea...

Page 559: ...p mounting hoses I 2 and 3 of swivel joint assembly at swivel joint assembly end Remove stopper link 4 Remove mounting bolts then lift off revolving frame assembly 5 1 A Leave 2 bolts 0 each at the fr...

Page 560: ...r LT 2 Revolving frame mounting bolt Item Mounting bolt Mounting bolt tightening torque Model PC200 6 PC21 O 6 PC220 6 PC250 6 Size 22 l 10 24 l 50 l Refilling with oil hydraulic tank Add oil through...

Page 561: ...g circle mounting bolts I leaving 1 bolt each in front and rear direction m Swing circle assembly mounting bolts 36 3 Sling swing circle assembly 2 at three points then remove remaining mounting bolts...

Page 562: ...base make start marks on the swing circle and socket Make an end mark at a point on swing circle 48 5 from the start mark Tighten so that the start mark on the socket is aligned with the end mark on...

Page 563: ...135 kg PC25OLC 6 166 kg 257 kg INSTALLATION OF IDLER RECOIL SPRING ASSEMBLY l Carry out installation in the reverse order to removal PC200 6 PC200LC 6 PC21OLC 6 and PC220LC 6 When installing the idle...

Page 564: ...OLC 126 420 N 12 900 kg PC25OLC 173 260 N 17 680 kg 2 Apply hydraulic pressure slowly to compress spring and remove lock plate 3 then remove nut 4 Compress the spring to a point where the nut becomes...

Page 565: ...ulic pressure slowly to compress spring and tighten nut 4 so that installed length of spring is dimension a then secure with lock plate 3 Jr Installed length a of spring PC200 437 mm PC2OOLC PC21OLC P...

Page 566: ...from shaft 5 and support 7 assembly It is filled with oil so drain the oil at this point or lay a cloth to prevent the area from becoming dirty 4 Remove floating seal 6 on opposite side from idler 4 a...

Page 567: ...floating seal 6 to idler 4 and shaft 5 and support 7 assembly Coat the sliding surface of the floating seal with oil and be careful not to let any dirt or dust get stuck to it Remove all grease and o...

Page 568: ...4 3 Remove all grease and oil from the contact surface of the O ring and the floating seal X14AVO24 6 Install O ring then install support 2 with dowel pin 1 7 Add oil and tighten plug Oil PC200 PC2OOL...

Page 569: ...ROLLER ASSEMBLY l Carry out installation in the reverse order to removal Adjust the track tension For details see TESTING AND ADJUSTING Testing and adjusting track tension lace the plug on the outsid...

Page 570: ...an angle tightening wrench tighten bolt 105 5 When not using tool K Using the angle of the bolt head as the base make start marks on the track roller and socket Make an end mark at a point 105 5 from...

Page 571: ...ll out roller 4 from shaft 5 It is filled with oil so drain the oil at this point or lay a cloth to prevent the area from becoming dirty 4 Remove floating seal 6 on opposite side from roller 4 and sha...

Page 572: ...no dirt or dust sticks to the contact surface of the floating seal 4 Using tool K install floating seals 6 and 3 to the roller 4 For details of the precautions when installing floating seals 6b and 6d...

Page 573: ...king The basic pressure shall be maintained for IO seconds and the indicator of the gauge shall not go down 10 Using tool K2 fill track roller assembly with oil then tighten plug 11 Plug 14 7 f 4 9 Nm...

Page 574: ...ng hydraulic jack 0 push up the track to a position where carrier roller assembly can be removed then remove carrier roller assembly 2 Carrier roller assembly m PC200 PC2OOLC PC21 OLC PC220LC 21 kg PC...

Page 575: ...sembly on stand 0 Remove cover 2 Remove ring 3 Using tool L remove nut 4 Using push tool 0 pull out shaft assembly 5 from roller 6 with press then remove inner race 7 6 lIsE l 8 9 7 Remove outer races...

Page 576: ...ke sure that no dirt or dust sticks to the contact surface of the floating seal 3 Assemble floating seals 1 I then using push tool 8 press fit inner race 10 For details of the precautions when install...

Page 577: ...8 kPa 1 kg cm2 Method of checking The basic pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down Using tool L fill carrier roller assembly with oil then tighten...

Page 578: ...n 2 m Remove tool I and move machine forward so that the position of temporary pin 0 is at front of idler and set block 0 in position Remove temporary pin Q and remove dust seal then drive machine in...

Page 579: ...I hood mounting bracket 2 cover 3 and engine room divider board 4 Disconnect pump outlet hoses 5 Remove pump suction tube 6 together with joint hose 7 6 Remove connector 8 at side of hydraulic tank f...

Page 580: ...ank 135 kg INSTALLATION OF TANK ASSEMBLY Carry out installation in removal HYDRAULIC the reverse order to Hydraulic tank mounting bolt 276 9 f 31 9 Nm 28 25 f 3 25 kgm Refilling with oil hydraulic tan...

Page 581: ...the hydraulic tank and inside the system Hydraulic tank Approx 170 e Remove control pump inlet tube 1 Disconnect control pump outlet hoses 2 Remove control pump assembly 3 then remove coupling 4 m INS...

Page 582: ...engine hood cover side cover by pump chassis cover on top of main pump assembly and mounting frame Disconnect control pump hoses 1 and 2 and F servo hoses 3 and 4 then disconnect tube 5 at pump end Re...

Page 583: ...ry out installation in the reverse order to removal Involute spline of main pump Anti friction compound LM G A Mating surface of main pump case Gasket sealant LG 6 0 Refilling with oil damper Add engi...

Page 584: ...ve control valve assembly 4 2 Disassembly of control valve assembly lVC valve 9 ii iii iv v vi Remove solenoid assembly 5 then remove sleeve 6 and spool 7 Remove seat 8 then remove springs 9 and 10 Re...

Page 585: ...nd cap be careful not to drop it 3 Remove valve plate 40 l Disassembly of end cap i Remove dowel pin 41 from end cap 39 ii Remove bearing 42 iii Remove snap ring 43 iv Remove coupling 44 and ring 45 C...

Page 586: ...nder block i Set tool U to cylinder block 46 Tool U Bolt 790 201 3330 Washer 792 422 l 120 Washer 01643 32460 Washer 01643 31845 Nut 01580 01815 ii Hold bolt of tool U with wrench tighten nut to compr...

Page 587: ...t 6mm remove stopper 61 Set tool V in position and assemble spacer 0 to left side of rod 62 Tool V Holder assembly 791 463 l 100 Plate 791 463 I 150 Bolt 791 463 I 160 Move to side and loosen piston 6...

Page 588: ...and remove screw 71 and seal washer j Before loosening the locknut measure dimension L between the end face of the case and the end face of the screw 2 Rotate tool A 90 remove snap ring 73 from pump c...

Page 589: ...move control pump assembly 76 then remove collar 77 and coupling 78 Cylinder block and piston assembly Same operation as in Item 6 Servo piston assembly Same operation as in Item 7 Shaft and cradle as...

Page 590: ...t and cradle assembly l Assembly of shaft and cradle assembly 1 Assemble flange ring to shaft 66 then use push tool to press fit bearing 70 Press fitting surface of bearing Grease G2 Ll 2 0 When press...

Page 591: ...47 to tool A front pump only l Set the rear pump to tool W 5 Fit dowel pin and O ring to bottom surface of inside of pump case 47 then install shaft and cradle assembly 65 Cradle mounting bolt 110 3 f...

Page 592: ...of adhesive Loctite 648 Coat with three drops near area Piston 318 7 f 24 5 Nm 32 5 2 5 kgm 4 Positioning minimum swash plate angle 1 Set tool X in position Tool X Cage assembly 796 460 1400 Plate 79...

Page 593: ...der block 48 Assemble with the tapered portion on the inside of seat 57 facing down 0 1 2 3 4 Set tool U to cylinder block 48 Hold bolt of tool U with wrench tighten nut to compress spring 55 then ins...

Page 594: ...the width across flats of the rocker cam to the cradle securely End cap and valve plate 1 Assembly of end cap i Assemble ring 45 to coupling 44 then assemble to end cap 39 ii Install snap ring 43 iii...

Page 595: ...tool Y to pump shaft ToolY Bolt 01435 01014 Torque wrench 795 630 I 803 2 Set torque wrench to tool Y rotate shaft at low speed 3 5 set l turn and measure rotating torque Check that the shaft rotates...

Page 596: ...s mm No of standard shims 708 21 24170 1 0 1 I 2 708 21 24180 0 2 2 708 21 24190 0 5 2 Bolt 35 156 9 9 8 Nm 16 1 kgm 2 After completion of assembly carry out a bench test of the performance and make t...

Page 597: ...locknut 23 Locknut 23 68 6 4 9 8 Nm 7 f 1 kgm Install so that the dimension between the end face of locknut 23 and the end face of plug 24 is the dimension measured during disassembly iv After comple...

Page 598: ...all plug 11 Plug 11 0 15 kgm vii Install O ring assembly 5 11 3 _1 5 Nm 1 15 then install solenoid Solenoid assembly mounting bolt 13 2 f 1 5 Nm 1 35 0 15 kgm Mating surface of solenoid assembly Gaske...

Page 599: ...emove pump assembly from tool A l 2 3 Assemble orifice 34 and install spacer 33 filter 32 and O ring Orifice 34 9 8 f 2 0 Nm I O f 0 2 kgm After completion of assembly carry out bench test of servo va...

Page 600: ...ition _ Assemble backup ring and O ring tighten screw 79 until it contacts piston 63 then tighten locknut 80 Screw 12 3 2 5 Nm 1 25 f 0 25 kgm Locknut 220 6 f 24 5 Nm 22 5 2 5 kgm After completion of...

Page 601: ...y or other parts Mating surface of pump case Gasket sealant LG 7 or LG 5 Loctite 572 575 Mounting bolt 176 5 19 6 Nm 18 f 2 kgm XlOAV22E Measuring rotating torque of pump assembly 1 Set tool Y to pump...

Page 602: ...all control pump assembly 76 Mounting bolt 66 2 7 4 Nm 6 75 0 75 kgm Mating surface of control pump Gasket sealant LG 7 or LG 5 Loctite 5721575 25 Control valve assembly Same operation as in Item1 1 2...

Page 603: ...block with inspection paint Coat thinly with paint Push the valve plate with a force of 39 2 49 0 N 4 5 kg against the cylinder block Turn the valve plate 90 then turn it back to the original positio...

Page 604: ...t contacts the stopper Repeat this process 2 or 3 times Remove the rocker cam transfer the contact surface to a tape and check the contact surface 1 ii iii The standard for the contact surface is as g...

Page 605: ...int the end cap with inspection paint j Coat thinly with paint Push the valve plate with a force of 39 2 49 0 N 4 5 kg against the end cap turn the valve plate 90 then turn it back to the original pos...

Page 606: ...2 3 Lever up oil seal 3 with a screwdriver to remove j When removing the oil seal be careful not to damage the shaft INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL 0 Carry out installation in the reve...

Page 607: ...lator Start the engine and run at low idling for approx 5 seconds then stop the operation and operate the control levers j Repeat the above operation several times to release the remaining pressure co...

Page 608: ...EMBLY l Carry out installation in the reverse order to removal l Refilling with oil hydraulic tank Add oil through the oil filler to the specified level Run the engine to circulate the oil through the...

Page 609: ...rk cover remove divider cover I then disconnect intake connector 2 Disconnect hoses 3 4 and 5 and remove 2 connectors 6 from clip then disconnect Remove the hose mounting elbow from the valve body Rem...

Page 610: ...SSEMBLY 7 spool control valve 1 service valve Carry out installation in the reverse order to removal Refilling with oil hydraulic tank Add oil through the oil filler to the specified level Run the eng...

Page 611: ...mpensation valve 24 boom LOWER pressure compensation valve 25 left swing pressure compensation valve 26 L H travel FORWARD pressure compensation valve 27 and arm OUT pressure compensation valve 28 Aft...

Page 612: ...OL VALVE Right side of machine From front of machine 16 17 18 19 29 21 22 Left side of machine From rear of machine Front of machine From top of machine 11 15 10 14 9 XlOBH202 XlOBH203 30 117 0 c l a...

Page 613: ...ram 2 Assemble valve 58 and spring 57 to valve body and install pump merge divider valve 33 Mounting bolts 166 3 f 9 4 Nm 17 1 kgm Tighten the mounting bolts in the order shown in the diagram 3 Instal...

Page 614: ...de of machine From front of machine 16 17 18 19 20 21 22 Left side of machine From rear of machine 29 23 24 25 30 26 27 28 8 13 7 12 6 Front of machine From top of machine 0 3 1 il r s lb i4 XlOBH204...

Page 615: ...ole pump merge divider valve assembly ASSEMBLY OF PUMP MERGE DIVIDER VALVE ASSEMBLY 0 Before assembling coat the sliding surface with 3 Fit O ring to plate 5 and install to valve body engine oil 4 Ass...

Page 616: ...Remove spring 5 then remove ring 6 and O rings 7 and 8 from sleeve 1 After disassembling if there is any abnormality in sleeve I seal 4 piston sub assembly 2 or piston 3 replace the whole pressure com...

Page 617: ...remove nut 1 from sleeve 2 Remove sleeve 8 then remove sleeve 9 spring IO retainer 1I piston valve 12 and valve 13 Remove seal 4 backup ring 15 and O ring from sleeve 8 Remove plug 16 then remove rin...

Page 618: ...2 retainer II spring IO and sleeve 9 Install sleeve 8 and assemble poppet 7 piston 6 and spring 5 Sleeve 85 9 f 7 4 Nm 8 8 r0 8 kgm Assemble nut I O ring retainer 4 and piston 3 to sleeve 2 and instal...

Page 619: ...ide the system Hydraulic tank Approx 170 e Disconnect TVC l LS valve inlet hose 1 Disconnect n C solenoid wiring connectors 2 Remove TVC l LS valve assembly 3 m INSTALLATION OF TVC LS VALVE ASSEMBLY F...

Page 620: ...ystem Hydraulic tank Approx 170 P Disconnect TVC l LS valve inlet hose 1 Disconnect hose 2 Disconnect NC solenoid wiring connectors 3 Remove bracket 4 Remove TVC l LS valve assembly 5 MI INSTALLATION...

Page 621: ...isconnect wiring connector 1 3 Disconnect hose 2 4 Remove LS control EPC valve assembly 3 m INSTALLATION OF LS CONTROL EPC VALVE ASSEMBLY 0 Carry out installation in the reverse order to removal LS co...

Page 622: ...lve Fit tags on the hoses Disconnect hoses 4 installed to top of valve Fit tags on the hoses Remove mounting bolts then remove solenoid valve assembly 5 When removing solenoid valve as an individual p...

Page 623: ...er 4 then remove jr Remove the lock with a screwdriver and gradually lift the cover up to remove Remove joint bolt 6 and disconnect hose 7 F Remove mounting bolts raise PPC valve assembly 8 then disco...

Page 624: ...emove joint 4 unless it is to be replaced Remove seal 6 and collar 7 Pull out piston 8 and remove retainer 9 springs 10 and 11 and shim 12 Spring 1 consists of a set of two types of springs with diffe...

Page 625: ...iston 8 coat the outside of the piston and the inside of the hole in the body with grease 4 Fit O ring to collar 7 and assemble in body 14 then install seal 6 5 Install plate 5 m Mounting bolt 13 2 f...

Page 626: ...emove covers 4 then remove springs 5 Disconnect dampers 6 m Disconnect 6 PPC hoses 7 and remove travel PPC valve assembly 8 ml INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY 0 Carry out installation in rem...

Page 627: ...PC 1 Assemble valve 11 in body 12 2 Assemble shims 10 and spring 9 to valve 11 It Assemble the same number and thickness of shims 10 as was removed during disassembly Standard shim thickness 0 3 mm Sp...

Page 628: ...the same number and thickness of shims 2 as was removed during disassembly Standard shim thickness 1 6 mm W Mounting bolt a 27 9 3 4 Nm 2 85 f 0 35 kgm Mounting bolt b 30 9 f 3 4 Nm 3 15 0 35 kgm XlOB...

Page 629: ...onnect tube 3 Remove mounting bolts of bracket 4 then remove boom lock valve 5 together with bracket 4 INSTALLATION OF BOOM LOCK VALVE ASSEMBLY l Carry out installation in the reverse order to removal...

Page 630: ...ine and retract piston rod then tie piston rod with wire to prevent it from coming out Set stand 0 under the cylinder assembly and adjust the position for slinging A Release the remaining pressure in...

Page 631: ...thickness 0 8 mm 1 5 mm m Inside surface of bushing when a assembling pin Anti friction compound LM P Greasing after assembling pin Grease LM G A When aligning the position of the pin hole never inser...

Page 632: ...piston rod then tie piston rod with wire to prevent it from coming out A Release the remaining pressure in the hydraulic circuit For details see TESTING AND ADJUSTING Releasing remaining pressure in...

Page 633: ...d LM P Greasing after assembling pin Grease LM G A When aligning the position of the pin hole never insert your fingers in the pin hole j Adjust the shim thickness so that the clearance between cylind...

Page 634: ...and keep in a safe place 5 Start engine and retract piston rod then tie piston rod with wire to prevent it from coming out A Release the remaining pressure in the hydraulic circuit For details see TES...

Page 635: ...ss 0 8 mm 1 5 mm Inside surface of bushing when A assembling pin Anti friction compound LM P Greasing after assembling pin a Grease LM G When aligning the position of the pin hole never insert your fi...

Page 636: ...ylinder 4 Disassemble piston rod assembly as follows i Set piston rod assembly 2 in tool 0 ii Using tool O remove nut 3 Width across flats of nut Unit mm PC200 PC210 1 95 1 95 1 85 PC220 PC250 95 95 9...

Page 637: ...emove wear rings 12 3 Remove piston ring 13 3 Disassembly of cylinder head assembly 1 Remove O ring and backup ring 14 2 Remove snap ring ICI then remove dust seal W 3 Remove rod packing 17 4 Remove b...

Page 638: ...buffer ring 18 3 Assemble rod packing 17 4 Using tool 06 install dust seal 16 and secure with snap ring 15 5 Install backup ring and O ring 14 2 Assembly of piston assembly 1 Using tool O expand pist...

Page 639: ...plunger 5 l Boom and arm cylinder only Assemble piston assembly 4 Set piston rod assembly 2 to tool 0 I tit Using tool 02 tighten nut 3 Nut Thread tightener LT 2 m Nut Unit Nm kgm Cylinder I Boom I Ar...

Page 640: ...ith mounting bolts W Mounting bolt Cylinder Tightening torque PC200 PC21 0 Boom 270 f 39 Nm 27 5 4 0 kgm PC220 PC250 Boom I 373 f 54 Nm 38 0 f 5 5 kgm 1 373 54 Nm 38 0 f 5 5 kgm Bucket 270 39 Nm 27 5...

Page 641: ...k A Disconnect the boom cylinder on the opposite side in the same way Release the remaining pressure in the hydraulic circuit For details see TESTING AND ADJUSTING Releasing remaining pressure in hydr...

Page 642: ...w 1 mm j Standard shim thickness 0 8 mm 1 5 mm m Inside surface of bushing when assembling pin Anti friction compound LM P Grease after assembling pin a Grease LM G A When aligning the position of the...

Page 643: ...the num er and thickness and keep in a safe place 3 Start engine and retract piston rod then tie piston rod with wire to prevent it from coming out 4 Remove lock bolt 3 ml 5 Remove plate 4 then remove...

Page 644: ...the clearance between bucket boss 7 and link 8 is below 1 mm Standard shim thickness 0 8 mm 1 5 mm m Inside surface of bushing when assembling pin inside surface end face of collar 10 Anti friction co...

Page 645: ...ent it from coming out A Release the remaining pressure in the hydraulic circuit For details see TESTING AND ADJUSTING Releasing remaining pressure in hydraulic circuit Disconnect 2 hoses 3 and 2 hose...

Page 646: ...rease after assembling pin Grease LM G A When aligning the position of the pin hole never insert your fingers in the pin hole Adjust the shim thickness so that the clearance between boom top 6 and arm...

Page 647: ...pressure in the hydraulic circuit For details see TESTING AND ADJUSTING Releasing remaining pressure in hydraulic circuit Disconnect 2 hoses 2 and 2 hoses 3 Install blind plugs at the male end and in...

Page 648: ...of bushing when assembling pin Anti friction compound LM P Grease after assembling pin Grease LM G A When aligning the position of the pin hole never insert your fingers in the pin hole X17FR04r Insid...

Page 649: ...ut and lower it onto block Disconnect the boom cylinder on the opposite side in the same way A Release the remaining pressure in the hydraulic circuit For details see TESTING AND ADJUSTING Releasing r...

Page 650: ...kness 0 8 mm 1 5 mm Inside surface of bushing when assembling pin Anti friction compound LM P Grease after assembling pin Grease LM G When aligning the position of the pin hole never insert your finge...

Page 651: ...operator s seat assembly 2 Operator s seat assembly 40 kg Remove knob 3 Remove 4 caps 4 and clip 5 then remove middle panel 6 Remove bottom panel 7 j The panel is held by a clip so remove the clip wh...

Page 652: ...ker wiring connector cannot be seen so lift up the cover to disconnect the wiring 9 Remove divider board 13 10 Remove air conditioner ducts 14 15 and 15A 11 Disconnect wiring connectors CN HOI 16 CN H...

Page 653: ...0 kg When raising the cab assembly check that all the wiring has been disconnected then lift off slowly and be careful not to hit any part INSTALLATION OF OPERATOR S CAB ASSEMBLY 0 Carry out installat...

Page 654: ...bolt Thread tightener LT 2 Counterweight mounting bolt 1 325 145 Nm 135 15 kgm j Installing and adjusting counterweight 1 2 3 Sling counterweight with craneand set in position on frame Use counterweig...

Page 655: ...air conditioner hose 3 and speaker wiring connector then remove cover 4 When removing cover 4 the speaker wiring connector cannot be seen so be careful 3 Remove divider board 5 4 Disconnect wiring co...

Page 656: ...hose 3 and speaker wiring connector then remove cover 4 When removing cover 4 the speaker wiring connector cannot be seen so be careful Remove divider board 5 Remove air conditioner duct 7 Disconnect...

Page 657: ...from the negative terminal of the battery Remove screws I then lift up monitor assembly 2 Disconnect wiring connectors 3 then remove monitor assembly 2 INSTALLATION OF MONITOR ASSEMBLY 0 Carry out ins...

Page 658: ...6 PC21 OLC 6 PC22OLC 6 Trackshoe PC250LC 6 Hydraulicpump Controlvalve Safety suction valve for service valve Swing motor Travel motor PC200 6 PC200LC 6 PC21 OLC 6 PC22OLC 6 Travel motor PC25OLC 6 Work...

Page 659: ...FINAL DRIVE PC200 6 PC200LC 6 PC21 OLC 6 PC22OLC 6 m 524 5283 5Nm 47 5f2 5kQm 1st 98Nm IOkQm 2nd 75f5 277 32Nm 28i3kQm __A i__ ___ l_ _____ _ X07HH031 40 2 c l a s s i c ma c h i n e r y n e t...

Page 660: ...ry carrier and motor 4 Backlash between No 2 sun 0 15 0 49 1 oo aear and No 2 olanetarv aear Replace 5 Backlash between No 2 0 19 0 60 I 1 10 planetary gear and ring gear I 6 Backlash between No 2 0 1...

Page 661: ...Initial tightening torque 98 N M w 10 kgm 382 2 39 2 N Additional tightening angle 120 39 4 kgm 533 M2 m 60 8 27 4 N M 6 75 50 75 kgm 637 49 NM 65 5 kgm 66 2 7 4 N M 6 75 to 75 kgm w 68 6 9 8 N M r 8...

Page 662: ...6 0 22 planetary carrier and motor 4 Backlash between No 2 sun 0 19 0 54 1 oo 1gear and No 2 planetary gear 1 5 Backlash between No 2 0 21 0 62 I 1 10 planetary gear and ring gear I 6 Backlash between...

Page 663: ...MAINTENANCE STANDARD SWING MACHINERY SWING MACHINERY 110 5 12 5Nm 11 25i1 25kgm 277 32Nm 28 25 3 25kgm 5 10 6 I p_ r 7 6 fi6 5 19 5Nm 18 2kgm 1 X09DH031 40 6 c l a s s i c ma c h i n e r y n e t...

Page 664: ...en swing pinion 0 22 1 32 2 00 and swing circle 10 Clearance between plate and 0 38 1 I6 Apply hard planetary carrier chrome plating Wear of swing pinion surface Standard size Repair limit recondition...

Page 665: ...6 Nm 19 5 22 kgm 48 5 PC200 PC210 804 4 283 4 Nm 82 28 5 kgm PC220 PC250 A A 999 6 2102 9 Nm 102 210 5 kgm 823 8 1029 7 Nm 84 105 kgm X09DH032 No Check Item Criteria I Remedy Axial clearance of bearin...

Page 666: ...2 Horizontal width of idler guide 3 3 X14AH012 Unit mm Recoil spring PC200LC 126 4 kN 576 100 9 kN PC21 OLC 603 5 X 239 466 12 900 kg 10 300 kg Idler support Track frame 105 250 Rebuild or replace Idl...

Page 667: ...127 1 I I I I I Idler support 120 f 0 5 118 Rebuild or replace Track frame 266 3 271 2 Horizontal width of idler guide 1 _ Idler support 261 259 Standard size Repair limit Free limit Installed Instal...

Page 668: ...MAINTENANCE STANDARD IDLER IDLER PC200 6 PC2OOLC 6 PC21 OLC 6 PC22OLC 6 21 5kgm t j _ _f m l J k 4 I _ 1 iI I i ZPI I I X14AVOO8 40 11 c l a s s i c ma c h i n e r y n e t...

Page 669: ...Clearance between shaft and bushing Clearance between shaft and support 65 0 250 0 110 0 290 0 220 0 03 0 180 Replace Interference between idler and bushing Standard size 72 Tolerance Shaft Hole 0 08...

Page 670: ...MAINTENANCE STANDARD IDLER IDLER PC25OLC 6 2 4 151 9 224 5 Pm 15 5 22 5 kgm 4 c a X14AVOO9 40 I 3 c l a s s i c ma c h i n e r y n e t...

Page 671: ...shaft and support Interference between idler and bushing Side clearance of idler each Standard Tolerance size Shaft Hole 80 0 225 0 130 0 325 0 010 80 0 225 0 085 0 290 0 195 Standard Tolerance size...

Page 672: ...d Standard size 165 140 43 Criteria Repair limit 130 50 Remedy Rebuild or replace interference between shaft and bearing Interference between roller and bearing Side clearance of roller Standard Toler...

Page 673: ...of tread Width of tread 168 49 5 158 57 5 rieuull I replace 4 5 Clearance between shaft and bearing Interference between roller and bearina Standard size 55 80 Tolerance Shaft Hole 0 021 0 0 002 0 015...

Page 674: ...gm I I _ 3 4 X14BROlO Unit mm Width of tread Width of flange ral dc e 44 5 52 24 5 _ Clearance between shaft and bushing Standard size Tolerance Standard Clearance limit clearance Shaft Hole I I Inter...

Page 675: ...ing Interference between roller and bushing Side clearance of roller Standard size Repair limit 216 180 49 168 55 Rebuild or replace Standard size Tolerance Standard Clearance limit clearance Shart Ho...

Page 676: ...MAINTENANCE STANDARD TRACK SHOE TRACK SHOE PC200 6 PC200LC 6 PC21 OLC 6 PC22OLC 6 9 X15AD006 40 19 c l a s s i c ma c h i n e r y n e t...

Page 677: ...lding L IA II I replace Interference between bushing and link Interference between regular pin and link Interference between master pin and link Protrusion of bushing Standard size 59 1 MM 1 0 74 1 o...

Page 678: ...TRACK SHOE PC25OLC 6 4 3 9 40 21 c l a s s i c ma c h i n e r y n e t...

Page 679: ...d link Interference between master pin and link Criteria Standard size Repair limit 61 9 31 116 Standard size 44 6 Shaft 44 35 Hole 44 4 Shaft 0 230 0 062 0 188 0 080 44 35 Hole 0 200 0 0 280 5 25 f 0...

Page 680: ...DARD HYDRAULIC PUMP HYDRAULIC PUMP Qa 66 1L7 35Nrn z 6 75 0 75kgm 2 _ 17 151t2 45Nm 1 5 0 25kgm 15 7 35Nm 75 0 75kgm m 66 15f7 35Nm 6f5f0 75kgm _ 68 6f9 8Nm 7f lkgm XlOAV269 40 23 c l a s s i c ma c h...

Page 681: ...IC PUMP CONTROL PUMP RELIEF VALVE w 53 9 4 9Nm 5 5 0 5kgm No 4 P B 1 l B 66 15 7 35Nm 6 75 0 75kgm XlOAV270 Unit mm Radical clearance between gear Control relief valve spring or deformations c l a s s...

Page 682: ...spool and 8 spool control valves w 166 7 f 9 8 Nm w 166 7 2 9 8 Nm 17 1 kgm 17 e 1 kgm 30 9 z 3 4 Nm 3 15 f 0 35 kgm w 66 2 7 4 Nm m 66 2 7 4 Nm w 30 9 3 4 Nm 6 75 0 75 kgm 6 75 0 75 kgm 3 15 2 0 35 k...

Page 683: ...n spring Spool return spring Spool return spring Free length X O D 54 2 X 34 8 54 2 X 34 6 54 2 X 34 8 Standard size installed length 51 2 51 2 51 2 Installed load 416 5 N 42 5 kg 420 4 N 42 9 kg 393...

Page 684: ...Nm 5 5 0 5kgm L L 85 85f7 35Nm 8 75 0 75kgm XlOBH178 Unit mm I Criteria I Remedv Free length X O D 43x19 4 20 9 X 17 2 23 2 X 7 2 30 7 X 9 6 Standard size Installed length Installed load Rep2 Free len...

Page 685: ...40 2 2 kgm 15 1 kgm E E 40 2 2 kgrri 147 7 9 8 Nm 15 t 1 kgm m 392 3 19 6 Nm 40 t 2 kgm w 392 3 2 19 6 Nm m 147 1 9 8 Nm w 392 3 2 19 6 hlm MO 2 kgm 15 1 kgm 40 2 kgm I w 392 3 it 19 6 Nm 40 k 2 kgm...

Page 686: ...e length Installed load x O D length 70 8 X 16 1 55 192 1 N 153 9 N 19 6 kg _ 15 7 kg Regeneration valve spring 31 5x10 3 19 5 5 9 N 4 4 N 0 6 kg 0 45 kg if Piston return spring 48 1 X 10 8 30 15 7 N...

Page 687: ...em I Criteria MM MM w 38 7 5 4Nm 4t0 5kgm XlOBH181 Unit mm Remedy Check valve spring Spool return spring 65 6 X 27 2 50 Spool return spring 13 6 x 5 5 I 10 Installed load 1 5N 0 15kg 167 6 N 17 1 kg 2...

Page 688: ...item Criteria Remedy Standard size Repair limit Suction valve spring 1 Free length Installed Installed load Free length Installed load X O D length Replace spring if any damages or 16 3 X 21 3 1 5 2...

Page 689: ...kgm X09DH033 Unit mm No Check item Criteria Remedy Standard size Repair limit Replace spring if 1 Check valve spring Free length Installed Installed load Free length Installed any damages or X O D len...

Page 690: ...k item Criteria Remedy Standard size Repair limit 1 Spool return spring Free length Installed Installed load Free length Installed load X O D length 58 43 X 30 0 42 0 426 3 N 341 O N Replace spring if...

Page 691: ...m 419 4f46 1 Nm 42 8 f4 7 kgm 66 5 f 7 5 kgm w 362 6 239 2 Nm 37 0 f4 0 kgm i 52 9 f 5 9 Nm 26 0 3 0 kgm 6 4 f 0 6 Nm Section A A Section B E XO7HliOtl Unit mm Spool return spring Check valve spring R...

Page 692: ...size Repair limit 1 Centering spring for P3 P4 Free length Installed Installed load Free length Installed load X O D length 42 4X 15 5 34 17 6 N 13 7 N 1 8 kg 1 4 kg 2 Centering spring for PI P2 44 4...

Page 693: ...Criteria Remedy I I I Standard size Repair limit I I 1 I 1 Metering spring Free length Installed Installed load Free length Installed load X O D length Replace spring if any damages or 26 5 X 8 15 24...

Page 694: ...Standard size Repair limit 1 Centering spring Free length Installed Installed load Free length Installed X O D length load Replace spring if 64 6 X 16 6 40 5 46 1 N 44 1 N any damages or _ 4 7 kg 4 5...

Page 695: ...PPC SHUTTLE TRAVEL JUNCTION VALVE PPC SHUTTLE TRAVEL JUNCTION VALVE m 34 3 4 9Nm 3 5 0 5kgm 34 3r4 9Nm 3 5 0 5kgm 17 15 2 45Nm 107 8 14 7Nm 3 m 66 15 7 35Nm 6 75 0 75kgm XlOBH185 40 38 c l a s s i c m...

Page 696: ...eria Remedy Standard size I Repair limit I I I I I 1 Spool return spring Free length Installed Installed load Free length Installed load Replace spring if X O D length any damages or deformations are...

Page 697: ...1 0 2kgm XlOBH187 Unit mm No Check item Criteria Remedy Standard size Repair limit Replace EPC 1 Return spring Free length Installed Installed load Free length Installed valve assembly if X O D length...

Page 698: ...ENTER SWIVEL JOINT 4 PORT SWIVEL JOINT x10zz021 Unit mm No Check item Criteria Remedy Standard size Standard clearance Clearance limit 1 Clearance between rotor and shaft Replace 90 0 056 0 105 0 111...

Page 699: ...L JOINT 6 PORT SWIVEL JOINT x1ozzo22 Unit mm No Check item Criteria Remedy Standard size Standard clearance Clearance limit 1 Clearance between rotor and shaft Replace 100 0 056 0 105 0 111 40 42 c l...

Page 700: ...kgm AA No Check item Criteria XlOBH188 Unit mm Remedy 1 2 Pilot valve spring Check valve spring Free length X O D 26 5 x 11 2 37 2 X 16 2 Standard size Installed length 25 0 30 0 Repair limit Installe...

Page 701: ...0 39 ONm 27 5 4 Okgm m 8 6k0 86kNt n 880Ifr88kgm Width across flat 95mm XIQBR042 ARM CYLINDER 372 4 53 9Nm 38 0i5 5kgm m 10 2 1 0kNm 1 FO 104kgm Width across flat 95mm XIOBR043 BUCKET CYLINDER m 270 _...

Page 702: ...30 0 258 0 076 0 048 0 078 0 334 0 434 Clearance between piston rod support pin and bushing Boom 80 0 030 0 060 80 0 030 0 076 0 457 0 370 0 457 0 370 Arm Bucket 0 424 0 350 0 380 0 500 1 0 I 0 400 0...

Page 703: ...0 39Nm 27 5i4 Okgm m 10 2 1 0kNm 1 040 104kgm Width across flat 95mm ARM CYLINDER m 373k54Nm 38iOF5 5kgm m 10 2 l OkNm 1 y 104kgm Width across fiat 95mm BUCKET CYLINDER w 270 39Nm 27 5f4 0kgm w 10 2 1...

Page 704: ...47 1 0 447 Bucket Boom 80 1 4 1 Ml tl 1 0 400 0 517 1 1 O Clearance between piston rod support pin and bushing Arm 80 1 4l tl 1 A 1 0 400 0 533 1 O Bucket 80 1 4 1 G 1 0 400 0 533 1 1 0 Boom 80 1 4 CD...

Page 705: ...MAINTENANCE STANDARD WORK EQUIPMENT WORK EQUIPMENT D G I A A B B E E F F D D G G X17FR024 40 48 c l a s s i c ma c h i n e r y n e t...

Page 706: ...bucket Clearance between connecting pin and bushing of link and bucket Clearance between connecting pin and bushing of link and link T Standard size 90 90 70 PC200 PC21 0 80 PC220 PC250 80 80 70 PC200...

Page 707: ...MAINTENANCE STANDARD WORK EQUIPMENT DIMENSION OF WORK EQUIPMENT 1 ARM PORTION i 1 I I x x X17FRO25 40 50 c l a s s i c ma c h i n e r y n e t...

Page 708: ...2f 0 5 187 2f 0 5 200 f 0 5 7 829 1f 1 829 1f 1 920 1 8 2 919 2 919 3 038 9 2 631 3 I 2 631 3 I 2 563 2f 1 10 410 1 41Okl 4651tl 11 640 f 0 2 640 f 0 2 585 f 0 2 12 600 f 0 5 600 f 0 5 600 f 0 5 13 45...

Page 709: ...MAINTENANCE STANDARD WORK EQUIPMENT 2 BUCKET PORTION Adjustable Device Configuration View B B 6 7 Standard Configuration Xl 7Fzo47 40 52 c l a s s i c ma c h i n e r y n e t...

Page 710: ...inebore Rt front only Linebore Rt front only 8 9 326 14 327 66 326 14 327 66 326 14 327 66 M20 X 2 5mm thru 4 M20 X 2 5mm thru 4 M20 X 2 5mm thru 4 holes equally spaced on holes equally spaced on hole...

Page 711: ...REVlslON Fax No 847 970 4186 PFMRl 081696 FOR INTERNAL USE ONLY No PMR 2 NAME OF COMPANY S DEPARTMENT E R NAME LOCATION PHONE NO DATE MANUAL NAME MANUAL NO MACHINE MODEL S N IF APPLICABLE PAGE NO PROB...

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Komatsu PC200-6, Shop Manual

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