Sebda2050508 SM PC220-5 PDF

SEBMA2050508
(SEBM02050508)
KOMRtbU
PC200,2OoLC-5
PC200,2ooLC-5 MIGHTY
PC220,22OLC-5
MACHINE MODEL SERIAL NO.
PC2004 45001 and up

A70001 and up
PC2004 MIGHTY 58019 and up
PC2OOLC-5 45001 and up
A70001 and up
PC2OOLC-5 MIGHTY 58019 and up
PC220-5 35001 and up
PC22OLC-5 35001 and up
A70001 and up
0 Open Serial Numbers references (i.e. 45001 and up) apply to all machine Serial Numbers listed
above.
Closed Serial Numbers references (i.e. 4500145003) apply only to those machine Serial Numbers.
l This shop manual may contain attachments and optional equipment that are not available
in your area.
Please consult your local Komatsu distributor for those items you may require. Material and
specification
are subject to change without notice.
l PC200, 2OOLG5,MIGHTY mount the S6D95L engine;

PC220, 22OLG5 mount the SA6D95L engine.
For details of the engine, see the 95 Series Engine Shop Manual.
FEB 92 00-l
@
CONTENTS
No. of page
10 STRUCTURE AND FUNCTION ................ lo-1
20 TESTING AND ADJUSTING .................. ~~-1
30 DISASSEMBLY AND ASSEMBLY ......:..... 3o_1
40 MAINTENANCE STANDARD ................. 4o_1
Not to be reproduced in whole or in part without the prior written permission of

KOMAl!BU, Tokyo, Japan.
The affected pages are indicated by the use of
the following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the

table below. 0 Page to be newly added Add
0 Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGES
Time of Time of Time of Time of Timeof

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
. oo- 1 lo- 1 IO-23 10-45-6 1O-69
. oo- 2 lo- 2 IO-24 0 10-45-7 . 10-69-I
l oo- 2-l . IO- 3 IO-25 0 10-45-8 1O-69-2
. oo- 2-2 0 lo- 3-1 lo-26 0 10-45-g 1O-69-3
l 00- 2-3 IO- 4 lo-27 0 1O-45-10 1O-69-4
l 00- 2-4 IO- 4-1 lo-28 0 1o-45-11 IO-70
l oo- 3 IO- 4-2 10-29 0 1O-45-12 IO-71
l oo- 4 l IO- 5 IO-30 IO-46 IO-72
l oo- 5 l IO- 6 IO-31 10-47 . IO-73
. 00- 6 lo- 7 IO-32 lo-48 . IO-74
. oo- 7 lo- 8 IO-33 10-49 IO-75
l 00- 8 lo- 9 10-34 10-49-I IO-76
l oo- 9 IO-IO 10-35 10-50 l IO-77
l 00-10 IO-11 lo-36 1o-51 1o-77-1
. 00-11 IO-12 l IO-37 IO-52 l 1O-77-2
. 00-12 l IO-13 . IO-38 1o-53 . 1o-77-3
l 00-13 0 IO-14 IO-39 1o-54 10-77-4
. 00-14 10-15 . IO-40 1O-56 . IO-78
l 00-15 l lo-16 IO-41 10-57 l IO-79
l 00-16 . 10-17 IO-42 IO-58 IO-80
0 00-17 l IO-18 IO-43 IO-59 lo-81
0 00-18 IO-19 10-44 IO-60 IO-82
0 00-19 0 10-19-I IO-45 IO-61 lo-83
0 00-20 10-20 l 10-45-I IO-62 . lo-84
0 00-21 10-20-l 10-45-Z IO-65 1O-85
0 00-22 10-20-2 1o-45-3 l IO-66 l 1O-86
0 00-23 IO-21 10-45-4 IO-67 IO-87
0 00-24 IO-22 10-45-5 IO-68 l 10-88

Time of Time of Time of Time of Time of
Mark Page Vlark Page Vlark Page Mark Page Mark Page
1O-89 0 IO-118 20-19 20-51 0 20-100
l 1O-89-1 10-118-1 0 20-20 20-52 0 20-101
1O-89-2 10-118-2 0 20-21 20-53 20-102
l 1O-89-3 l IO-119 0 20-22 20-54 . 20-103
1O-89-4 l 10-120 20-23 20-55 20-104
1O-89-5 0 10-121 0 20-24 20-56 . 20-104-I
. 1O-89-6 10-122 l 20-25 20-57 20-105
0 1O-89-8 lo-123 20-26 20-58 0 20-106
1O-90 lo-124 20-27 20-59 20-107
l 1o-91 10-124-I l 20-28 20-60 0 20-107-l
l 1o-92 10-124-2 a 20-28-I 20-61 20-107-2
1o-93 10-124-3 20-28-2 20-62 20-108
1o-94 10-124-4 20-28-3 20-63 20-109
1o-95 IO-125 20-29 20-64 20-110
1O-96 IO-126 20-30 20-65 20-111
1o-97 l IO-127 20-31 20-66 20-113
1 O-97-1 . IO-128 20-32 20-67 . 20-114
1o-97-2 IO-129 20-33 l 20-68 20-115
l 1o-97-3 IO-130 20-33-I l 20-69 . 20-116
1O-98 IO-131 20-34 l 20-70 0 20-117
. 1o-99 IO-132 20-35 . 20-71 0 20-117-l
0 1o-99-1 20-36 0 20-72 0 20-117-2
. 1o-99-2 20-37 l 20-73 0 20-117-3
10-100 20- 1 20-38 . 20-74 0 20-117-4
. 10-101 20- 2 20-39 . 20-75 20-118
. 10-102 20- 3 20-40 . 20-76 . 20-119
. 10-103 20- 4 20-41 20-77 . 20-120
l IO-104 20- 5 20-42 0 20-78 20-121
IO-105 . 20- 6 20-43 20-79 20-122
IO-106 . 20- 7 20-44 20-90 20-123
0 IO-107 20. 8 20-45 20-91 20-124
IO-109 20- 9 20-46 20-92 20-126
10-110 20-10 20-47 20-93 20-127
10-111 20-11 20-47-I 20-94 l 20-128
IO-112 20-12 . 20-47-2 20-95 20-129
10-113 20-13 0 20-48 20-96 0 20-129-l
. 10-114 20-14 0 20-49 20-97 20-129-2
. 10-115 20-15 l 20-49-l 20-97-l 0 20-130
lo-116 20-16 . 20-49-2 . 20-98 20-131
IO-117 20-18 20-50 . 20-99 20-132

Mark Page Mark Page Mark Page Mark Page Mark Page
20-133 20-162 20-205 . 20-246 30-36
. 10-133-I 20-163 20-206 30-37
20-133-2 20-164 20-207 30-38
20-133-3 20-165 20-208 . 30- 1 30-39
20-133-4 20-166 20-209 0 30. 2 30-40
0 20-134 20-167 20-210 30. 4 30-41
20-135 20-169 20-211 30. 5 . 30-42
. 20-135-I . 20-170 20-213 30. 6 0 30-42-I
20-135-2 0 20-171 20-214 l 30. 7 0 30-42-2
0 20-136 l 20-172 20-215 30- 7-I 0 30-43
20-137 20-173 20-216 0 30- 7-2 30-43- 1
0 20-137-l 20-174 20-217 . 30- 8 30.43- 2
20-137-2 20-175 . 20-218 . 30- 9 30-43- 3
l 20-137-3 20-176 20-219 a 30-10 30-43- 4
20-137-4 20-177 20-220 (30-10-I) 30-43. 5
20-138 20-178 20-221 0 30-11 30-43. 6
20-139 20-179 20-222 30-12 30-43. 7
l 20-140 20-180 20-223 30-13 30-43. 8
. 20-141 20-181 20-224 30-14 30.43- 9
. 20-142 20-182 20-225 30-15 30-43-10
. 20-142-I 20-183 20-226 30-16 30-43-11
. 20-143 20-184 20-227 30-17 30-43-12
. 20-144 20-185 20-228 30-18 30-43-13
. 20-145 20-186 20-229 30-19 30-43-14
. 20-146 20-187 0 20-230 30-20 30-44
. 20-147 20-188 20-231 30-21 30-45
20-148 20-189 20-232 30-22 30-45-I
20-149 20-190 20-233 30-23 30-45-2
. 20-150 20-192 20-234 30-24 30-45-3
. 20-151 20-193 20-235 30-25 30-45-4
0 20-152 20-194 20-236 30-26 30-45-5
. 20-153 20-195 20-237 30-27 30-45-6
0 20-154 20-196 20-238 30-28 30-45-7
20-155 20-198 20-239 30-29 30-45-8
20-156 20-199 20-240 30-30 30-46
20-157 20-200 20-241 30-31 30-47
20-158 20-201 20-242 30-32 30-48
20-159 20-202 20-243 30-33 30-49
20-160 20-203 20-244 30-34 30-50
20-161 20-204 0 20-245 30-35 30-51
00$3
i
Mark Page Mark Page Mark Page Mark Page Mar.k Page
30-52 30-74 30-104 0 40-21-14
30-53 30-75 30-105 0 40-21-15
30-54 . 30-76 30-106 0 40-21-16
30-55 . 30-77 30-107 0 40-21-17
30-56 0 30-77-l 40-22
30-57 0 30-77-2 40-23
30-58 0 30-77-3 40- 1 40-24
30-59 0 30-77-4 0 40. 2 . 40-25
30-60 30-78 40- 3 . 40-26
30-61 30-79 40- 4 40-27
30-62 30-80 40- 5 . 40-27-I
30-63 30-81 40- 6 . 40-27-2
30-64 30-82 40- 7 0 40-28
30-65 30-83 40- 8 40-29
30-65-I 30-83-l 40. 9 40-30
30-65-2 30-83-2 40-10 40-31
30-65-3 30-84 40-11
30-65-4 30-85 40-12
30-65-5 30-85-I 40-13
30-65-6 30-85-2 40-13-2
30-65-7 30-86 40-14
30-65-8 30-87 0 40-15
30-65-g 30-88 40-16
30-65-10 30-89 40-17
30-65-11 30-90 40-18
30-65-12 30-91 40-19
30-65-13 30-92 40-20
30-65-14 30-93 40-21
30-65-15 30-94 0 40-21-2
30-65-16 30-95 40-21-3
30-65-17 30-95-l 40-21-4
30-65-18 30-95-2 40-21-5
30-66 30-96 40-21-6
30-67 30-97 40-21-7
30-68 30-98 40-21-8
30-69 30-99 (40-21-9)
30-70 30-100 0 40-21-10
30-71 30-101 0 40-21-11
30-72 30-102 0 40-21-12
30-73 30-103 0 40-21-13
o”ii-4
A IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu and described in this
manual are both effective and safe methods of operation. Some of these operations re-
quire the use of tools specially designed by Komatsu for the purpose.
A
YY
To prevent injury to workers, the symbols and are used to mark safety pre-
$
cautions in this manual. The cautions accompanying these symbols should always be
followed carefully. If any dangerous situation arises or may possibly arise, first consider
safety, and take the necessary actions to deal with the situation.
A SAFETY
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for
1. Before carrying out any greasing or repairs,
smoking. Never smoke while working.
read all the precautions given on the
decals which are fixed to the machine.
2.When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
l Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when
8. Before starting work, lower blade, ripper,
grinding parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, equipment from falling. In addition, be sure
always wear welding gloves, apron, glasses, to lock all the control levers and hang
cap and other clothes suited for welding warning signs on them.
work. 9. When disassembling or assembling, sup-

port the machine with blocks, jacks or
4.When carrying out any operation with two
stands before starting work.
or more workers, always agree on the op-
erating procedure before starting. Always 10. Remove all mud and oil from the steps or
inform your fellow workers before starting other places used to get on and off the
any step of the operation. Before starting machine. Always use the handrails, ladders
or steps when getting on or off the
work, hang UNDER REPAIR signs on the
machine. Never jump on or off the machine.
controls in the operator’s compartment.
If it is impossible to use the handrails,
5. Keep all tools in good condition and learn ladders or steps, use a stand to provide safe
the correct way to use them. footing.
00-3
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be
loosen them slowly to prevent the oil from sure that they will not be damaged by
spurting out. contact with other parts when the ma-
Before disconnecting or removing compo- chine is being operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
circuit. sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
12.The water and oil in the circuits are hot
ful when installing tubes for high pressure
when the engine is stopped, so be careful
circuits. Also, check that connecting parts
not to get burned.
are correctly installed.
Wait for the oil and water to cool before car-
rying out any work on the oil or water 21 When assembling or installing parts, always
circuits. use the specified tightening torques. When
13. Before starting work, remove the leads from installing protective parts such as guards, or
the battery. Always remove the lead from parts which vibrate violently or rotate at
the negative (-1 terminal first. high speed, be particularly careful to check
that they are installed correctly.
14. When raising heavy components, use a
hoist or crane. 22. When aligning two holes, never insert your
Check that the wire rope, chains and hooks fingers or hand. Be careful not to get your
are free from damage. fingers caught in a hole.
Always use lifting equipment which has
ample capacity. 23. When measuring hydraulic pressure, check
Install the lifting equipment at the correct that the measuring tool is correctly assem-
places. Use a hoist or crane and operate bled before taking any measurements.
slowly to prevent the component from hit-
24.Take care when removing or installing the
ting any other part. Do not work with any
tracks of track-type machines.
part still raised by the hoist or crane.
When removing the track, the track sepa-
15. When removing covers which are under in- rates suddenly, so never let anyone stand at
ternal pressure or under pressure from a
either end of the track.
spring, always leave two bolts in position on
opposite sides. Slowly release the pressure,
then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil

from spilling out. If any fuel or oil drips on to
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18.As a general rule, do not use gasoline to

wash parts. In particular, use .only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into chapters for each main group of
components; these chapters are further divided into the following sections.
STRUCTURE 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 troubleshooting.
TESTING AND ADJUSTING

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

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Contact your KOMATSU distributor for the
latest information.
I I
00-5
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK (a@)@ .... )
Shop manuals are issued as a guide to carry- When a manual is revised, an edition mark is
ing out repairs. They are divided as follows: recorded on the bottom outside corner of the
pages.
Chassis volume: issued for every machine
model
Engine volume: Issued for each engine series
Each issued as
Electrical volume : REVISIONS
one volume to
Attachments volume :
cover all models Revised pages are shown at the LIST OF
REVISED PAGES on the between the title page
and SAFETY page.
These various volumes are designed to avoid
duplicating the same information. Therefore to
deal with all repairs for any model, it is neces-
sary that chassis, engine, electrical and attach-
ment volumes are ready. SYMBOLS
So that the shop manual can be of ample

DISTRIBUTION AND UPDATING
practical use, important places for safety and
Any additions, amendments or other quality are marked with the following symbols.
changes will be sent to KOMATSU distributers.
Get the most up-to-date information before
you start any work.
Symbol Item Remarks
FILING METHOD
Special safety precautions are
1. See the page number on the bottom of the necessary when performing the
work.
page. File the pages in correct order. Safety
2. Following examples shows how to read the Extra special safety precautions
page number. are necessary when performing
Example 1 (Chassis volume): the work because it is under
internal pressure.
10-3
TT Special technical precautions or
other precautions for
Item number (IO. Structure * Caution preserving standards are
and Function) necessary when performing the
Consecutive page number for work.
each item.
Weight of parts or systems.
Example 2 (Engine volume): Caution necessary when
12-410
elkg Weight selecting hoisting wire, or when
working posture is important,
etc.
Unit number (I. Engine)
Item number (2. Testing and Places that require special
Tighten-
Adjusting) attention for the tightening
ig torque
torque during assembly.
Group No. (4. Fuel system)
‘t Consecutive page No. (Page Places to be coated with
10 of Group 4) Coat
adhesives and lubricants etc.
3. Additional pages: Additional pages are in- Places where oil, water or fuel
dicated by a hyphen i-1 and number after the
page number. File as in the example.
Q Xl. water must be added, and the
capacity.
Example:
Places where oil or water must
1 o-4 12-203 Drain be drained, and quantity to be
drained.
1 o-5 12-204
00-6
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
A
lifted
Heavy parts (25 kg or more) must be
with a hoist etc. In the Disassembly
Slinging near the edge of the hook may
cause the rope to slip off the hook during
hoisting, and a serious accident can result.
and Assembly section, every part weigh-
Hooks have maximum strength at the
ing 25 kg or more is indicated clearly with
middle portion.
the symbol &
1. If a part cannot be smoothly removed from

the machine by hoisting, the following
checks should be made:
. Check for removal of all bolts fastening
100% 88% 79% 71% 41%
the part to the relative parts.
FSO064
. Check for existence of another part
causing interference with the part to be 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
removed.
symmetrically wound on to the load.
2. Wire ropes
A Slinging with one rope may cause
turning of the load during hoisting,
I) Use adequate ropes depending on the untwisting of the rope, or slipping of
weight of parts to be hoisted, referring to the rope from its original winding
the table below: position on the load, which can result
in a dangerous accident.
4) Do not sling a heavy load with ropes

Wire ropes
forming a wide hanging angle from the
(Standard “Z” or “S” twist ropes
hook.
without galvanizing)
When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter (mm) Allowable load (tons)
will increase with the hanging angles. The
table below shows the variation of
10 1 .o
allowable load (kg) when hoisting is made
11.2 1.4 with two ropes, each of which is allowed
12.5 1.6 to sling up to 1000 kg vertically, at various
hanging angles.
14 2.2
When two ropes sling a load vertically, up
16 2.8 to 2000 kg of total weight can be
18 3.6 suspended. This weight becomes 1000 kg
when two ropes make a 120“ hanging
20 4.4
angle. On the other hand, two ropes are
22.4 5.6 subjected to an excessive force as large as
30 10.0 4000 kg if they sling a 2000 kg load at a
lifting angle of 150”.
40 18.0
50 28.0
60 40.0
The allowable load value is estimated to

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

60” 90” 120” 1 5o”
of the hook.
Lifting angle : a
FSO065
00-7
STANDARD TIGHTENING TORQUE
mm
1 STANDARD
STANDARD
TIGHTENING TORQUE
TIGHTENING
OF BOLTS
The following charts give the standard tightening

AND
torques
NUTS
TORQUE
of bolts and nuts. Exceptions are given in

sections of “Disassembly and Assembly”.
Thread diameter Width

of bolt across flat ? z
(mm) (mm) 0 0
kgm Nm
6 10 1.35kO.15 13.2* 1.4

8 13 3.2kO.3 31.4+-2.9
10 17 6.7 +0.7 65.7k6.8
12 19 11.5fl.O 112k9.8
14 22 18.Ok2.0 177*19
16 24 28.5*3 279&29
18 27 39+-4 383t39
20 30 56a6 549t58
22 32 76+8 745 & 78
24 36 94.5*10 927?98
27 41 135*15 1320t140
30 46 175*20 172Ok 190
33 50 225*25 221 O-+240
36 55 280?30 2750a 290
39 60 335*35 328Ok 340
This torque table does not apply to the bolts with which nylon packings or other non-
ferrous metal washers are to be used, or which require tightening to otherwise specified
torque.
Sr Nm (newton meter): 1 Nm & 0.1 kgm
2.TlGHTENlNG TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Threaorj gianeter Width Tightening torque

across flats
(mm) (mm) kgm Nm
10 14 6.7kO.7 65.7k6.8
12 17 11.5*1 1 12+9.8
16 22 28.5*3 279*29
00-8
STANDARD TIGHTENING TORQUE
Sealing surface
3.TlGHTENlNG TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter
of nut part
Width across flats
of nut part
T Tightening torque
(mm) (mm) kgm Nm
14 19 2.5i0.5 24.5 24.9

18 24 5k2 49* 19.6
22 27 822 78.5 k 19.6
24 32 14+3 137.3229.4
30 36 18*3 176.5229.4
33 41 20+5 196.1 -t49
36 46 25+5 245.2 *49
42 55 30-+5 294.2249
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Nomenclature Komatsu code Applications
LT-IA Used to apply rubber pads, rubber gaskets, and cork plugs.
Used to apply resin, rubber, metallic and

LT-1B
non-metallic parts when a fast, strong seal is needed.
LT-2” Preventing bolts, nuts and plugs from loosening and leaking oil.
Provides an airtight, electrically insulating seal.

LT-3
Used for aluminum surfaces.
Used to coat plugs (plate shaped, bowl shaped) and holes, and
LT-4
mating portion of shaft.
LG-1 Used with gaskets and packings to increase sealing effect.
Heat-resistant gasket for precombustion chambers

LG-3
and exhaust piping.
Sealant gasket
Used b itself on mounting surfaces on the final drive and transmission
LG-4
cases. YThickness after tightening: 0.07 - 0.08 mm)
Used by itself to seal grease fittings, tapered screw fittings and tapered
LG-5
screw fittings in hydraulic circuits of less than 50 mm in diameter.
LG-6 Silicon base type used in combination with LG-1 and LG-4.
Has a shorter curing time than LG-6, and is easier

LG-7
to peel off.
Antifriction compound
Applied to bearings and taper shafts to facilitate press-fitting and to
(Lubricant including LM-P
prevent sticking, burning or rusting.
molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust
G2-LI
(Lithium grease) prevention and facilitation of assembling work.
Vaseline - Used for protecting battery electrode terminals from corrosion.

I
lLT-2 is also called LOCTITE in the shop manuals.
00-9
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire Current rating

Nominal Cable O.D.
Applicable circuit
number Number / Dia. of strands/ Cross section (mm) I (A)
strands (mm) (mm?
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 I-~ 0.32 I 5.23 1 4.6 I 37 I Charging and signal
15 I 84 I 0.45 I 13.36 7.0 I 59 1 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting

I
CLASSIFICATION BY COLOR AND CODE
Lighting Instrument Signal Other
R Y G L
Red Yellow Green Blue
RW YR GW LW
Red &White Yellow & Red Green & White Blue &White
GR LR
Auxi_ Color White&Black - Black &Yellow Green & Red Blue & Red
liary _ Code WL BR GY LY
I I I
Color White 81 Blue - Black & Red Green &Yellow Blue &Yellow
(GB) (LB)
Red & Green Yellow & Blue (Green &Black) (Blue &Black)
(GL) -
(Green & Blue) -
00-l 0
CONVERSION TABLE
CONVERSION TABLE
Method of using the Conversion Table

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
Example
l Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @J, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point 0 gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by IO (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the came procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches @ 1 mm = 0.03937 in

I
0 1 2 3 4 5; 6 7 8 9
I
0 0.039 0.079 0.118 0.157 0.197 / 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 I 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 I 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 j 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 I 1.811 1.850 1.890 1.929
0 /
-----
50 -----_1.969-----__---_.---____________------..
2.008 2.047 2.087 2.126 12.165 2.205 2.244 2.283 2.323
@--
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-l 1
CONVERSIONTABLE
Millimeters to Inches 1 mm =O.O3937in
0 1 3 4 6 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb
l-
I
Kilogram 0 1 2 3 4 5 6 7 8 9
2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 I :216.05 218.26
/ I I
00-12
CONVERSIONTABLE
Liter to U.S. Gallon 1 g = 0.2642 U.S. Gal
10
0
2.642
1
0.264
2.906
I
2
0.528
3.170
3
0.793
3.434
4
1.057
3.698
5
1.321
3.963
I 6
1.585
4.227
7
1.849
4.491
8
2.113
4.755
9
2.37E
5.015
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
t
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.30:
I
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 i9.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
L l-
Liter to U.K. Gallon 1 P=O.21997 U.K.Gal
10
20
0
2.200
4.399
6.599
c 1
0.220
2.420
4.619
6.819
2
0.440
2.640
4.839
3
0.660
2.860
5.059
7.259
4
0.880
3.080
5.279
7.479
5
1.100
3.300
5.499
6
1.320
3.520
5.719
7.919
7
1.540
3.740
5.939
8
1.760
3.950
6.159
9
1.980
4.179
6.379
30 7.039 7.969 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-13
CONVERSION TABLE
kgm to ft.lb 1 kg.m = 7.233ft.lb
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 1 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-14
CONVERSIONTABLE
kg/cm* to lb/in* 1 kg/cm' = 14.22331b/in2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3124 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-l 5
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion. -A simple way to convert a Fahrenheit temperture reading into a Centigrade
temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees,consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it isdesired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
OC OF OC OF OC OF OC "F
40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 a2 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 I la.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 a6 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6

-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 a 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 34z.o
00-16
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
PC200,2OOLC-5
Unit: kg
Machine Model PC200-5 PC2OOLC-5
Serial Numbers 45001 and up 45001andup
Engine assembly 647 647
l Engine 432 432
l Damper 20 20
l Hydraulic pump 195 195
Radiator and oil cooler assembly 91 91
Hydraulic tank assembly

194 194
(without hydraulic oil)
Fuel tank (without fuel) 98 98
Revolving frame 1,555 1,555
Operator’s cab 238 238
Operator’s seat 31.7 31.7
Counterweight 3,300 3,300
Swing machinery 258 258
Control valve assembly 171 171
Swing motor assembly 50 50
Travel motor assembly 137x2 137x2
Center swivel joint 43 43
Track frame assembly 4,391 4,604
l Track frame 2,362 2,390
l Swing circle assembly 270 270
l Idler 140x2 140x2
l Idler cushion 135x2 135x2
0 Carrier roller 21 x4 21 x4
l Track roller 37x14 37x18

l Final drive 322x2 322x2
Unit: kg
Machine Model PC200-5 I PC2OOLC-5
Serial Numbers I 45001 and up I 45001 and up
Track shoe assembly I 1

l Triple-grouser shoe (500 mm)
I 2,360 I
-
l Triple-grouser shoe (600 mm) 2,620 I 2,850

I
l Triple-grouser shoe (700 mm) 2,870 3,120
l Swamp shoe (860 mm) 3,280 -
l Flat shoe (610 mm) 2,900 -
Boom assembly
Arm assembly 628
Bucket assembly I 646 I 646
Boom cylinder assembly I 187x2 I 187x2
Arm cylinder assembly I 251 I 251
Bucket cylinder assembly I 153 I 153
Link (large) assembly I 80 I 80
Link (small) assembly I 22 x 2 I 22 x 2
Boom pin 43+10x2 43+10x2

+25+10+20 +25+10+20
Arm pin 10x2 10x2
Bucket pin 20 x 2 20 x 2
Link pin 18x2 18x 2

PC200,2OOLC-5 MIGHTY
Machine Model PC200-5 MIGHTY PC2OOLC-5 MIGHTY
Serial Numbers 58019 and up 58019 and up
Engine assembly 647 647
l Engine 432 432
l Damper 20 20
Radiator and oil cooler assembly 105 105

(without hydraulic oil) 194 194
Fuel tank (without fuel) I 98 I 98
Counterweight I 4,300 I 4,300
Swing machinery 258 258

I I
Control valve assembly 171 171
I I
I I
Travel motor assembly 137 x 2 137x2
I I
Center swivel joint I 43 I 43
l Swing circle assembly 270 270
l Idler 140x2 140x2
l Carrier roller 21 x4 21 x4
l Track roller 37x 14 37x18
l Final drive 322 x 2 322 x 2

Unit: kg
Machine Model 1 PC200-5 MIGHTY 1 PC2OOLC-5 MIGHTY
Serial Numbers I 58019 and up I 58019 and up
Track shoe assembly

l Triple-grouser shoe (500 mm) 2,360 -
l Rubber shoe (600 mm) 2,940
Boom assembly 1,362 1,362
Arm assembly 875 875
Bucket assembly 710 710
Boom cylinder assembly 187x2 187x2
Arm cylinder assembly 251 251
Bucket cylinder assembly 182 182
Link (large) assembly 80 80
Link (small) assembly I 30 x 2 I 30 x 2
43+10x2 43+10x2
Boom pin
+25+ IO+20 +25+10+20
Arm pin 10x2
Link pin 18x2 18 x 2
0°k20
PC220,22OLC-5
Unit: kg
Machine Model PC220-5 PC22OLC-5
Engine ass’y 647 647
l Engine 432 432
l Damper 20 20
Radiator and oil cooler assembly 101

(without hydraulic oil)
Fuel tank assembly (without fuel) 98 98
Counterweight 4,300 4,300
Swing machinery I 258 I 258
Control valve assembly
Travel motor assembly 137x2 137x2
Center swivel joint
0 Swing circle 270 270
l Idler 140x2 140x2
0 Carrier roller 21 x4 21 x4
l Track roller 37x16 37x20
l Final drive 322x2 322x2

I
Unit: kg
Machine Model PC220-5 PC22OLC-5

I I
Track shoe assembly
l Triple-grouser shoe (500 mm) 2,460 -

Boom assembly
Arm assembly 718 718
Bucket assembly 774 774
Boom cylinder assembly 214x2 214x2
Arm cylinder assembly 297 297

I
Bucket cylinder assembly 182 182 ::

g
Link (large) assembly 80 80 z
Link (small) assembly 22 x 2 22 x 2
Boom pin 51+10x2 51+10x2

+30+10+32 +30-I-10+32
Arm pin 10x2 10x2

I I
Link pin 18x 2 18x2
0022
LIST OF LUBRICANT AND WATER
PC200,2OOLC-5 Serial No: 45001 - 58018

PC220,22OLC-5 Serial No: 35001 - 36613
I ..~ -- I .AMBIENT
_...-._. TEMPERATURE CAPACITY ( Q)
KIND OF
RESERVOIR 14 32 50 68 86’ F
FLUID Specified Refill
I -1l-l n 10 20 30°C
Engine oil pan 18.5 17.5
Swing machinery case 11.3 10

Engine oil
Final drive case (each) ,:..::. . ,: :...,...,.. ’: ‘7.6 7.6
Damper case I 1.0
‘:’ :
230 170
I ..:. :
j-,:..:
..;.:,,,
: .:.i:::.‘:~.:~:.:.:::jl:~~~:~::~...::~.,~
:I::::::.A:
:, :, ... . . :; j
-& , 5w_4: _;,:‘y+::,;;_:: :.
I , I I I
0.19 - 0.21 0.19 - 0.21
Track roller (1 piece) Gear oil 0.23 _ 0.25 0.23 _ 0.25
Idler (1 piece) 0.07 - 0.08 0.07 - 0.08
:: 3%;:::.
Fuel tank Diesel fuel 310 -
.. . .
.;.. :...”,:.,” ‘: ASTM D975 No. 2.
......j..i: >’
‘,S,’,,.,, ~,,:,,,
I I I I
Cooling system Water -
z Add antifreeze 19.7
_
0”
2 x ASTM D975 No. 1
NOTE:
(I) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than O”C, be sure to
tenance hours described in this manual. use engine oil of SAEI OW, SAEI OW-30 and
Change oil according to the following table if SAE15W-40 even though an atmospheric
fuel sulphur content is above 0.5%. temperature goes up to 10°C more or less in
the day time.
I (3) Use API classification CD as engine oil and if
Change interval of oil in API classification CC, reduce the engine oil
Fuel sulphur content
I engine oil pan
change interval to half.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
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 maintenance.
o”623
PC200,2OOLC-5 Serial No: 58019 and up
PC200,22OLC-5 MIGHTY
PC220,22OLC-5 Serial No: 36614 and up
AMBIENT TEMPERATURE CAPACITY ( Q)

KIND OF
RESERVOIR
3o”c
FLUID -10
14
0
32
IO
50
20
68 86’ F I-rSpecified Refill
Engine oil pan 18.5
Swing machinery cast 9.3

Final drive case (each: 7.6
Damper case
t
Hydraulic system
Carrier roller (1 piece) I.1 9 - 0.21

Track roller (1 piece) 8.23 - 0.25
Idler (1 piece) .07 - 0.08
Fuel tank -
.,., .. . .
1 I I I
Cooling system 19.7 -

Water Add antifreeze [20.2]
t :
[ 1: PC200, 2OOLC-5 MIGHTY s
% ASTM D975 No. 1 0
NOTE:
(I) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than 0°C. be sure to
tenance hours described in this manual. use engine oil of SAEI OW. SAEI OW-30 and
Change oil according to the following table if SAEl5W-40 even though an atmospheric
fuel sulphur content is above 0.5%. temperature goes up to 10°C more or less in
the day time.
(3) Use API classification CD as engine oil and if
Change interval of oil in
Fuel sulphur content API classification CC, reduce the engine oil
engine oil pan
change interval to half.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
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 maintenance.
0024
10 STRUCTURE AND FUNCTION
Engine related parts and

engine mount ......................... lo- 2
Radiator, oil cooler and after-cooler ..... IO- 3
Fuel tank and piping ...................... IO- 4
Power train .............................. IO- 4-2
Final drive ................................. IO- 5
Swing circle ............................... IO- 7
Swing machinery ......................... IO- 8
Track frame and recoil spring ............ IO- 9
Idler ........................................ IO-I 0
Track roller, carrier roller ................. 1O-l 1
Track shoe ................................. 1O-l 2
Hydraulic piping ........................... IO-15
Hydraulic circuit diagram ................. IO-I 6
Hydraulic tank ............................. IO-20
OLSS (Open center Load Sensing
System) .............................. 10-20-I
Hydraulic pump ........................... lo-21
Control valve .............................. lo-40
Swing motor .............................. 1O-50
Center swivel joint ........................ IO-54
Travel motor .............................. IO-56
Valve control .............................. IO-65
PPC valve .................................. 1O-66
Accumulator ............................... IO-72
Safety lock valve .......................... 1O-73
Solenoid valve assembly .................. 1O-74
Shuttle valve ............................ 1O-77-4
Boom holding valve ...................... 1O-78
Hydraulic cylinder ......................... IO-82
Electrical wiring diagram ................. IO-84
Electrical circuit diagram ................. 1O-86
Engine control system .................. 1O-89-6
Governor motor linkage .................. IO-90
PEMC system ............................. 1O-98
EMACC ................................... 1O-l 25
10-l
8
Section A - A
Section B - B
I
Section C-C Section D - D Section E-E

205FO5005
1. Drive plate 7. Damper assembly Outline

2. Torsion spring 8. Air cleaner l The damper assembly is a wet type.
3. Stopper pin 9. Muffler Oil capacity: 1.80 Q
4. Friction plate l 10. Intake connector
5. Cone spring 11. Front engine mount
6. Friction washer 12. Rear engine mount
1o-2
Gc
RADIATOR OIL COOLER AND AFTER-COOLER
PC200,2OOLC-5 * The after-cooler attached only PC220,22OLC-5

PC220,22OLC-5
4 5 6 7 8 9
3
ZI,
View Z
205FO5006
1. Fan shroud 8. After -cooler SPECIFICATIONS

2. Fan 9. Oil cooler inlet hose Radiator
3. Radiator outlet hose IO. Oil cooler outlet hose PC200-5 Serial No: 45001 - 51419
4. Radiator inlet hose 1 1. Net PC220-5 Serial No: 35001 - 35928
5. Radiator 12. After-cooler inlet CG-2
6. Radiator cap 13. After-cooler outlet PC200-5 Serial No: 51420 and up
7. Oil cooler 14. Sub-tank PC220-5 Serial No:,35929 and up
cwx-4
Oil cooler: SF-2

After-cooler: 6 rows
8 7 8
View 2
205FO5604
1. Fan shroud 7. Oil cooler SPECIFICATIONS

2. Fan 8. Oil cooler inlet hose Radiator: CWX-4
3. Radiator outlet hose 9. Oil cooler outlet hose Oil cooler: SF-3
4. Radiator inlet hose 10. Net
5. Radiator 11. Sub-tank
6. Radiator cap
FUEL TANK AND PIPING
Section A-A
205FO5007
1. Drain valve
2. Fuel tank
3. Filler cap (with lock device)
4. Sight gauge
5. Fuel level sensor
1o-4
DIAGRAM OF FUEL SYSTEM (with automatic air bleeding mechanism)
6206F120-1
1. Fuel tank Automatic bleeding of the fuel system

2. Gauze filter An overflow valve has been added to the
3. Priming pump fuel injection pump to bleed any air that
4. Feed pump has entered the fuel supply system during
5. Fuel filter replacement of the fuel filter, etc.
6. Air bleed plug When cranking is carried out by the starting
7. Fuel injection pump motor, the feed pump starts to send fuel
8. Fuel injection nozzle under pressure. Because of this, the fuel
9. Over-flow valve containing air is drained from the overflow
valve in the injection pump, and returns to
the fuel tank.
POWER TRAIN
205FO5008
1. Idler 7. Hydraulic pump

2. Center swivel joint 8. Swing brake solenoid valve
3. Control valve assembly 9. Travel speed solenoid valve
4. Final drive IO. Swing motor
5. Travel motor 1 1. Swing machinery
6. Engine 12. Swing circle
FINAL DRIVE
PC200,2OOLC-5 Serial No: 45001 - 58018

PC220,22OLC-5 Serial No: 35001 - 36613
1.Oil level plug

2. Drain plug
3. No. 1 sun gear (I 8 teeth)
5. No. 2 planetary carrier
6. Cover
8. Sprocket
9. Floating seal
10. Travel motor
ll.Hub
12. No.1 planet gear (31 teeth)
13. Ring gear (81 teeth)
14. No. 2 planet gear (34 teeth)
SPECIFICATIONS
Reduction ratio:
81 +I2 x 81 i-18
-
( 12 )( 18 1
+1 =
-41.625
14 13 12 11
205FO5009
1. Oil level plug

2. Drain plug
6. Cover
8. Sprocket
9. Floating seal
10. Travel motor
ll.Hub
12. No.1 planet gear (31 teeth)
14. No. 2 planet gear (34 teeth)
SPECIFICATIONS
Reduction ratio:
- 81 +I2 81 + 18 +1 =
t 12 )i ’ 18 )
-41.625
-10
Section A - A
205FO5806
SWING CIRCLE
‘b
Section B - B /
Section A- A i
205FO5010
1. Swing circle outer race SPECIFICATIONS

2. Ball bearing 110 = 7.333
Reduction ratio: -
3. Swing circle inner race (I 10 teeth) 15
Grease volume: 21 Q (G2-LI)
a. Inner race soft zone“S”
b. Outer race soft zone “S”
10-7
SWING MACHINERY
1. Swing pinion (I 5 teeth)

2. Cover
3. Cage
4. Planetary carrier
6. Bearing holder
7. Drive gear (15 teeth)
8. Swing motor
9. Bearing holder
10. Breather
1 1. Oil level gauge
12. Cover
13. Driven gear (76 teeth)
14. Planetary gear (24 teeth)
15. Sun gear (I 5 teeth)
16. Drain plug
SPECIFICATIONS
Reduction ratio: gx(63 A15) =
26.347
Section B - B
6
Section C - C
Section A - A 205FO5011
TRACK FRAME AND RECOIL SPRING
\ _.--A _
9 8 7 6 5
205FO5012
1. Idler Depending on the model, the dimensions and

2. Track frame number of track rollers is different, but the
3. Carrier roller basic structure is the same. (The diagram
4. Final drive shows PC2001
5. Track roller Sr Number of track rollers
6. Track PC200: 7 (each side)
7. Center guard PC200LC: 9 (each side)
8. Recoil spring PC220: 8 (each side)
9. Front guard PC22OLC: 10 (each side)
1o-9
IDLER
205FO5013
1. Lubricating plug
2. support
3. Idler
4. Floating seal
5. Idler shaft
6. Bushing
10-10
TRACK ROLLER
1. Lubricating plug
2. Collar
3. Floating seal
4. Track roller
5. Bushing
6. Shaft
205F2452
CARRIER ROLLER
1. Shaft
2. Collar
3. Floating seal
4. Carrier roller
5. Ring
6. Cover
7. Lubricating plug
205FO5014
10-l 1
TRACK SHOE
1 2 3 4 5 6 7 8
205FO5015
1. Link Standard shoe specifications

2. Shoe PC200 600 mm triple-shoe
3. Regular pin Link pitch: 190 mm
4. Regular bushing Number of shoe: 90
5. Regular dust seal PC220 600 mm triple-shoe
6. Master bushing Link pitch: 190 mm
7. Master dust seal Number of shoe: 94
8. Master pin PC2OOLC 700 mm triple-shoe
9. Shoe nut Link pitch: 190 mm
10. Shoe bolt Number of shoe: 98
PC22OLC 700 mm triple-shoe
Link pitch: 190 mm
Number of shoe: 102
10-12
SELECTION OF TRACK SHOE
l Select the most suitable track shoe f;om the following table.
0”
z PC220 PC22OLC
2
Cate- Cate-
Specification Specification
gory gory
500 mm 600 mm
A A
triple shoe triple shoe
600 mm 700 mm
A B
700 mm 800 mm
B C
800 mm -
C
triple shoe I 1
610 mm -
D
flat shoe I I
600 mm -
D
rubber shoe I I 1 -
. Category
Cate-
Use Precautions when using
gory
Rocky ground, l Travel in Lo when traveling on rough ground with obstacles
A
normal river soil such as large boulders and fallen trees.
. Cannot be used on rough ground where there are large

obstacles such as boulders and fallen trees.
Normal soil,
B l Travel in Hi speed only on flat ground, and when it is
soft land
impossible to avoid traveling over obstacles,
lower the travel speed to approx. half of Lo. speed.
t
. Use only for ground where “A” and “B” sink and
are impossible to use.
l Cannot be used on rough ground where there are large
Extremely short
obstacles such as boulders and fallen trees.
C ground
l Travel in Hi speed only on flat ground, and when
(swampy ground)
it is impossible to avoid traveling over
obstacles, lower the travel speed to approx.
half of Lo speed.
D t Paved surface l The shoe are flat, so they have low gradeability.
* Categories “B” and “C” are wide shoe, so * When selecting the shoe width, select the
there are restrictions on their use. Therefore, narrowest shoe possible within the range
before using, check the restrictions and con- that will give no problem with flotation and 8
sider carefully the conditions of use before ground pressure. 8
recommending a suitable shoe width. If If a wider shoe than necessary is used, there
s1
necessary, give the customer guidance in will be a large load on the shoe, and this
their use. may lead to bending of the shoe, cracking
of the links, breakage of the pins, loosening
of the shoe bolts, or other problems.
1024
ADDITIONAL CIRCUIT
Circuit for 1 -pump - 1 -actuator (1 PI A)
Control valve NCBF NCALI _ : NCBL .-

-- I
I.H. travel
El
Arm-Lo Arm-Hi
I
AIR
I +
BAR
Service 1
d=
Boom-Lo
Arm. swing
PPC shuttle valve i 1
I I Boom-Hi
I1 Swing
j/ I I 1 I
I
I I Main relief valve tiain relief valve
1I
-_ __
PF PL Travel shuttle valve
i
4 P3
1
Shuttle valve
I
I
I
---------- A
3-way valve
j
I J
205FO5810
* 210 kg/cm2, 250 kg/cm2, 280 kg/cm2
Set (select) the set pressure of the safety valve to match the actuator.
Circuit for 2-pump-l-actuator (2PlA)
Control valve Ncsr _~NCAR NCAL1
r-r
XH. travel
El
L\rm-Lo 4rm-Hi
I I
A3u
I
BAR Gervice 1 Bucket
=,
A I
I
I
.---A
‘oom-Lo
Arm. swing Boom-Hi
PPC shuttle valve El
Swing .H. travel
I I
Main relief valve Main relief valve
PF
l-pump. Z-pump
3-way valve
A I
’ 3-way
valve
d\ A >
I
I
I 1
1 To accumulator, solenoid
valve ass’y
1 205FO58 I2
+ 210 kg/cm2, 250 kg/cm2, 280 kg/cm2

Set (select) the set pressure of the safety valve to match the actuator.
10-&9-l
HYDRAULIC TANK
Section A- A
Section C- C
Section B-B
‘!
-11
Section D-D
205FO5016A
1. Bypass valve SPECIFICATIONS

2. Filter element Tank capacity: 240 Q
3. Bypass filter Oil amount: 150 Q
4. Filter check valve Pressure valve
5. Filler cap Relief set pressure: 0.17 kO.007 kg/cm2
6. Lift check valve Suction set pressure: 0 - 0.046 kg/cm2
7. Sight gauge Bypass valve set pressure: 1.05 *0.2kg/cm2
8. Strainer Filter check valve set pressure:
9. Hydraulic tank 1.82 *0.2kg/cm2
10. Filter case Lift check valve set pressure: 4.2kg/cm2
1 1. Hydraulic oil level sensor
1O-20
OLSS (Open center Load Sensing System)
Motor
Cylinder
I I I
F205C5006-1
OLSS (Open center Load Sensing System) is

an energy-saved system to reduce the fuel
consumption by means of controlling the
swash plate angle (delivery) of the variable-
displacement swash-plate type piston pump.
Therefore this system acts to reduce the hy-
draulic loss during operation, to increase the
fine control and to control the pump delivery.
’o-~“-l
1. EFFECTIVE USE OF ENGINE
Main pump delivery
HORSEPOWER
In H mode, the set speed of the engine
and the actual speed of the engine are
always detected. As a result, even if the
load changes during operation, the dis-
charge amount (swash plate angle) of the
pump is controlled so that the load on
the engine (engine speed) is always main-
tained constant, thus ensuring effective _
use of the engine horsepower. Pump delivery volume Q
205F05121A
(Engine speed, oil pressure sensing (Note) H.0: Heavy duty operation mode,
control) G.0: General operation mode.
F.0: Finishing operation mode,
L.0: Lifting operation mode
2. CUT-OFF CONTROL
l The cut-off control is a function to re-
duce relief loss during operations.
If the load increases, the discharge
pressure of the main pump is in- Loss when there is no cut-off
creased; if the load comes close to

the relief pressure, the discharge vo-
lume is decreased.
l This function is carried out with the
CO valve.
For details of the operation of the CO
valve, see HYDRAULIC PUMP.
3. FLOW CONTROL Pump discharge volume (P/min.)

PNC (pump neutral control) F205C5008
l When the control levers are at neu-
tral, the pump discharge volume is
kept to the minimum to reduce the
wasteful flow of oil when the control
valve is at neutral.
PFC (pump fine control)
l When the lever is operated, the ne-
cesary flow is ordered to the pump
based on the flow command that
corresponds with the lever travel.
This reduces the wasteful flow of oil
that occurs during fine control.
l At the same time, by increasing the
Lever travel (mm)
pump discharge pressure to the opti-
205FO5145
mum value according to the lever tra-
vel, the fine control performance is
improved.
l This function is carried out with the
NC valve and jet sensor.
For details of the operation of the NC
valve and jet sensor, see HYDRAULIC
PUMP.
’o-;o-2
HYDRAULIC PUMP
View Z
e
205FO5017
a. Jet sensor output pressure Pt IN port 1. Front servo valve

b. Jet sensor output pressure Pd IN port 2. Front CO NC valve
l
c. Jet sensor output pressure Pt IN port 3. Rear CO NC valve

l
d. Jet sensor output pressure Pd IN port 4. Rear servo valve

e. CO cancel pressure PSOR IN port 5. TVC valve
f. CO cancel pressure PSOF IN port 6. Charging pump
7. Rear main pump
8. Front main pump
1. FRONT MAIN PUMP AND REAR MAIN PUMP (HPVOSO +0901
a b
r? \
View Z
hij kl
View X View Y 205FO5018
a. Front main pump discharge PPI port 9. Servo valve output pressure Pcin port
b. Front main pump discharge PP~ port h. Servo valve output pressure Pc2n port
Suction PS port i. Front main pump output pressure PPI port
;: Servo valve output pressure kls port j. Rear main pump output pressure PP~ port
e. Charging pump pressure PCI port k. Charging pump pressure Pc2 port
f. Front main pump output pressure Pal port I. Servo valve output pressure Pcse port
1o-22
cc
Section C- C
205FO5019
1. Front drive shaft 11. Rear end cap

2. Front cradle 12. Rear valve plate
3. Front pump case 13. Rear cylinder
4. Front rocker cam 14. Rear piston
5. Front piston 15. Rear rocker cam
6. Front cylinder 16. Rear pump case
7. Front valve plate 17. Rear cradle
8. Front end cap 18. Rear drive shaft
9. Impeller 19. Servo piston
10. Coupling
1 O-23
2. SERVO VALVE * The drawing shows the servo valve for
front main pump
b c d
\ i
Section A-A
Section B-B Section C -C
Section D-D Section E - E Section F - F Section G-G

205F65020
a. Servo actuator port h. CO l NC valve drain Pdr IN port

b. Servo actuator port i. CO * NC valve output pressure Pi IN port
c. Servo actuator port j. Charging pump pressure Ppo OUT port
d. NC valve output pressure Pi pick-up port k. Rear main pump output pressure PP~ OUT
e. Servo valve drain Pdr OUT port
POfl
f. Rear main pump output pressure Pa2 IN port I. Front main pump output pressure PPI OUT
g. Front main pump output pressure Pal IN port
port
li 16
Section A- A
205FO5021
1. Lock nut 8. Pin 15. Guide spool

2. Cover 9. Control piston 16. Spring
3. Plug 10. Lock nut 17. Plug
4. Spring 1 1. Plug 18. Cover
5. Body 12. Lock nut 19. Lock nut
6. Spring 13. Cover
7. Arm 14. Sleeve
FUNCTION
Discharge volumes 01 and Q2 of main pumps
PPI and PP~ are controlled individually by
their own servo valve.
The relationship between pump discharge vo-
lume Q and input signal Pi sent to the
servo valve is as shown in the graph on the
right. Q changes in proportion to Pi.
(cc/rev) ,,Y’
CO * NC valve output pressure Pi (kg/cm*)
205FO5022
OPERATION
1) Operation for increasing pump discharges (rocker cam angle changes to the large)
b Pi
NC valve
i CO valve
TVC valve
205F05023A
Charging pump pressure PC is sent to port l The movement of guide spool (15) closes
a. port a and port d, and connects port d with
Signal pressure Pi from the NC valve is drain chamber e. As a result, servo piston
sent from port b to chamber c. chamber f is also connected to chamber e
As signal pressure Pi rises, the pressure in through port g and port d.
chamber C pushes control piston (9) to At the same time, port a and port h are
the left in the direction of the arrow. The connected, and the flow passes through
piston stops in a position where it is port piston chamber j to push
i to servo
balanced with the force of springs (4) and servo piston (20) to the left in the direction
(6). of the arrow. The rocker cam angle of the
At the same time, arm (7) uses servo piston main piston pump becomes larger, and the
(20) as a fulcrum, moves to the left in the pump discharge volume increases.
same way as control piston (91, and while o Because of the movement of servo piston
fluctuating, moves guide spool (15) to the (201, arm (7) rotates clockwise around pin
left. (81, moves guide spool (15) to the right, and
closes port a, port d, and port h, so the
discharge volume increases only by an
amount corresponding to signal pressure
Pi.
2) Operation for decreasing pump discharges (rocker cam angle changes to the small)
15 e h
Pi
205FO5024A
l When signal pressure Pi drops, control At the same time, port a and port d are
piston (9) moves to the right in the direction connected, and the flow passes through
of the arrow to a point where the hydraulic port g to servo piston chamber f to push
pressure of chamber c is in balance with the servo piston (20) to the right in the
force of springs (4) and (6). direction of the arrow. The rocker cam
At the same time, arm (7) uses servo piston angle of the main piston pump becomes
(20) as a fulcrum, moves to the right in the smaller, and the pump discharge volume
same way as control piston (9). and while decreases.
fluctuating, moves guide spool (I 5) to the l Because of the movement of servo piston
right. (201, arm (7) rotates counterclockwise
l The movement of guide spool (15) closes around pin (81, moves guide spool (15) to
port a and port h, and connects port h with the left, and closes port a, port d, and port
drain chamber e. As a result, servo piston h, so the discharge volume decreases only
chamber j is also connected to chamber e by an amount corresponding to signal
through port i and port h. pressure Pi.
‘3. TVC VALVE
a b C
e d
C--i B-i
fF
Section B- B
Section A- A
D-i
Section C-C Section D-D Section E-E Section F-F
205FO5025
a. Charging pump pressure Ppo IN port Spring 5. Sleeve

b. Front main pump output pressure PPI IN 2. Spool 6. Piston
Port 3. Piston 7. Body
c. Rear main pump output pressure PP~ IN 4. Piston 8. Solenoid
POfl
d. TVC valve drain Pdr OUT port
d. TVC valve output pressure Pt2 OUT port
FUNCTION AND OPERATION
I) When command current from pump controller is small (when pump controller is normal)
TVC valve
PPI
P2
De rease
Discharge
WI 1 TVC prolix switch
Resistor 20jF05026A
FUNCTION OPERATION
When the pump controller is normal, the l Because of the command current sent from
main pump discharge volume can be the controller, solenoid push pin (9) moves,
controlled as desired over a wide range and piston (2) also moves. It stops at a
according to the command current from the point where the sum of the force of spring
pump controller to carry out the power (1) and the force of push pin (9) and the
mode function. force of TVC output pressure Pt2 acting on
When the pump controller is abnormal, piston (3) is in balance. When this happens,
hydraulic sensing is carried out to control the command current is small, so piston (2)
the main pump discharge volume according balances at the bottom.
to the load ‘(pump discharge pressure) to As a result, port a and port b are almost
carry out the constant torque control completely open, and almost all the
function (prolix function.) pressurized oil from the charging pump is
For details, see PEMC SYSTEM. output as TVC output pressure Pt2. Be-
cause of this, the pump discharge volume
is maximum.
1 O&29
2) When command current from pump controller is large (when pump controller is normal)
TVC valve
Fl
I
Decrease -
Servo valve
Servo piston
u
Discharge
Increase
I
Resistor 205F05027A
l Because of the command current sent from

the controller, solenoid push pin (9) moves,
and the piston (2) also moves. It stops at
the point where it is balanced with the force
of spring (I). When this happens, the com-
mand current is large, so piston (2) is bal-
anced at the top. As a result, the flow of oil
sent from the charging pump is throttled at
port a and port b, and the area of the open-
ing at port b and port c (drain port) becomes
larger. Because of this, TVC valve output
pressure Pt2 drops and the pump discharge
volume is reduced.
3) Main oumo under light load (pump controller abnormal and TVC prolix switch ON)
TVC valve
r
Pi
I NC
valve
co
valve
Servo valve
‘_I
Servo piston
Decrease L@ -
Discharge
Increase
I .I lxx--l ,-,TT_
__.._. _..-.
I
TVC prolix switch
Resistor 205F05028A
0 Main pump discharge pressures PPI and

PP~ are low, so spool (2) is pushed down
by spring (1). As a result, charging pump
discharge pressure PC and TVC valve out-
put pressure Pt2 are equal.
When this happens, TVC valve output
pressure Ptz is maximum and the main
pump discharge volume is also maximum.
4) Main pump under heavy load (pump controller abnormal and TVC prolix switch ON)
TVC valve
-
.:.:.
:.:.:
.:.> co
valve
r--v”
$
:.y.:
(1:
. .. ..
g;i
:.:.:
.:.>
:.x
.:.:.
. ..i
Servo valve
Discharge
Resistor 205F05029A
l When main pump discharge pressure PPI

(or PPP) increases, spool (2) is moved up
by piston (4) or piston (6). As a result,
the flow at port a and port b is throttled
by the notch in the spool, and the area
of the opening at port b and port c (drain
port) becomes larger. Because of this,
TVC valve output pressure Pt2 drops and
the main pump discharge volume is
reduced.
4. CO l NC VALVE Sr The diagram shows the CO l NC valve for
the front pump.
a
d
h
b
4 10
11
5
12
6
Section A- A
205FO5030
a. Charging pump pressure PRO OUT port co VALVE NC VALVE

b. Main pump output pressure PPI (PP~) OUT 1. Plug 7. Plug
port 2. Piston 8. Sleeve
c. Main pump output presure PP~ (PPI) OUT 3. Spring 9. Piston
port 4. Spool 10. Spool
d. TVC valve output pressure Pt2 IN port 5. Piston 11. Spring
e. WC valve drain Pdr port 6. Plug 12. Plug
f. CO cancel pressure Pcf (Per) IN port
g. TVC valve output pressure Pt2 F-R * ( I: For rear servo valve
connection port
h. Jet sensor output pressure Pd IN port
i. Jet sensor output pressure Pt IN port
1o-33
@
FUNCTION AND OPERATION OF CO VALVE
1) When main pump discharge pressure is below relief pressure
I
:i.:.:...:
.,
.-
.
.:.:
.+>
,F
j:j:j
.::.
PF
Discharge
205F05031A
FUNCTION OPERATION
If the load increases during operation, and 0 Spool (4) is pushed down by spring (3).
the main pump discharge pressure in- As a result, port a and port b are com-
creases, when it becomes nearly the relief pletely open, and n/C valve output pres-
pressure, the CO valve carries out the cut- sure Pco are equal.
off function to reduce the discharge Because of this, CO valve otput pressure
amount of the pump and reduce the relief Pco becomes maximum, and the dis-
loss. charge volume of the main pump is also
At the same time, the pilot pressure of the maximum.
CO function cancel solenoid valve also has
the function of canceling the cut-off.
The CO valve is controlled by balancing the
sp’ring with the sum of main pump dis-
charge pressure PP and CO valve output
pressure Pco.
2) When the main pump discharge pressure is higher than the main relief pressure
Decrease -
Discharge
205F05032A
l When main pump discharge pressure PP

comes close to the relief pressure owing
to an increase in the load, piston (5) is
pushed by main pump discharge pressure
PP and at the same time piston (5) is
pushed by CO valve output pressure Pco.
When the force of spring (3) is overcome
by the pressing force of the pistons,
spool (4) moves upward.
As a result, the spool land restricts the oil
flow from port a to port b and at the same
time the opening areas of port b and port c
jdrain port) are made larger.
With angle reduced by the operation of the
servo valve, the main pump discharge is
reduced.
1o-35
@
3) When cut-off function is canceled by CO cancel solenoid valve
CO cancel
solenoid valve
Pi r-l_.A
Discharge
205F05033A
0 When the CO cancel solenoid valve is

switched, pilot pressure is taken to port
Pso and piston (2) is pushed down.
As a result, the setting of spring (3) be-
comes larger, so even when main pump
discharge pressure PP rises and reaches
the relief pressure, spool (4) is not actuat-
ed and CO valve output pressure Pco re-
mains at the maximum.
FUNCTION AND OPERATION OF NC VALVE
1 I Control valve at neutral
Ii-n
, ,Jfj Jet sq”sor
I I
Control valve
NC valve
PP.
1M#
FUNCTION OPERATION
The NC valve controls the main pump dis- l The differential pressure (Pt - Pd) of the
charge volume according to the amount of jet sensor reaches the maximum and jet
operation of the control valve spool, and sensor output pressure Pt acting on piston
carries out the function of controlling the oil (101 becomes greater than the sum of the
flow to reduce the neutral loss and fine con- force of spring (12) and jet sensor output
trol loss. pressure Pd acting on the lower end of
The NC valve is controlled by balancing the spool (1 1).
sum of jet sensor output pressure Pt and As a result, spool (1 I) is pushed downward,
NC valve output pressure Pi with the causing a restriction of the oil flow between
sum of the force of NC valve spring (I 2) port c and port b and in turn opening port b
and jet sensor output pressure Pd. and port a (drain port).
The jet sensor detects the flow of return oil Output pressure Pi of the NC valve is
passing through the control valve and re- then reduced to the minimum and the
turning to the tank, and takes it as NC valve main pump discharge is also reduced to
Pt and Pd. the ml’nimum with the swash plate angle
minimized through the operation of the
servo valve.
2) When the control valve is operated
/iI Jet sensor
Control valve
NC valve
205FO5035B
l With the jet sensor differential pressure (Pt

- Pd) reduced according to the operation
of the control valve, spool (1 I) is pushed
upward, fully opening port c and port b.
Thus, the NC valve output pressure in-
creases. Together with the increase in the
main pump swash plate angle through the
servo valve operation, the main pump dis-
charge is also increased. That is to say, the
pump discharge increases as the stroke of
the lever increases.
’o&38
5. CHARGING PUMP
4
Suction+
0
!!!J-
+
Discharge
205FO5036
1. Relief valve SPECIFICATIONS

2. Body Theoretical delivery: 25 cc/rev
3. Cover Operating pressure: 32kglcm”
4. Drive gear
5. Driven gear
6. Filter
1o-39
CONTROL VALVE
PC200,2OOLC-5 Serial No: 45001 - 53192

PC220,22OLC-5 Serial No: 35001 - 36052
n A-( q r s
mm
\
kk
205FO5037
1. Travel shuttle valve OUTLINE
2. 4-spool valve (Built-in straight-travel valve, l This control valve consists of a 4-spool
arm throttle valve) valve and a 5-spool valve. In addition, it also
3. 5-spool valve (Built-in swing priority valve) has a travel shuttle valve.
It has a built-in straight-travel valve, arm
a. P3 port (From arm PPC valve) throttle valve and swing priority valve.
b. PL port (From rear main pump) l The 4-spool valve and 5-spool valve are
C. PR port (From front main pump) connected by bolts to form one unit. The oil
d. B~L port (To bucket cylinder bottom side) flow merges inside the valve, so the valve is
e. B~L port (To boom cylinder head side) compact and provides excellent ease of
f. BI L port (To L.H. travel motor PB port) maintenance.
9. P5 port (From swing PPC shuttle valve)
h. P4 port (From boom bucket PPC shuttle
valve)
i. P6 port (To work equipment oil pressure
switch)
j. Al L port (To L.H. travel motor PA port)
k. AWL port (To boom cylinder bottom side)
I. A3L port (To bucke cylinder head side)
m. P4AL port (From arm PPC valve)
n. P3AL port (From bucket PPC valve)
0. PZAL port (From boom PPC valve)
P- PEAL port (From L.H. travel PPC valve)
g
q. PRL port (From 2-stage relief solenoid valve)
::
c\l r. PRR port (From 2-stage relief solenoid valve)
0
S. Pi AR port (From swing PPC valve)
t. P3AR port (Service)
u. P4AR port (From arm PPC valve)
V. P5AR port (From R.H. travel PPC valve)
w. A3R port (Service)
X. AIR port (To swing motor MA port)
Y. Bl R port (To swing motor port MB)
2. B3R port (Service)
aa. B4R port (To arm cylinder bottom side)

bb. B5R port (To R.H. travel motor PA port)
CC. T port (To tank)
dd A5R port (To R.H. travel motor PB port)
ee. A4R port (To arm cylinder head side)
ff. PtL port (To rear NC valve)
99. PdL port (To rear NC valve)
hh. PtR port (To front NC valve)
ii. PdR port (To front NC valve)
jj. PI BL port (From L.H. travel PPC valve)
kk. P2BL port (From boom PPC valve)
II. P3BL port (From bucket PPC valve)
mm. Ts port (To tank)
nn. P5BR port (From R.H. travel PPC valve)
00. P4BR port (From arm PPC valve)
PP. PBBR port (Service)
qq. PI BR port (From swing PPC valve)
10-41
0
7 6
Section A-A
Section B- B
1. Spool return spring 6. Jet sensor orifice

2. Spool (L.H. travel) 7. Jet sensor relief valve
3. Spool (Boom-Lo) 8. Main relief valve
4. Spool (Bucket) 9. Spool (Straight-travel)
5. Spool (Arm-Hi) IO. Spool (Arm throttle valve)
1042
6
Section C -C
10'
Section D - D
205F05039A
1. Spool return spring 6. Spool (R.H. travel)

2. Spool (Swing) 7. Jet sensor relief valve
3. Spool (Boom-Hi) 8. Jet sensor orifice
4. Spool (Service) 9. Main relief valve (5-spool)
5. Spool (Arm-Lo) 10. Spool (Swing priority)
1o-g43
-1
-2
Section E - E Section F - F
Section G-G Section H - H

205FO5040
1. Check valve 7. Suction valve

2. Check valve spring 8. Spool (Boom-Lo)
3. Spool (L.H. travel) 9. Check valve
4. Spool (Straight-travel) 10. Spool (Boom-Hi)
5. Spool (Swing priority) 11. Safety-suction valve.
6. Spool (Swing)
Section J-J Section K- K
Section L-L 205FO5041
1. Safety-suction valve 6. Check valve

2. Spool (Bucket) 7. Spool (Arm-Lo)
3. Spool (Arm throttle) 8. Safety-suction valve
4. Spool (Service) 9. Check valve
5. Spool (Arm-Hi) 10. Spool RH. travel)
1o-45
/
e f 9 h i j
i I I I
ee dd cc bb a‘a
99, hh
ff. ii
5% F-l
“”
II- 00
kk- PP
jj- qq
205FO5779
’O-F-’
2. 4-spool valve (Built-in straight-travel valve, l This control valve consists of a 4-spool
arm throttle valve) valve and a 5-spool valve. In addition, it also
3. 5-spool valve (Built-in swing priority valve) has a travel shuttle valve.
a. P3 port (From arm PPC valve) throttle valve and swing priority valve.
b. PL port (From rear main pump) l The 4-spool valve and 5-spool valve are
C. PR port (From front main pump) connected by bolts to form one unit. The oil
d. B~L port (To bucket cylinder bottom side) flow merges inside the valve, so the valve is
e. B~L port (To boom cylinder head side) compact and provides excellent ease of
f. BI L port (To L.H. travel motor PB pot-t) maintenance.
9. P5 port ‘(From swing PPC shuttle valve)
h. P4 port (From boom bucket PPC shuttle
valve)
i. PS port (To work equipment - swing oil
pressure switch)
j. Al L port (To L.H. travel motor PA port)
k. AWL pot-t (To boom cylinder bottom side)
I. AWL port (To bucke cylinder head side)
m. P4AL port (From arm PPC valve)
n. P3AL port (From bucket PPC valve)
0. PPAL port (From boom PPC valve)
P. Pl AL port (From L.H. travel PPC valve)
::
q. PRL port (From 2-stage relief solenoid valve)
: r. PRR pot-t (From 2-stage relief solenoid valve)
0
S. Pi AR port (From swing PPC valve)
t. PBAR port (Service)
U. P4AR port (From arm PPC valve)
V. PBAR port (From R.H. travel PPC valve)
w. A3R port (Service)
X. AIR port (To swing motor MA port)
Y. Bl R port (To swing motor port MB)
2. B3R port (Service)
aa. B4R port (To arm cylinder bottom side)

bb. B5R port (To R.H. travel motor PA port)
cc. T port (To tank)
dd. A5R port (To R.H. travel motor PB port)
ee. A4R port (To arm cylinder head side)
ff. PtL port (To rear NC valve)
99. PdL port (To rear NC valve)
hh. PtR port (To front NC valve)
ii. PdR port (To front NC valve)
jj. Pl BL port (From L.H. travel PPC valve)
kk. PSBL port (From boom PPC valve)
II. P3BL port (From bucket PPC valve)
mm. Ts port (To tank)
nn. P5BR port (From R.H. travel PPC valve)
00. P4BR port (From arm PPC valve)
PP. P3BR port (Service)
qq. Pl BR port (From swing PPC valve)
i
Section A - A
205FO5780
Section B - B
205FO5038

5. Spool (Arm-Hi) 10. Spool (Arm throttle valve)
8 7
Section C - C
10’
Section D - D 205FO578 I

4. Spool (Service) 9. Main relief valve
Section E - E
Section F - F
Section G - G Section H - H
205FO5782
1. Check valve 6. Spool (Swing)

2. Check valve spring 7. Suction valve
3. Spool (L.H. travel) 8. Spool (Boom-Lo)
5. Spool (Swing priority) 10. Safety-suction valve
1 2 3 4 5 8 7 8 9
Section J - J Section K - K
Section L - L
205FO5783

4. Spool (Service) 9. Check valve
5. Spool (Arm-Hi) IO. Spool (R.H. travel)
PC200,2OOLC-5 MIGHTY (with 2PlA circuit)
.,” t ” V
..
JJ\ kk
ii,
qq
rr
PP
00 ss
nn
mm
205FO58 I4
1045-7
2. 5-spool valve (Built-in straight-travel valve, 0 This control valve consists of a 5spool
arm throttle valve) valve and a 5-spool valve. In addition, it
3. 5-spool valve (Built-in swing priority valve) also has a travel shuttle valve.
throttle valve and swing priority valve.
0 The 5-spool valve and 5spool valve are
connected by bolts to form one unit. The
oil flow merges inside the valve, so the
valve is compact and provides excellent
ease of maintenance.
a. P3 port (From arm PPC shuttle valve) aa. AIR port (To swing motor MA port)
b. PL port (From rear main pump) bb. BIR port (To swing motor MB port)
PR port (From front main pump) B3R port (Service 1)
:: B6L port (Service 2) z. B4R port (To arm cylinder bottom side)
B3L port (To bucket cylinder head side) B5R port (To R.H. travel motor PA port)
f”.’ B2L port (To boom cylinder head side) EY’ T port (To tank)
9. BIL port (To L.H. travel motor PB port) 99. A5R port (To R.H. travel motor PB port)
h. P5 port (From swing PPC shuttle valve) hh. A4R port (To arm cylinder head side)
P4 port (From boom, bucket PPC shuttle ii. PtL port (To rear NC valve)
in valve) jj. PdL port (To rear NC valve)
i? PtR port (To front NC valve)
j P6 port (To work equipment, swing oil kk.
% pressure switch) II. PdR port (To front NC valve)
k. AIL port (To L.H. travel motor PA port) mm. PIBL port (From L.H. travel PPC valve)
I. A2L port (To boom cylinder bottom side) nn. PZBL port (From boom PPC valve)
m. A5L port (Service 2) 00. P3BL port (From bucket PPC valve)
n. A3L port (To bucket cylinder bottom side) PP. P5BL port (Service 2)
0. P5AL port (Service 2) qq. T3 port (To tank)
P. P4AL port (From arm PPC valve) rr. P5BR port (From R.H. travel PPC valve)
Cl. P3AL port (From bucket PPC valve) ss. P4BR port (From arm PPC valve)
r. P2AL port (From boom PPC valve) tt. P3BR port (Service 1)
S. PIAL port (From L.H. travel PPC valve) uu. PIBR port (From swing PPC valve)
t. PRL port (From 2-stage relief solenoid
valve)
U. PRR port (From 2-stage relief solenoid
valve)
V. PIAR port (From swing PPC valve)
W. PSAR port (Service 1)
X. P4AR port (From arm PPC valve)
Y. P5AR port (From R.H. travel PPC valve)
Z. A3R port (Service 1)
1 O-&5-8
8 Section A - A i
Section B - B 205FO58 I5

5. Spool (Arm-Hi) 11. Spool (Arm throttle valve)
6. Spool (Service 2)
Section C - C
Section D - D 205FO58 I6

4. Spool (Service 1) 9. Main relief valve
‘o-Fo
Section E - E
Section F- F
3 4 5 6 7 8 9
10
205FO58 I7
1. Check valve 6. Spool (Swing)

2. Check valve spring 7. Suction valve
3. Spool (L.H. travel) 8. Spool (Boom-Lo)
5. Spool (Swing priority) 10. Safety-suction valve
Section L - L
205FO58 I8

4. Spool (Service 1) 10. Check valve
5. Safety-suction valve 11. Spool (Service 2)
6. Spool (Arm-Hi) 12. Spool (R.H. travel)
TRAVEL SHUTTLE VALVE
a
I
i j
Section A - A Section C - C
Section B - B Section D - D
205FO5823
a. PS port (Oil pressureswitch) g. PT port (To tank) 1. Cover

b. P4 port (From boom - bucket h. PO port (To straight-travel valve) 2. Spool return spring
shuttle valve) i. PI port (From L.H. travel valve AIL 3. Body
c. P5 port (From swing shuttle valve) port) 4. Spool
d. P3 port (From arm shuttle valve) j. P2 port (From L.H. travel valve BIL
e. P4a port (To arm throttle valve) port)
f. P5a port (To swing priority valve)
FUNCTIONS
l The travel shuttle valve is installed to the
top of the 4-spool valve control valve. It
takes the PPC valve pressures from the left
travel, work equipment, and swing, and
sends pilot pressure to the straight-travel
valve when the travel and work equipment
or swing are operated at the same time.
OPERATION
Travel lever at “FORWARD” (other levers at
“NEUTRAL”)
Fron
l Pilot pressure oil flows to Pl port from the FORWARD circuit travel v&e REVERSE circuit
left travel circuit and pushes the spool to To arm
the rig ht. ~~ c+ throttle valve
Therefore, ports P3, P4, P5 and PO are con- switch
nected through the groove in the spool, and
are also connected to the straight-travel
valve. However, there is no flow of pilot
pressure oil from the shuttle valves of the
PPC valves, so the straight-travel valve is
not actuated.
(When operating in “REVERSE”, pressure
oil is sent to port P2, and pushes the spool From shuttle valve
of arm PPC valve valve of boom From shuttle
to the left.1 bucket PPC valve of swing
valve PPC valve
205F2032-2
During simultaneous operation

When the arm and travel FORWARD are
operated at the same time, pilot pressure oil
flows from the left travel circuit to port PI
and pushes the spool to the right.
At the same time, when the arm is
operated, pilot pressure oil flows to port P3
from the shuttle valve of the arm PPC valve.
From L.H From L.H. travel
This passes through the groove in the spool REVERSE circuit
and port PO, and then flows to the
straight-travel valve.
The pilot pressure oil from the shuttle valve
of the swing PPC valve flows port P5b
port PO-straight-travel valve, and the
pilot pressure oil from the shuttle valve of
the boom and bucket PPC valves flows port
P4-port PO-straight-travel valve.
pressure switch
arm PPC valve valve of From shuttle valve of
boom, bucket swing PPC valve
PPC valve
205F2033-2
1o-&l7
STRAIGHT-TRAVEL VALVE
FUNCTION
l While operating the swing, boom, arm, or
bucket when traveling, the pressure oil
flowing to the R.H. and L.H. travel circuit
branches into the swing, boom, arm, or
bucket circuit.
Since the supply of pressure oil in a
branched travel circuit is less than that in
the circuit before the branch, the motor
naturally slows down, resulting in a turn.
l When the straight-travel valve is switched
over to establish continuity between the
R.H. and L.H. travel circuits, this undesired
turning is prevented by equalizing the
supply of pressure oil to the R.H. and L.H.
travel motors so that they rotate at the
same speed.
OPERATION
When traveling only
l Since no pilot hydraulic oil flows from the
shuttle valve in the PPC valve, no hydraulic
oil flows from the travel shuttle valve to the
straight-travel valve.
l Therefore, the circuit between port PR (R.H.
travel circuit) and port PL(L.H. travel circuit)
remains closed and both circuits remain
independent.
w
205FO5042
While operating the swing, boom, arm, or

bucket when traveling
l Spool (I 1 of the straight-travel valve is
pushed to the right by the pilot pressure
from the travel shuttle valve.
l Port PR and port PL then become connect-
ed to each other and an equal amount of
pressure oil is supplied to the R.H. and L.H.
travel motors, allowing both motors to
rotate at the same speed. The machine trav-
els thus in a straight line.
205FO5043
SWING PRIORITY VALVE
FUNCTION
When operating the swing and arm at the
same time, most of the oil flows to the arm,
which has less load. The flow of oil to the
swing circuit is reduced so the arm speed is
faster than the swing speed. This makes
combined operations difficult.
To prevent this, the swing priority valve is
switched to restrict the flow of pressure oil
to the arm-Lo control valve. This restricts
the arm speed and makes it easier to
operate the arm and swing at the same time.
OPERATION
When swing is at neutral
1 Arm-Lo 1
l No pilot pressure oil flows from the travel
shuttle valve, so the swing priority valve is
not switched. Because of this, the pressure
oil from the front main pump passes
through port PR and all the oil flows to the
arm-lo control valve.
205FO5044
When swing is operated

l When the swing is operated, spool (I) of Arm-Lo
the swing priority valve is pushed to the left
by the pilot pressure from the travel shuttle
valve.
Because of this, the pressurized oil flowing
from front main pump - port PR to the
arm-Lo control valve is throttled, and the
arm speed is controlled, so the simultaneous
operation performance is improved.
205FO5045
ARM THROTTLE VALVE
FUNCTION
l When the arm control lever and boom l The arm is actuated by the merged oil flow
control lever are operated at the same time, from two pumps, and the bucket is
most of the pressure oil flows to the arm actuated by the flow from one pump.
circuit, where the load is less. The amount For this reason, when the arm and bucket
of oil flowing to the boom circuit drops, so are operated together, the flow of oil to the
the arm speed is faster than boom speed. arm circuit is greater, so the arm moves
This makes combined operations difficult. much faster than the bucket. This makes
(particularly when using “ARM OUT” and combined operations difficult. (Particularly
“BOOM RAISE” at the same time.) when using “ARM OUT” and “BUCKET
When this happens, the arm throttle valve is CURL” at the same time.)
switched and the flow of oil to the arm-Hi When this happens, the arm throttle valve is
control valve is restricted. This regulates the switched and the flow of oil to the arm-Hi
arm speed and makes combined operations control valve is restricted. This regulates the
easier. arm speed and makes combined operations
easier.
OPERATION
When arm is operated independently
l The pilot pressure does not flow from the
travel shuttle valve, so the arm throttle
valve is not actuated and the pressure oil
from the rear pump passes through port PL
and all flows to the arm Hi control valve.
[valve ]
205FO5046
Simulataneous operation
l When the arm is operated together with the
boom or bucket, the pilot pressure from the
travel shuttle valve pushes spool (I) of the
arm throttle valve to the left. When this hap-
pens, the flow of pressure oil from the rear
pump to the arm Hi control valve is throttled,
and the arm speed is controlled to improve
the ease of simultaneous operation.
valve J
205FO5047
a
205F05048
a. Sport SPECIFICATIONS
b. MB port (From control valve) Type: KMFgOAB-2
c. MA port (From control valve) Theoretical delivery: 87.8cclrev
d. T port (To tank) Safety valve set pressure:
e. B port (Swing brake solenoid valve)
280 ‘“0 kg/cm* at 140 Q/min (PC200)
285 ‘“0 kg/cm* at 180 Q/min (PC220)
Rated speed: 2,132 rpm (PC200)
2,288 rpm (PC220)
Brake releasing pressure: Max. 14kg/cm*
1O-50
Go
H Section A- A
Section C-C
13 112
Section I3- B 205FO5049
1. Brake spring 10. Cylinder

2. Drive shaft 11. Valve plate
3. Cover 12. Air bleeding plug
4. Housing 13. Center shaft
5. Disc 14. Center spring
6. Plate 15. Safety valve
7. Brake piston 16. Check valve
8. End cover 17. Check valve spring
9. Piston
1o-51
.
SWING HOLDING BRAKE
OPERATION
I) When swing brake solenoid valve is
deactivated
When the swing brake solenoid valve is
deactivated, the pressurized oil from the
charging pump is shut off and pot-t B is con-
nected to the tank circuit.
pump
Because of this, brake piston (7) is pushed
down in the direction of the arrow by brake
spring (I), so disc (5) and plate (6) are
pushed together and the brake is applied.
205FO5050 ::
::
z
2) When swing brake solenoid valve is

excited
When the swing brake solenoid valve is ex-
cited, the valve is switched, and the pressu-
rized oil from the charging pump enters
port B and flows to brake chamber a.
Pump
The pressurized oil entering chamber a
overcomes the force of brake spring (I),
and brake piston (7) is pushed up in the di-
rection of the arrow. Because of this, disc
(5) and plate (6) separate, and the brake is
released.
205FO5051
1o-52
SAFETY VALVE
FUNCTION
l The relief characteristics of this swing kg/cm2 1
motor safety valve consist of two stage as p2---_-__--
shown in the diagram on the right.
It acts to reduce the shock when starting PI: 150 kg/cm2
ans stopping the swing. P2: 280 kg/cm2
TI: 0.05 sec.
T2: 0.05 sec.
205FO5052
OPERATION
I) When circuit pressure is PO
The safety valve is not actuated.
205FO5053
2) When circuit pressure is PI 20 18 19 21

When the circuit pressure is PI, rod (18) \ \ I I
pushes spring (I 91, so plunger (20) is open,
and the pressurized oil is relieved.
The time taken for rod (18) to contact bush-
ing (21) is TI, and the pressure during this
time remains at PI.
205FO5054
3) When circuit pressure is P2 18 23 22 a 21

After rod (I 8) contacts bushing (211, and
the pressure rises (PI -P2), the pressure
from hole a in rod (18) pushes piston (22)
and compresses spring (23) to increase the
set pressure.
The time taken to raise the set pressure is
T2, and the set pressure after the rise is P2.
205FO5055
CENTER SWIVEL JOINT
/A’
--Cl
Section A- A
View Z I
B2
I \
A2 c2
205F05056A
1. Cover Al : From control valve A5R port DI: From control valve AI L port
2. Body A2: To R.H. travel motor PB port D2: To L.H. travel motor PA port
3. Slipper seal BI : From control valve P 1 L port FI: From travel speed solenoid valve
4. Oil seal B2: To L.H. travel motor PB port F2: To L.H. and R.H. travel motor P port
5. Shaft Cl : From control valve B5R port TI: To tank
C2: To R.H. travel motdr PA port T2: From L.H. and R.H. travel motor T port
TRAVEL MOTOR
205FO5057
a. PB port (From control valve) SPECIFICATIONS

b. PA port (From control valve) Theoretical delivery:
c. T port (To tank) Min. 100.5 cc/rpm (PC2001
d. P port (From travel speed solenoid valve) 109.0 cc/rpm (PC220)
Max. 160.8 cc/rpm
Rated pressure: 340 kg/cm2
Rated speed: Min. I,8 10 rpm (PC 200)
1,830 rpm (PC 220)
Max. 1,160 rpm (PC 200)
1,240 rpm (PC 220)
Brake releasing pressure: 12 *2kg/cm2
Hi-Lo switching pressure: 8 * 2kg/cm2
1 O-56
Section C - C
Section A- A
Section 6 - B 205FO5058
1. Output shaft 8. End cover 15. Regulator piston

2. Motor case 9. Regulator valve 16. Spring
3. Cradle 10. Spring 17. Check valve spring
4. Rocker cam 1 1. Brake spring 18. Check valve
5. Piston 12. Brake piston 19. Counterbalance valve
6. Cylinder 13. Plate 20. Spool return spring
7. Valve plate 14. Disc 2 1. Safety valve
1o-57
MOTOR
OPERATION
I) At Lo speed (motor rocker cam angle at maximum)
.:.:.
:.:.:
.:.:.
:.:.:
.:.:.
::.:
.:
:.
i:;:g
.:.:.
:.:.:
.:.:.
:.:.:
.:.:.
::.:
:;:i
:.:.:
.:.:.
:.:.:
:::::
:>.>.
;i;i;
:;:i:
:.:.:
.:.:.
:.:.:
1.:.
:.: :
.:.:.
:.:.:
:; j:
:.:.:
.:.:.
:.:.:
.:.:.
:.:.:
.. . .. . .
Travel :::::::
control :
205FO5059
The solenoid valve is deactivated, so the 0 At the same time, the pressurized oil at
pilot pressure oil from the charging pump regulator piston (15b) at the bottom passes
does not flow to port P. through orifice b in regulator valve (9) and
For this reason, regulator valve (9) is is drained to the motor case.
pushed to the right in the direction of the 0 As a result, rocker cam (4) moves in the
arrow by spring (I 0). maximum rocker cam angle direction, the
Because of this, it pushes check valve (221, motor capacity becomes maximum, and the
and the main pressure oil from the control system is set to Lo speed.
valve to end cover (8) passes through
passage a in regulator valve (91, enters
regulator piston (I 5a) at the top, and
pushes regulator piston (I 5a) to the right in
the direction of the arrow.
1 O-58
2) At Hi speed (motor rocker cam angle at minimum)
15a
\
1 ravel
..I
0
:
0
15b
205FO5060
The solenoid valve is excited, so the pilot 0 At the same time, the pressurized oil at
pressure oil from the charging pump flows regulator piston (I 5a) at the top passes
to port P, and pushes regulator valve (9) is through orifice d in regulator valve (91 and
pushed to the left in the direction of the is drained to the motor case.
arrow. 0 As a result, rocker cam (4) moves in the
Because of this, the main pressure oil from minimum rocker cam angle direction, the
the control valve passes through passage c motor capacity becomes minimum, and the
in regulator valve (9). enters regulator system is set to Hi speed.
piston (15b) at the bottom, and pushes
regulator piston (15b) to the right in the di-
rection of the arrow.
1o-59
PARKING BRAKE
OPERATION
I) When starting to travel
When the travel lever is operated, the
pressurized oil from the pump actuates
counterbalance valve spool (191, the circuit
to the parking brake is opened, and the oil
flows into chamber a of brake piston (I 21,
overcomes the force of spring (I I), and
pushes piston (12) to the right in the direc-
tion of the arrow.
When this happens, the force pushing plate
(I 3) and disc (I 4) together is lost, so plate
(I 3) and disc (I 4) separate and the brake is
released.
205FO5061
2) When stopping travel

When the travel lever is placed in neutral, 14 13
counterbalance valve spool (19) returns to al2 11
the neutral position and the circuit to the
parking brake is closed. The pressurized oil
in chamber a of brake piston (I 2) is drained
to the case from the orifice in the brake
piston, and brake piston (I 2) is pushed to
the left in the direction of the arrow by
spring (I I).
As a result, plate (I 3) and disc (14) are
pushed together, and the brake is applied.
205FO5062
1 O-60
0
BRAKE VALVE
l The brake valve consists of a check valve,

counterbalance valve, and safety valve in a
circuit as shown in the diagram on the right.
(Fig. I)
l The function and operation of each compo-
nent is as given below.
(Fig. I) 205FO5063
II Counterbalance valve, check valve

Function
l When traveling down a slope, the weight of
the machine makes it try to travel faster
than the speed of the motor.
As a result, if the machine travels with the
engine at low speed, the motor will rotate
without load and will run away, which is ex-
tremely dangerous.
To prevent this, these valves act to make
the machine travel according to the engine
speed (pump discharge volume).
Operation when pressure is supplied
l When the travel lever is operated, the
pressurized oil from the control valve is sup-
(Fig. 2) 205i05064A
plied to port PA. It pushes open check valve
(18a) and flows from motor inlet port MA
to motor outlet port MB. However, the Control valve
motor outlet port is closed by check valve
(I 8b) and spool (I 91, so the pressure at the ljb
supply side rises. (Fig. 2)
l The pressurized oil at the supply side flows
from orifice El in spool (19) to chamber
Sl, and when the pressure in chamber Sl
goes above the spool switching pressure,
spool (I 9) is pushed to the right in the direc-
tion of the arrow.
As a result, port MB and port PB are con-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate. (Fig.
3)
(Fig. 3 1 205FO5065
lo-61
Operation of brake when traveling downhill
l If the machine tries to run away when travel-
ing downhill, the motor will turn under no
load, so the pressure at the motor inlet port
:.:.
will drop, and the pressure in chamber SI f # -- lflb
through orifice El will also drop.
When the pressure in chamber Sl drops
below the spool switching pressure, spool
(I 9) is returned to the left in the direction of
the arrow by spring (201, and outlet port
MB is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the ro-
tation of the motor, and this prevents run-
ning away.
In other words, the spool is moved to a posi-
tion where the pressure at outlet port MB
(Fig. 4)
balances the pressure at the inlet port and 205FO5066
the force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the speed according to the dis-
charge volume of the pump. (Fig. 4)
2) Safety valve
Function
l When travel is stopped (or when traveling
downhill), the circuit at the inlet and outlet
ports of the motor are closed by the coun-
terbalance valve, but the motor is rotated by
inertia, so the pressure at the oulet port of
the motor will become abnormally high and
damage the motor or piping. The safety
valve acts to release this abnormal pressure
and sent it to the inlet port side of the motor
to prevent damage to the equipment.
Operation
When stopping travel (or when traveling I
downhill), chamber E in the outlet port cir-
(Fig. 5) 205F2044
cuit is closed by the check valve of the
counterbalance valve, but the pressure at
the outlet port rises because of inertia. (Fig.
51
If the pressure goes above the set pressure,
the force produced by the difference in area
between Dl and D2 [7r/4(Df - D$ x pres-
sure] overcomes the force of the spring and
moves the poppet to the right, so the oil
flows to chamber F in the circuit on the
(Fig. 6) 205F2045
opposite side. (Fig. 6)
1 O-62
VALVE CONTROL
Bucket dump Boom raiSe
1’0
205FO5602
1. L.H. travel control lever 8. Boom, bucket and travel shuttle valve
2. R.H. travel control lever 9. Hydraulic pump
3. R.H. PPC valve 10. Accumulator
4. R.H. work equipment control lever 11. L.H. work equipment control lever
5. Arm half flow solenoid valve 12. L.H. PPC valve
6. Control valve 13. Safety lock valve
7. Arm and swing shuttle valve 14. Travel PPC valve
1 O-65
0
PPC VALVE
PC200,2OOLC-5 Serial No: 45001 - 58018

PC220,22OLC-5 Serial No: 35001 - 36613
FOR WORK EQUIPMENT AND SWING
D
I
a
C d
View Z 205FO5068
a. P port (From charging pump)

b. T port (To tank)
c. P3 port (L.H.: arm in/R.H.: bucket dump)
d. P2 port (L.H.: R.H. swing/R.H.: boom lower)
e. P4 (L.H.: arm out/R.H.: bucket curl)
f. PI port (L.H.: L.H. swing/R.H.: boom raise)
7
9
6
10
5
11
4
12
3
Section A- A Section E?- 6
Section D - D
Section C-C 205FO5069
1. Spool 7. Disc
2. Metering spring 8. Lever
3. Centering spring 9. Joint
4. Pilot piston 10. Plate
5. Pilot spring 1 1. Collar
6. Piston 12. Body
1O-67
OPERATION
I) At neutral
Ports PI and P2 of the PPC valves in circuits
A and B of the control valve are connected
to drain chamber D through fine control
hole f in spool (I 1. (Fig. I)
2) Control lever operated slightly (fine

control)
When piston (6) starts to be pushed by disc
(71, retainer (I 31 is pushed. Spool (1) is also
pushed by spring (2) and moves down.
When this happens, fine control hole f is
shut off from drain chamber D. At almost
the same time it is connected to pump pres-
(Fig. I) 205FO5072
sure chamber Pp, and the pilot pressure of
the control valve is sent through fine control
hole f to port PI. When the pressure at port
PI rises, spool (I 1 is pushed back. Fine con-
trol hole f is shut off from pump pressure
chamber Pp. At almost the same time it is
connected to drain chamber D, so the pres-
sure at port PI escapes to drain chamber D.
Spool (I) moves up and down until the
force of spring (2) is balanced with the pres-
sure of port Pi.
The relationship of the positions of spool
(I) and body (I 21 (fine control hole f is in
the middle between drain hole D and pump
pressure chamber Pp), does not change
until damper piston (4) contacts piston (6).
Therefore, spring (2) is compressed in pro-
portion to the travel of the control lever, so
the pressure at port PI also rises in propor-
tion to the travel of the control lever. The
spool of the control valve moves to a posi-
tion where the pressure of port A (same as
pressure at port PI and the force of the
return spring of the control valve are bal-
anced. (Fig. 2)
(Fig. 2) 205FO5073
3) During fine control (control lever
returned)
When disc (7) starts to be returned, spool
(1) is pushed up by the force of centering
spring (3) and the pressure at port PI.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressu-
rized oil at port P 1 is released.
If the pressure at port PI drops too much,
spool (1) is pushed down by metering spr-
ing (2), so fine control hole f is shut off
from drain chamber D. At almost the same
time it is connected to pump pressure
chamber Pp, so the pressure at port PI
supplies the pump pessure until the pres-
sure recovers to a pressure equivalent to
the position of the lever.
When the control valve spool returns, oil in
drain chamber D from fine control hole f’ of
the valve on the side that is not moving
flows through port P2 and goes to chamber
B, so the oil is charged. (Fig. 3)
::
::
c\l 205FO5074
0
4) At full stroke
Disc (7) pushes down piston (6), but
damper piston (4) also follows this and
pushes down spool (1). Fine control hole f is
shut off from drain chamber D, and is con-
nected to pump pressure chamber Pp.
Therefore, the pilot pressure oil from the
charging pump passes through fine control
hole f and flows to chamber A from port PI
to push the control valve spool.
The return oil from chamber B passes from
port P2 through fine control hole f’ and
flows to drain chamber D.
With damper piston (4) that was following
piston (6). the pressurized oil in the spring
chamber flows out from orifice a, and
damper piston (4) and spool (I) are pushed
back by the force of metering spring (2) and
the hydraulic pressure at port Pl.
The time lag when the lever is suddenly
operated is prevented by damper piston (4).
(During fine control, damper piston (4) does
not follow piston (6), so the fine control per-
formance is maintained.) (Fig. 4)
(Fig. 4) 205FO5075
View 2
2OTFO1042
a. P port (From control pump)

b. T port (To tank)
c. P2 port (L.H.: Arm dump/R.H.: Boom lower)
d. P4 port (L.H.: Swing left/R.H.: Bucket curl)
e. PI port (L.H.: Arm curVl3.H.: Boom raise)
f. P3 port (L.H.: Swing right/R.H.: Bucket dump)
Section A - A Section B - B
Section D - D
Section C - C
20TF01043
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disc 10. Body
OPERATION
1) At neutral
Ports A and B of the control valve and ports PI
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)
20TF01044
(Fig.1)
2) During fine control (neutral - fine control)
When piston (4) starts to be pushed by disc (5)
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut
off from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP. so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port Pt to port A.
When the pressure at port Pt becomes higher,
2
spool (1) is pushed back and fine control hole
f is shut off from pump pressure chamber PP. f ;’ ‘I.!
At almost the same time, it is connected to drain * P t
chamber D to release the pressure at port PI.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is balanced
with the pressure at port PI. The relationship
in the position of spool (1) and body (10) (fine
control hole f is at a point midway between drain
hole D and pump pressure chamber PP) does not
change until retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
20TF01045
control lever, so the pressure at port PI also rises
(Fig.2)
in proportion to the travel of the control lever.
In this way, the control valve spool moves to a
position where the pressure in chamber A (ttie
same as the pressure at port Pt) and the force
of the control valve spool return spring are
balanced. (Fig. 2)
1O-$9-3
3) During fine control
(when control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port PI.
When this happens, fine control hole f is
connected to drain chamber D and the pressure
oil at port PI is released.
If the pressure at port PI drops too far, spool
(1) is pushed down by metering spring (2), and
fine control hole f is shut off from drain chamber
D. At almost the same time, it is connected to
pump pressure chamber PP, and the pump
pressure is supplied until the pressure at port
PI recovers to a pressure that corresponds to
the lever position.
When 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 passes through port PZ and enters
chamber B to fill the chamber with oil. (Fig. 3)
ZOTF01046
(Fig.3)
4) At full stroke
When disc (5) pushes down piston (4) and
retainer (9) pushes down spool (l), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charging
pumppassesthroughfinecontrol holef andflows
to chamber A from port PI, and pushes the
control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f’ and flows
to drain chamber D. (Fig. 4)
I II
I ‘PP
2OTFO1047
(Fig.4)
’o-9-4
FOR TRAVEL
a C d
f ‘e
a. P port (From charging pump)

b. T port (To tank)
c. P2 port (L.H. reverse)
d. P4 port RH. reverse)
e. PI port (L.H. forward)
f. P3 port RH. forward)
1ago
Section A- A Section B - B
Section D - D
Section C-C
205FO507 1
1. Spool 5. Bolt
2. Metering spring 6. Plate
3. Centering spring 7. Collar
4. Piston 8. Body
10-g
ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATION
Gas capacity: 300 cc
205FO5076
SAFETY LOCK VALVE
PC200,2OOLC-5 Serial No: 45001 - 49317
PC220,22OLC-5 Serial No: 35001 - 35568
1. Lever
2. Body
3. Seat
4. Ball
5. End cap
i I \ \
2 3 4 5
205FO5077
PC200,200LC-5 Serial No: 49318 and up

1. Lever
2. Body
3. Seat
4. Ball
5. End cap
F205C5018
’0673
SOLENOID VALVE ASSEMBLY
PC200,2OOLC-5 Serial No: 45001 - 52783

PC220,22OLC-5 Serial No: 35001 - 36023
FOR 2-STAGE RELIEF l CO CANCEL, SWING BRAKE AND TRAVEL SPEED
‘e
F20505351
a. To L.H. and R.H. travel motor 1. Travel speed solenoid valve

b. To swing motor 2. Swing brake solenoid valve
c. To main relief valve, and front and rear CO 3. 2-stage relief l CO cancel solenoid valve.
valve
d. P port (From charging pump)
e. T port (To tank)
1o-g4
1) FOR P-STAGE RELIEF l CO CANCEL AND TRAVEL SPEED
1. Connector
2. Plunger
3. Coil
4. Push pin
5. Spool
6. Spring
7. Bracket
205FO50 79
OPERATION
Solenoid deactivated C
z 0 No signal current flows from the controller,
so solenoid is deactivated.
:
0 Because of this, port A is closed, and the
pressurized oil from the charging pump
does not flow to the actuator.
At the same time, the oil from the actuator
flows from port B to port C and is drained
to the tank.
205FO5080-1
Solenoid excited
0 When the signal current flows from the
controller to solenoid, solenoid is excited.
As a result, the Dressurized oil from the
charging pump flows from port A to port B,
and to the actuator.
At the same time, port C is closed, and the
Actuator
does not flow to the tank.
205FO5081-1
2) FOR SWING BRAKE
1. Connector
2. Plunger
3. Coil
4. Spring
5. Spool
6. Body
7. Plug
205FO5082
OPERATION
Solenoid deactivated l-l
Swing
motor
a No signal current flows from the controll-

er, so coil is deactivated.
Because of this, port P is closed, and the
does not flow to the swing motor.
At the same time, the oil from the swing
motor flows from port A to port T and is
drained to the tank.
205FO5083-1
Solenoid excited
l When the signal current flows from the
controller, coil is excited.
Because of this, port P and port A are inter-
connected, and the pressurized oil from the
charging pump flows to the swing motor. Exci
At the same time, port T is closed, so the oil
does not flow to the tank.
205FO5084-1
FOR 2-STAGE RELIEF * CO CANCEL, SWING BRAKE AND TRAVEL SPEED
d e
205 F05826
a. To L.H. and R.H. travel motor 1. Travel speed solenoid valve

b. To swing motor 2. Swing brake solenoid valve
C. To main relief valve, and front and rear CO 3. 2-stage relief * CO cancel solenoid valve
valve
d. P port (From charging pump)
e. T port (To tank)
1. Connector
2. Plunger
3. Coil
4. Push pin
5. Spring
6. Spool
7. Body
Section A - A
205FO5827
OPERATION T
Solenoid deactivated
l The signal current from the controller does Deactiv;ted p? , ,
not flow, so coil is deactivated.
l As a result, port P is closed, and the press-
ure oil from the charging pump does not
flow to the actuator.
At the sarne time, the oil from the actuator
flows from port A to port T, and drains to
the tank.
Solenoid excited
l When the signal current from the control-
ler flows to coil, coil is excited. Excite- , /
l Because of this, pressure oil from the
charging pump flows from port P to port
A, and then flows to the actuator.
At the same time, port T is closed, so the
oil does not flow to the tank.
205FO5829
PC200,2OOLC-5 Serial No: 45001 - 52783
PC220,22OLC-5 Serial No: 35001 - 36052
FOR ARM HALF FLOW
1. Connector
2. Plunger
3. Coil
4. Spring
5. Spool
6. Body
7. Plug
205FO5085
OPERATION
0 No signal current flows from the controll-
er, so coil is deactivated.
Because of this, port P and port S are in-
terconnected, so the pressurized oil from
the PPC valve flows to the control valve.
205FO5086
Solenoid excited
l When the signal current flows from the con-
troller, coil is excited.
Because of this, port P is closed, and the
pressurized oil from the PPC valve does not
flow to the control valve.
At the same time, port S and Port T are in- Exci
terconnected, so the pressurized oil from
the control valve is drained to the tank.
205FO5087
FOR ARM HALF FLOW
1. Connector
1 2 3 4 5 6 7 2. Plunger
3. Coil
4. Push pin
5. Spring
6. Spool
7. Body
OPERATION
l The signal current from the controller does
not flow, so coil is deactivated.
l As a result, port P and port A are intercon-
nected, and pressure oil from the PPC
valve flows to the control valve.
Solenoid excited
l When the signal current from the control-
ler flows to coil, coil is excited.
l Because of this, port P is closed, and the
pressure oil from the PPC valve does not
flow to the control valve.
At the same time, the oil from the control
valve flows from port A to port T, and
drains to the tank.
205FO5832
’o-&7-3
SHUTTLE VALVE
FOR ARM AND SWING
a b c 9 h
1. Plug
2. Body
3. Ball
a. PI B port (Swing right)

b. P5 port (Swing oil pressure switch)
c. P2B port (Swing Left)
d. P4B port (Arm in)
e. P6 port (travel shuttle valve)
f. P3B port (Arm out)
9. P2A port (Swing left)
h. P 1 A port (Swing right)
i. P3A port (Arm out)
j. P4A port (Arm in)
Section A- A
205FO5088
FOR BOOM, BUCKET AND TRAVEL
1. Plug
2. Body
3. Ball
I-D
a. P7Aport
k--
,- -i b. PEA port
c. P2A port
I-
d. PlAport
m- e. P9A port
j f. P8A pot-t
n-
g. P4A port
h. P3A port
i. PlOport
j. P5 port
k. P9B port
I. PUB pot-t
m. P4B port
n. P3B port
0. P7B port
p. P6~p0rt
q. P2Bport
Section A__A Section B-B Section C - C r. PIB port
Section D- D
205FO5089
BOOM HOLDING VALVE
PC200,2OOLC-5 Serial No: 45001 - 53229

PC220,22OLC-5 Serial No: 35001 - 36052
Section B - B Section A- A
205FO5090
1. Safety-suction valve
2. Pilot spring
3. Pilot spool
4. Poppet spring
5. Poppet
PC200,200LC-5 MIGHTY
I I I I
Section B - B Section A - A
205FO5784
2. Pilot spring
3. Pilot spool
4. Poppet spring
5. Poppet
OPERATION
I) At boom RAISE
When the boom is raised, the main pressure
from the control valve pushes up poppet (5)
in the direction of the arrow.
Because of this, the main pressure oil from
the control valve passes through the valve
and flows to the bottom end of the boom
cylinder.
205FO5091
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 the bottom end of
the boom cylinder is closed by poppet (51,
and at the same time, the circuit for the oil
flowing into poppet (5) through orifice a of
poppet (5) is closed by pilot spool (3).
As a result, the boom is held in position.
205FO5092
3) Boom LOWER
When the boom is lowered, the pilot pres-
sure from the PPC valve pushes pilot spool
(3) and the pressurized oil in chamber b
inside the poppet is drained.
When the pressure at port Cy rises because
of the pressurized oil from the bottom end
of the boom cylinder, the pressure of the
pressurized oil in chamber b is lowered be-
cause of orifice a.
If the pressure in chamber b drops below
the pressure at port V, poppet (5) opens,
the pressurized oil flows from port Cy to
port V, and then flows to the control valve.
If any abnormal pressure is generated in the
circuit at the bottom end of the boom cylin-
der, safety valve (I 1 is actuated.
205FO5093
HYDRAULIC CYLINDER
1. BOOM CYLINDER
1 2 3456 7 9 10 11 12 13 14 15 16
205FO5094
2. ARM CYLINDER
1'8 1'7
205FO5095
3. BUCKET CYLINDER
12 3456 7 10 11 12 13 14 15
205FO5096
1. Bottom side bushing 7. Cylinder 13. Piston

2. Piston rod 8. Head side tube 14. Piston nut
3. Cylinder head 9. Head side cushion plunger 15. Bottom side tube
4. Rod packing 10. Ring 16. Bottom side bushing
5. Buffer ring 1 1. Piston ring 17. Bottom side cushion plunger
6. Wear ring 12. Wear ring 18. Ball
SPECIFICATIONS
Unit: mm
1, Boom I Arm I Bucket
Item PC200
Rod outside diameter 120
Cylinder inside diameter 85
Stroke 1,285
Maximum length 3,160
Minimum length 1,875
Piston nut width across flats 85

ELECTRICAL WIRING DIAGRAM
9
8 11
i / /
1\
23
18 I
17 /
16
205FO5744
View 2
1. Monitor panel 13. Pump controller

2. Window washer switch 14. Engine throttle controller
3. Swing lock switch 15. TVC prolix resistor
4. Horn switch 16. Power maximizing switch
5. Starting switch 17. Wiper relay
6. Fuel control dial 18. Additional lamp relay
7. Cigarette lighter 19. Heater Lo relay
8. Service meter 20. Heater Hi relay
9. Buzzer 21. Speaker
10. Radio 22. Lamp relay
11. NC prolix switch 23. Fuse box
12. Swing lock prolix switch
2-PUMP-I-ACTUATOR SYSTEM (PC200,2OOLC-5 MIGHTY)
CN-V9(X2)
1-pu
solenoid valve
To swing flusher
Pump selector switch

ON : Z-pump
OFF : l-pump
Fuse box
205FO5848
HORN (PC200,2OOLC-5 MIGHTY)
Horn (Hi) 348 Hz ‘s” I.25LR
Horn (Lo) 290 Hz I7 1.25LR
205FO5849
10439-6
ENGINE CONTROL SYSTEM
i /
View Z
205FO5104
1. Battery relay OUTLINE

2. Battery The engine can be started and stopped
3. Fuel control dial simply by using the starting switch.
4. Starting switch The engine speed can be controlled using a
5. Governor motor dial control system for the fuel control.
6. Starting motor The engine throttle controller also controls
7. Engine throttle controller the engine speed at the same time using
8. Fuel injection pump signals from the pump controller.
* For detail, see PEMC SYSTEM.
1 O-89-8
GOVERNOR MOTOR LINKAGE
Angle origin
(Position of stopper)
\
Full
-
FL20505391
1. Locknut
2. Yoke
3. Governor actuater
4. Spring assembly
5. Engine governor
1. OPERATION OF SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,220LC-5 Serial No: 35001 - 36613
Starting engine
l When the starting switch is turned to the Starting
START position, the start signal flows to

the starting motor, and the starting motor
turns to start the engine.
When this happens, the engine throttle con-
troller checks the signal voltage from the
fuel control dial and sets the engine speed
to the set speed.
205FO51051
Engine speed control

l The fuel control dial sends a signal voltage Starting
to the engine throttle controller according
to the position of the dial.
The engine throttle controller calculates the
angle of the governor motor according to
this signal voltage, and drives the governor
motor so that it is set to that position.
When this happens, it detects the operating
angle of the governor motor using a poten-
tiometer and observes the governor motor.
Stopping engine
Starting
l When the engine throttle controller detects
that the starting switch is at the STOP posi-
tion, it drives the governor motor to set it to
the NO INJECTION position, and stops the
engine.
When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle controller
itself drives the battery relay.
205FCi5 10 7-1
Starting engine
Starting
l When the starting switch is turned to the
START position, the start signal flows to
the starting motor, and the starting motor
turns to start the engine.
When this happens, the engine throttle con-
troller checks the signal voltage from the
fuel control dial and sets the engine speed
to the set speed.
205FO5752
Engine speed control

Starting
l The fuel control dial sends a signal voltage
to the engine throttle controller according
to the position of the dial.
The engine throttle controller calculates the
angle of the governor motor according to
this signal voltage, and drives the governor
motor so that it is set to that position.
When this happens, it detects the operating
angle of the governor motor using a poten-
tiometer and observes the governor motor.
205FO5753
Starting
Stopping engine
l When the engine throttle controller detects
F
that the starting switch is at the’STOP posi-
tion, it drives the governor motor to set it to
the NO INJECTION position, and stops the
engine.
When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle controller
itself drives the battery relay.
205FO5754
1 O&92
2. COMPONENT EQUIPMENT OF SYSTEM
1) ENGINE THROTTLE CONTROLLER
CN-El
v “0
View Z 1
205FO5108
1. Self-diagnostic display LEDs

Control function of controller
(Inputsignal) (Output signal)
0 The engine throttle controller receives the Pump controller
input signals shown in the diagram on the (Starting stop SIgnall IThrottle signall
right, processes these internally and sends

output signals to the pump controller,
governor motor, and battery relay.
(Potentmmeter stgnal)
205FO5 109
u
1) Engine speed set function using fuel con- Controller output
trol dial $ characteristics
,Hi-idling
An output signal that matches input voltage .-P /
E%
a corresponding to the position of the fuel =m @
zm
control dial is sent so that the governor 0%
zal
motor is set to turning angle b. E .E
2 $ Lo-idling
Turning angle b is fed back to the controller L-
by the potentiometer signal, and the opera- z
8 output
tion of the governor motor is always
observed.
output
205FO5110
2) Engine speed control by No. 2 throttle

signal from pump controller
The pump controller controls the engine
speed directly using the No. 2 throttle signal
in order to carry out the PEMC system.
The engine throttle controller controls the
engine using the lower signal (higher vol-
tage) of the throttle signal from the fuel
control dial and the No. 2 throttle signal
from the pump controller.
Example:
Even if the fuel control dial is set to the
MAX. position, if LF.0 mode and S model is
selected for the working mode and power
set, the engine speed will automatically be
set to partial speed.
* For details, see PEMC SYSTEM.
1024
3) Auto-deceleration function using auto-
deceleration signal from pump controller
When the pump controller detects that all
levers are at neutral, it sends the auto-
deceleration signal to the engine throttle
controller. When this signal is received, the
engine throttle controller reduces the
engine speed to the deceleration position.
* For details, see PEMC SYSTEM.
4) Automatic warming-up function using

warming-up signal from monitor
After the engine is started, if the engine
water temperature is low, the monitor sends
the warming-up signal to the engine throttle
controller.
When this signal is received, the engine
throttle controller raises the engine speed
to carry out warming up.
+ For details, see PEMC SYSTEM.
51 Engine stop function using starting

switch signal Starting switch xl oFF
::
When the starting switch is turned OFF, the
:: Operation of
(v engine throttle controller detects this and
0
drives the battery relay to maintain the elec-
tric power. At the same time, it drives the
E=Lk
governor motor to pull back the fuel injec-
tion pump lever to the STOP position.
2.5 set
205F05111A
6) Self-diagnostic function
Three LEDs (red, green, red) light up and go
out to indicate that the machine is normal, Voltage between connector CN-El (13) - (12).
or to indicate the location of any failure (Battery relay drive signal)
when any abnormality occurs.

Signal Voltage (VI)
+ For details., see the TROUBLE-
SHOOTING. ON-l 20 - 30
ON-2 18-28
I OFF I -15--30 I
Internal structure of controller
0 The inside of the controller consists of the -
input circuit, microcomputer, and drive cir- 1 6
6 - k U
cuit shown in the diagram on the right, and al .Z .= L’
S -0
these have the various functions described $ -2
.f g .g 5
below. -00 - E
5 ’ 2 8 aB
- 2 .> z
2 .P E
.E 2
1) Input circuits G-e r $
These receive the signals from the fuel con- G
-
trol dial (throttle signal), pump controller
(No. 2 throttle signal, auto-deceleration 205FO5112
signal), monitor (warming-up signal), and
starting switch (start signal), and send them
to the microcomputer. In this portion, the
noise in the signal is removed and the wave
pattern of the signal is regulated.
In addition, it makes the power source
(approx. 5V) for the governor motor poten-
tiometer and fuel control dial.
2) Microcomputer
The angle of the governor motor is calculat-
ed from the input signals sent from the
input circuits, and the pulse signal to drive
the governor motor is sent to the drive
circuit.
3) Drive circuit
The pulse signal sent from the micro-
computer is used to switch the direction of
1the current flowing to the governor motor
to rotate the motor clockwise or
counterclockwise.
2) FUEL CONTROL DIAL
1. Knob
2. Dial
3. Spring
Machine 4. Ball
forward
5. Potentiometer
6. Connector
Section A - A
Composition of circuit
205FO5113
FUNCTION
l This is installed under the monitor panel. A
potentiometer is installed under the knob,
and when the knob is turned, it rotates the
potentiometer shaft.
This rotation changes the resistance of the
variable resistor inside the potentiometer, s
and sends the desired throttle signal to the !z

engine throttle controller. The shaded area .I
n
in the graph on the right shows the abnor-
mal detection area, and the engine speed is
set to low idling. 0 0.25 1 4 4.75 5
Throttle voltage
l There are detents at ten places on the knob
characteristics (VI
of the fuel control dial, but the knob can be 205FO51 14
set at any desired position.
3) GOVERNOR MOTOR
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
Section A- A
@ (E&3)
@ (jS{
205FO5115
FUNCTION OPERATION
l The motor is rotated and the governor lever Motor stationary
of the fuel injection pump is controlled by l Current is passing through both the
the drive signal from the engine throttle A-phase coil and B-phase coil of the motor.
controller. Motor rotating
l A stepping motor is used for the motor l A pulse current is applied to the A phase
which provides the motive power. and B phase by the engine throttle controller
In addition, a potentiometer to give feed- to give synchronous rotation with the pulse.
back is installed to allow observation of the
operation of the motor.
The rotation of the motor is transmitted to
the potentiometer through a gear.
OUTLINE OF OPERATION OF STEPPING
MOTOR
Fig. 1 shows a diagram of the stepping mo-

tor expanded in the direction of the circum-
ference.
It shows the relative positions of the teeth of
the rotor and stator, and the condition corre-
sponds to current drive pattern 1 in Table 1.
If the motor is changed from this condition
into current drive pattern 2, the relative posi-
tions of the stator and rotor will become as
shown by the dotted line in Fig. 1 (the stator
is fixed, so the rotor moves to the left).
When switched in the pattern 2 -+ 3 -+ 4 -1
. . .. the rotor also moves to the left in the
same way. If the current drive pattern is
changed 4 -+ 3 - 2 - 1 - 4 . . .. the
rotor moves to the right.
Fig. 1 Expanded diagram of stepping motor
Rotor (permanent magnet)
N S N S N S N S N S N
--1
-1 -7 --i
N S S I N
I
I I I I
I I I
I I I I
_J AA --I _-I An . -_I
+i Stator -i
t’
r[ (
b “b
A phase B phase
Table 1
Current drive pattern Pattern 1 Pattern 2 Pattern 3 Pattern 4
A-phase current +i +i -i -i
B-phase current -i +i +i -i
4) LOOSE SPRING
PC200,2OOLC-5 Serial No: 45001 - 56525

PC220,220LC-5 Serial No: 35001 - 35437
1. Yoke
2. Pipe
3. Spring
4. Spring
5. Rod
r
L
205 F0585 1

1 2 3 4 5 1. Rod
2. Spring
3. Pipe
4. Spring
5. Joint
205FO5868
1o-9&7-3
PEMC SYSTEM
Working mode selection function

Pump & engine mutual control system
Power set selection function
Pump flow control (PFC, PNC) function
i~*ZI~~~~~~~~~Zon
Power maximizing system

1
Auto-deceleration system
I[t Lo
0
Engine automatic warming-up function g
Engine automatic warming-up and c*l
overheat prevention system 0
Engine overheat prevention function
Swing lock function

Swing control system
I Swing holding brake function
(Pump control function

When machine is traveling)
Travel control system
Automatic Hi-Lo travel speed shift
function
Self-diagnostic function
I
205FO5116
l PEMC system: Pump and Engine Mutual Control System

The PEMC system is a system of total control to give a high level of both power and fuel economy
by controlling both the pump and engine.
PCZOO, 2OOLC-5 Serial No: 45001-49706
PC220,22OLC-5 Serial No: 35001-35661
Travel motor
Swing motor
&izz--b---! I
IArmthrottle /j
1t
-Main L______--____J~
relef “alYe
Swing
lock
switch
(switch
205FO5117B
10699
PC200,2OOLC-5 Serial No: 49707 - 58018
PC220,22OLC-5 Serial No: 35662 - 36613
Travel motor
Swing motor
------_ I Controlvalve
r I
I
I i
I
r-
Swing
lock
switch
01
;; s wing
Power max Ic,ck
switch P rolix
s\Nitch
207F@5@52-1
’0Z9-’
PC200, 2OOLC-5 Serial No: 58019 and up
PC200, 2OOLC-5 MIGHTY
PC220, 22OLC-5 Serial No: 36614 and up
Travel motor
I I Swing motor
f39
Regulator, _
T
, Regulator
,_____,fL______
I
r-
- Controlvalve _------,+--q.) I
L--J
pres.
(Arm curl1
I
I switch
I
,
Swing
Chargm lock
pump switch
Power max lock

switch prolix
switch
controller
205FO5755
1. PUMP AND ENGINE MUTUAL CONTROL SYSTEM (WORKING MODE SELECTION
AND POWER SET SELECTION)
Engine
Fuel injection Covernor
Travel control lever
PPC shuttle valve
(Travel lever signal1

Engine throttle
Pump controller -
controller
‘HO GO FO LO
I
Fuel control dial t _;. 0000
,switci,
s,gnaliWORKING MODE @
(Switch signal) 5 6 (;
205FO5118A
OUTLINE
l The changes in the engine speed caused by 0 The combination of the 4-level working
the pump load are detected by the engine mode and 3-level power set makes it possi-
speed sensor and fuel control dial output ble to choose a pump absorption torque
signal. The pump controller calculates these corresponding to the nature of the work, so
signals, and sends the results to the TVC it is possible to use the engine more effec-
valve as a signal to control the pump dis- tively while also reducing fuel consumption.
charge volume. In this way, it can’always 0 Normally, the combination of the working
give the optimum matching of the engine mode and power mode takes the working
torque and pump absorption torque. mode as the basic mode, and the power
mode is automatically set according to the
selection of the working mode.
Engine torque Engine horsepower Main pump delivery

L.O + L G.O. F.O. L.0 + S L.0 + L H
Engine speed N 205F0511 9A Engine speed N Pump delivery volume 0

205FO5 120A
Note) H.0: Heavy duty operation mode, G.0: General operation mode, 205F05121A
F.0: Finishing operation mode, L.0: Lifting operation mode

CONTROL OF H MODE . Engine torque
When using H.O. G.O. F.0 or L.0 mode and H
mode
Working mode: Same for any mode
Power set:
CO function: Actuated
Pump absorption
horsepower:
Engine speed N
205FO5122
When the pump controller receives the

l
power set [HI signal from the monitor, it Engine horsepower
sends out an electric command for the H

mode output setting to the engine throttle
controller.
The engine throttle controller receives this
and uses the governor motor to set the
engine governor lever to the FULL position.
If the pump load becomes too high and the
engine speed drops, the engine speed sens-
ing reduces the pump discharge amount,
and momentarily resets the engine speed to
Engine speed N
the rated point. In this way, the engine
205FO5 123
torque and pump absorption torque are
always matched at the rated point, and the
l Main pump delivery
engine horsepower can be used to the
maximum.
The CO (Cut-off) function is actuated, and
when it reaches near the relief pressure, the
pump discharge amount is reduced to
reduce hydraulic loss and power loss.
Pump delivery volume Q

205FO5124
CONTROL OF S MODE
When using H.0 mode and S mode l Engine torque l Engine horsepower
Working mode: H.0
Power set: S
Pump absorption At 80% partial
horsepower: output point
PC200 PC220
98.6 HP/2,050rpm 123.2 HP/2,200rpm Engine speed N p Engine speed N

Lu
205FO5125 205FO5126
When the pump controller receives the
working mode lH.01 and power set [Sl
Main pump delivery
signal from the monitor, it sends out an
electric command for the S mode output
setting to the engine throttle controller.
governor lever to the FULL position.
The pump absorption horsepower and
engine speed are different, but the control
is basically the same as for [HI mode
(engine speed sensing at the matching
point).
205FO5133 Ei
0
When using G.0, F.0 or L.0 mode and S mode

l Working mode: G.O. F.0 or L.0 Engine torque Engine horsepower
0 Power set: S
0 CO function: Actuated
l Pump absorption At 80% partial
PC200 PC220
98.6 HP/l ,900rpm 123.2 HP/2,000rpm Engine speed N Engine speed N

&
205FO5128 205FO5129
l When the pump controller receives the
working mode LG.01 (or fF.01 fL.01) and l Main pump delivery
power set El signal from the monitor, it
sends out an electric command for the S al
mode output setting to the engine throttle
controller.
governor lever to the partial position.
l The pump absorption horsepower and
point). 205FO5136
‘O-LAO2
CONTROL OF L MODE
When using H.0 mode and L mode l Engine torque l Engine horsepower
l Working mode: H.0 a
L
0 Power set: L
1,1
b
0 CO function: Actuated 3
l Pump absorption At 68% partial E
I
_c
b
PC200 PC220
I \ .-E
83.8 HP/2,050rpm 1 103.5 HP/2,200rpm Engine speed N w
P Engine speed N
205FO5131 205FO5132
working mode fH.01 and power set [Ll
l Main pump delivery
signal from the monitor, it sends out an
electric command for the L mode output
governor lever to the FULL position.
::
point). Pump delivery volume Q
z
(\I 205FO5 127
0
When using G.O. F.0 or L.0 mode and L mode

l Engine torque l Engine horsepower
l Working mode: G.0 or F.0
0 Power set: L
l Pump absorption At 68% partial
PC200 PC220
83.8 HP/ 1,900rpm 103.5 HP/2,000rpm Engine speed N Engine speed N

LLI
205FO5134 205FO5 135
working mode LG.01 (or tF.01) and power
Main pump delivery
set [LI signal from the monitor, it sends out
an electric command for the L mode output
governor lever to the partial position.
point). Pump delivery volume Q
205FO5 130
1O-&O3
When using L.0 mode and L mode l Engine torque
Working mode: L.0
Power set: L
Pump absorption At 62% partial
PC200 PC220
75.9 HP/l ,400rpm 96.6 HP/l ,500rpm
Engine speed N
When the pump controller receives the 205FO5137
working mode IL.01 and power set [Ll signal
from the monitor, it sends out an electric l Engine horsepower
command for the L mode output setting to
the engine throttle controller.
and sets the governor lever to the partial
position.
The pump absorption horsepower and
point).
The area around the matching point is a Engine speed N
highly efficient area for engine fuel con- 205FO5138
sumption, so the fuel reduction effect is ex-

tremely large. l Main pump delivery
At the same time, by throttling the pump
output, it is possible to obtain a high level of
fine control performance to match fine con-
trol operation.

205FO5139
1O-&O4
CONTROL OF POWER MAXIMIZING FUN- l Engine torque
CTION
l When the power max. switch is OFF
l Working mode: H.0 or G.0

0 Power set: Same for any mode
l Pump absorption Depends on the
horsepower: setting for working
mode and power set
I \
Engine speed N
a 205FO5 122
l When power maximizing switch ON
l Working mode: H.0 l Engine horsepower

0 Power set: H
0 CO function: Cancel
l Pump absorption At rated output point
horsepower:
0 Operation time: Even if the switch is
kept ON, it is auto-
matically canceled
after 8.5 seconds.
1
0 l When the working mode switch is at iH.01
Engine speed N
or IG.01, and the power max. switch is
205FO5123
pushed ON, the following functions are ac-
tuated while the switch is being pressed.
0 Main pump delivery
II If either of the working modes and any
of the power sets is selected, the
system will switch to LH.01 and [HI.
2) The CO (cut-off) function is canceled,
and the flow at near relief pressure is
increased.
* For details, see PUMP CONTROL
SYSTEM.
* Even if the switch is kept pressed, the
above function is automatically canceled
after 8.5 seconds, and the system is Pump delivery volume Q
reset to the condition before the switch 205FO5 140
was pressed.
t This function does not work when the
working mode switch is at iF.01 or tL.01.
10-105
0
CONTROL FUNCTIONS WHEN TRAVELING l Engine torque
0 When the travel is operated, even if any
working mode or power set is selected,
the working mode and engine speed will
stay as they are, and only the power set
is switched to the equivalent of H mode
(Pump control by engine speed sensing)
to increase the pump absorption torque.
Engine speed N
205FO5141
l Engine horsepower
w.
Engine speed N
205FO5142A
CONTROL FUNCTION WHEN TVC PROLIX l Main pump delivery

SWITCH IS ON
l If any abnormality occurs in the controller or
sensors, a constant current flows from the
battery to the TVC valve so that the function
can be maintained through a pump absorp-
tion torque more or less equivalent to S
mode.
In this condition, only hydraulic sensing
using the TVC valve is used.
207FO5079
1 O-l 06
cc
2. PUMP CONTROL SYSTEM
Power max.
( (Sw$ch signal) ,
(Switch signal)
_ Pump (Drive signal)
controller ‘:(Drive signal):
i (Travel lever signal)
,,
,, ,,
F20505352
OUTLINE
By controlling the main pump discharge
volume according to the stroke of the con-
trol lever, it is possible to reduce the neutral
loss and fine control loss.
The half flow mode function that is auto-
matically set by the working mode provides
excellent fine control performance.
The cut-off function and cut-off cancel
function, together with the 2-stage relief
function provide both reduction of relief
loss and increase of digging power.
lo-lo?
0
I) FLOW CONTROL FUNCTION
PNC (Pump Neutral Control)
l When the control levers are at neutral,
the pump discharge volume is controlled
to the minimum to reduce the wasted
oil flow that occurs when the control
valve is at neutral.
PFC (Pump Fine Control)
l When the lever is operated, the control
for the necessary oil flow is sent to the
pump based on the flow command cor-
responding to the stroke of the lever. In
this way, the wasted oil flow that Lever stroke L
occurs during fine control is reduced. 205FO5145
l At the same time, by increasing the
pump discharge volume by a suitable
amount to correspond to the stroke of
the lever, the fine control performance
is improved.
* For detail, see HYDRAULIC PUMP.
21 CUT-OFF (CO) FUNCTION

l When the load increases during opera-
tions and the main pump discharge
pressure rises, it reduces the pump dis-
charge volume when the pressure is
near the relief pressure, and acts to
reduce relief loss.
* For details, see HYDRAULIC PUMP.
3) CUT-OFF CANCEL FUNCTION

When the load increases during opera- Pump discharge volume Q
tions and the main pump discharge 205FO5146
pressure rises, the pump discharge
volume is not cut-off even when the
pressure is near the relief pressure. This Pump discharge volume is
ensures the flow of oil and prevents any not cut-off.
drop in speed.
Actuation and cancelation of the cut-off
function is automatically determined by
the position of the power max. switch,
travel lever and swing lock switch.
Operation of switches and cut-off

function
Pump discharge volume 0

205FO5 147
Note I) This is only effective when the

working mode switch is at
IH.01 or LG.01.
* Quick warming up of hydraulic oil
when swing lock switch is ON
When the swing lock switch is turned
ON, the CO function is canceled.
In this condition, if the work equipment
is relieved, the hydraulic oil temperature
can be raised quickly to reduce the time
taken for warming up.
4) HALF FLOW MODE FUNCTION

When LF.01 or lL.01 is selected with the
working mode switch, the operation of the
control valve for the arm Hi (acceleration) is
stopped. The pumps actuating the boom
and arm are separated, so the digging
(finishing) operation is not affected by the
load on the other circuit. This improves the
fine control and finishing precision.
l Relationship between working mode
and pump discharge volume (during in-
dependent operation)
Ir The portion for one pump is taken as

100%.
-)r When the arm OUT and bucket are
operated simultaneously, the half flow
mode does not function.
5) 2-STAGE RELIEF FUNCTION

When the power max. switch is pushed ON
Power max. Swing lock
(Note I), or the travel,lever is operated, or Travel lever
switch (Note I) switch
the swing lock switch is ON, the 2-stage OFF Operated Neutral ON OFF
relief l CO cancel solenoid valve pilot pres-
Main relief
sure raises the set pressure of the main valve set 340
325 340 325 340 325
relief valve from 325 kg/cm2 to 340 kg/cm2 pressure
to increase the digging power and travel (kg/cm21
force.
Note 1) This is only effective when the
working mode switch is at IH.01
or iG.01.
10-l 1.1
0
3. POWER MAXIMIZING FUNCTION
Control valve
--
I I Swing ( ( L.H. travel
t (Swtich yj>nal) ,
(Engine speed signal) , t 1

Engine throttle (Thro?tlesignal) (Drive signal)
= Pump controller
controller (No. 2 thjottle signal)
r , ‘H.0 GO F.0 LO
000 t t ,:. 0000
POWER
SET @ (Switch signal) (Switch signal) WoRKlNGMODE@
I I
F20505353
OUTLINE
l By pressing the switch on the left work
equipment lever knob, the maximum digging
power is increased to give superior
production.
10-112
a
l When the working mode is switched to
IH.01 or LG.01, and the power max. switch is
switched ON, the following functions are
actuated.
Working mode 1 H.0 or G.0 1 H.0
Power set Any mode H
Main relief
340 kg/cm2
valve pressure 325 kg’cm”
Even when pressed

Length of _
continuously, it is
operation
canceled after 8.5 set
i;l * This function does not work if the working

0
mode switch is at IF.01 or fL.01.
4. AUTO DECELERATION SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 49706

PC220,22OLC-5 Serial No: 35001 - 35661
Engine
Fuel control dial
FLo
i
r-k
E (Drive signal)
‘g =
Sl
om
& ‘5
7
(Throttle signal) Engine throttle
- controller
R.H. control L.H. control
A
c-
I
.g
-:
ti
2
Y
I PPC shuttle valve
Oil pres.
S
2
switch (Work equipment
\
’ ON
(Swing lever signal) ~ Pump controller _ (Switch signal) 0
AUTO
DECEL 0,/%
205FO5149
OUTLINE
l This is a fully electronic control type, and Fuel control dial setting rpm
when all the work equipment, swing and
rpm
travel levers are at neutral, and the pump NO. 1
100 I50
decel. position
controller receives the signal, it sends a
command to the engine throttle controller. No. 2
decel. position
When this is received, the engine throttle -I_ 0.2 (1400)
controller drives the governor motor to
reduce the engine speed, thereby reducing 4 Max. 2 Max. 1
4 -
fuel consumption and noise.
set
Control lever Neutral Control lever Operation
205FO5150
‘O-Al4
Engine
Fuel control dial 1

HI Governor
c r ‘. ‘ection motor I
7
Lo

controller
L.H. control R.H. control
1
%
.-6)
In
5
:
PPC shuttle valve ?
5
Oil pres.
:
switch (Work equipment -
swing lever signal)
- ‘ON
(Switch signal) 0
Pump controller = AUTO
(Travel lever signal) DECEL I/l /%
-
207KX-354
Engine
OPERATION
When auto-deceleration switch ON
1. If the fuel control dial is set at a position
higher than 1500 rpm, and all control levers
are at neutral, the pump controller receives
the neutral signal and sends the auto-
deceleration signal to the engine throttle
controller.
When the engine throttle controller receives
the signal, it sends the drive signal to the
governor motor to drive the governor motor
and pull back the injection pump governor
lever to the No. 1 deceleration position. It
holds it at this position for approximately 4
seconds. When this happens, the engine 205FC5151.1
speed is lowered by about 100 rpm from

Enaine
the dial setting.
2. After the levers have been at neutral for

more than 4 seconds, the drive signal is
again sent from the engine throttle control- Fuel d
ler to the governor motor, and the governor
lever is pulled back and held in the No. 2
deceleration position.
The engine speed in this position is approx.
1400 rpm.
205FO5152-1
3. In the deceleration condition, if any control Enaine
lever is operated, the pump controller re-

ceives the signal and cancels the auto-
deceleration signal sent to the engine throt-
tle controller. When this happens, the
engine throttle controller sends a drive
signal to the governor motor to return the
governor lever to its original setting.
When auto-deceleration switch is OFF

PPC shuttle valve
l The engine speed can be set as desired IX
using the fuel control dial, and even if all the

levers are at neutral, the engine speed is not
Pump
reduced. controller
205FO5 153-l
lo-116
0
5. ENGINE AUTOMATIC WARMING-UP AND OVERHEAT PREVENTION FUNCTION
Engine
Fuel control dial

Hi
f
Lo
t 1
(I)=
5 zz
as-l
z.5,
2 .e
~“,
2 r\l
,, (Coolant temp. 102T signal)

e z
(Coolant temp. 107”C/105”C signal)

(Drive signal)
(Working mode signal) Pump controller
w
(Power set signal)
205FO5154
OUTLINE
l After the engine is started, this raises the engine
speed automatically to warm up the engine. (Au-
tomatic warming-up function)
In addition, to protect the engine, if the coolant
temperature rises too high, it lowers the pump
load and engine speed to prevent overheating of
the engine. (overheat prevention function)
10-117
/7
6
I) AUTOMATIC WARMING-UP FUNCTION
l Actuation table
Conditions Action
\
Coolant temperature: Less than 30°C

Fuel control dial: Below set speed
[set speed: 1,200 rpml
Engine speed: 1,200 rpm
* If all the above conditions are satisfied,
the automatic warming-up function
is actuated.
Coolant temperature: Above 30°C

Fuel control dial: Held above 70% of high idling
for more than 3 sec.
Engine speed: As desired
Warming up time: At least 10 minutes
-k If any of the above conditions is applicable, the
automatic warming-up function is canceled.
21 OVERHEAT PREVENTION FUNCTION

l Actuation table
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
Conditions Action
Power set:
Selected mode Action mode
H.0 and H,S mode H.0 and L mode

Coolant temperature: 102” - 107°C
(Coolant temperature gauge: G.0 and H,S mode G.L and L mode
Red range)
F.0 and H,S mode F.0 and L mode
L.0 and H,S mode L.0 and L mode
Engine speed: Default mode speed
Coolant temperature: Above 107°C Power set: L mode (same as No. 1 setting)
(Coolant temperature gauge: Engine speed: Low idlig
Red range Warning lamp, buzzer: ON
Coolant temperature: Under 102°C

(Coolant temperature gauge: Power set: Default mode
Green range) Engine speed: Default mode speed
Ir Automatic reset
When coolant temperature is less

Power set: Default mode
than 102”C, return fuel control
Engine speed: Fuel control dial set speed
dial to low idling position.
(as desired)
* Manual reset
‘O-A’*
6. SWING CONTROL SYSTEM
PC200-5 Serial No: 45001 - 49706

PC220-5 Serial No: 35001 - 35661
L.H. control lever
Swing motor
/
OFF ON $/
-
Pump controller (Swing lever signal)
, ,l
,, //
205F05155B
OUTLINE
l The swing is controlled comprehensively
both when stopping and when operating
the swing, by the swing lock, swing holding
brake, and swing priority functions.
1o-‘A8-1
PC200-5 Serial No: 49707 and up
PC220-5 Serial No: 35662 and up
L.H. and R.H. control levers

Swing motor
Swing holding brake
Swing brake
solenoid valve 7
xes.
vii :ch
7 Monitor panel
207F05055A
Conditions Action
Power set:
Selected mode Action mode
H.0 and H,S mode H.0 and L mode
g Coolant temperature: 102” - 105°C G.0 and H,S mode G.L and L mode
z (Coolant temperature gauge:
-0 7 F.0 and H,S mode F.0 and L mode
B d
Red range)
!i 2
L.0 and H.S mode L.0 and L mode
2
Engine speed: Default mode speed
Warning lamp: ON
.E Coolant temperature: Above 105°C Power set: L mode (same as No. 1 setting)
I (Coolant temperature gauge: Engine speed: Low idlig
c*l
Red range Warning lamp, buzzer: ON
z”
p
‘= Coolant temperature: Under 102°C
5 (Coolant temperature gauge: Power set: Default mode
Green range) Engine speed: Default mode speed
-0 .* Automatic reset
2 z”
:
5 p
‘5 When coolant temperature is less
Power set: Default mode
0 0, than 102”C, return fuel control
Engine speed: Fuel control dial set speed
z dial to low idling position.
(as desired)
* Manual reset
z”
‘OiF9
6. SWING CONTROL SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 49706

PC220,22OLC-5 Serial No: 35001 - 35661
L.H. control lever
Swing motor
Swing holding brake

Swing
PPC shutlle
.es.
k
valve Oi
SW
7
:h
(Swing lock signal)

# I
205F05155B
OUTLINE
l The swing is controlled comprehensively
both when stopping and when operating
the swing, by the swing lock, swing holding
brake, and swing priority functions.
’0-i20
PC200,2OOL-5 MIGHTY
L.H. and R.H. control levers

Swing motor
Swing holding brake
7
res.
sh
) Sw,ing lock
Monitor panel
Awing lock signa,tt, ‘I’{ :‘I OFF
207F05055A
11 SWlNG LOCK AND AUTOMATIC SWING l Relationship between swing lock lamp and
HOLDING BRAKE SYSTEM the brake
The swing lock (manual) and swing holding
brake (automatic) are employed to lock the Lock lamp Actuation
swing in the desired position and to prevent
hydraulic drift after stopping the swing. The swing brake is applied
approx. 4 seconds after the
swing control lever is placed
OFF (switch OFF) at neutral.
(Swing holding When the swing control
brake applied) lever is operated, the swing
brake is released and the
upper structure can swing
freely. (Note)
The upper structure is held

in place by the swing brake,
3N (switch ON) and even if the control lever
[Swing lock applied) is operated, the swing brake
is not canceled, so the upper
structure does not swing.
Note:
On the following machines, both the work g
equipment control levers are interconnected: z
PC200-5 Serial No.: 40707 and up 2
PC220-5 Serial No.: 35662 and up
Sr Swing lock prolix switch function Actuation table

When the pump controller is abnormal
and the swing holding brake function
does not work normally, the swing lock
prolix switch cancels the swing brake
and operates the swing.
+I Even when the swing lock prolix switch
is turned ON, the swing lock switch
stays ON and the swing brake is not
canceled.
Sr When the swing brake is canceled, the
swing has only a hydraulic brake operat-
ed by the safety valve, so if the swing is
stopped on a slope, there may be hy-
draulic drift.
21 HYDRAULIC OIL QUICK WARM-UP

FUNCTION WHEN SWING LOCK
SWITCH IS ON
t For details, see PUMP CONTROL
SYSTEM.
1O-&22
7. TRAVEL CONTROL SYSTEM

Travel motor

controller
(Swing signal)
c
205FO5 156
OUTLINE
l This increases the pump absorption torque
and drawbar pull when traveling.
l The travel performance is improved by
switching the travel speed manually or
automatically.
‘o-A23
II PUMP CONTROL FUNCTION WHEN
TRAVELING
When traveling, the following functions are
actuated.
l If any of the working mode and power
set are selected, the working mode and
engine speed stay as they are and the
power set only is switched to the
equivalent of H mode.
* For details, see ENGINE AND PUMP
MUTUAL CONTROL SYSTEM.
2) TRAVEL SPEED SWITCHING FUNCTION
The switching of the travel speed can be
carried out manually or automatically, and
has the following functions.
i) When the travel speed switch is
switched, the solenoid valve is
switched. The action of the pilot pres-
sure then changes the motor rocker
cam angle and changes the travel speed.
ii) If the speed setting of the fuel control
dial is set to less than approx. 1400
rpm:
l When traveling in Lo, even if it is
switched to Hi, the transmission is
not shifted.
l When traveling in Hi, the transmis-
sion is automatically shifted to Lo.
iii) Automatic switching between Hi and Lo
according to pump discharge pressure
When traveling with the travel speed
switch at Hi, if the machine travels up a (Travel speed (Travel pressure
slope and the pressure in the travel cir- switch at Hi) continues at
cuit goes above 310 kg/cm2 for more more than 3 10
than 1.0 second, the solenoid valve is kg/cm2 for
deactivated (closed) and the travel more than 1 .O
speed is switched to Lo. If the machine seconds)
continues to travel at Lo (with the travel
speed switch still at Hi) and it comes
again to flat ground or travels downhill,
and the pressure in the travel circuit
drops below 210 kg/cm2 for more than
1.0 second, the solenoid is excited (Travel pressure (Travel speed
(opened) and the speed is switched continues at switch at Hi)
again to high speed. less than 2 10
* Detection of the pressure in the kg/cm2 for
more than 1 .O
travel circuit when only the travel is
seconds)
being operated is made by sensing
the pressure for both the front
pump and the rear pump, and taking
the higher value; for compound op-
erations, only the sensor for the rear
pump pressure is used.
’o-A24
8. SYSTEM COMPONENT EQUIPMENT
1) PUMP CONTROLLER
CN-C3 CN-C2 CN-Cl
1. Self-diagnostic
display window
84:
Section A- A
205FO5 157
2) ENGINE SPEED SENSOR
___
9
i i
6 0
205FO5158A
z
1. Magnet FUNCTION z
2. Terminal l The engine speed sensor is installed to the z
3. Case ring gear of the engine flywheel, and acts to
4. Boot count electrically the number of gear teeth
5. Connector that pass in front of the sonsor. This detec-
tion is carried out magnetically, and the
sensor contains a magnet and detection coil.
3) ENGINE THROTTLE CONTROLLER, FUEL

CONTROL DIAL AND GOVERNOR
MOTOR
* For detail see ENGINE CONTROL
SYSTEM.
4) MONITOR PANEL
* For detail, see EMACC.
5) TVC VALVE
* For detail, see HYDRAULIC PUMP.
61 2-STAGE RELIEF *CO CANCEL SOLE-
NOID VALVE
TRAVEL SPEED SOLENOID VALVE
ARM HALF FLOW SOLENOID VALVE
Ir For detail, see SOLENOID VALVE
ASSEMBLY.
7) PUMP PRESSURE SENSOR
_l& (=-J ii- igY_
4. Flange
5. Detect module of oil pressure
6. Introduction pipe of oil pressure
Amplifier
205FO5159A
OUTLINE
l The pump discharge pressure is converted OPERATION
to a voltage, and the signal is sent to the
pump controller. Isolation
To amplifier seam
FUNCTION
l The voltage output is proportional to the
pressure.
t
Oil pressure 205FO5160
When the pressurized oil entering from

pressure introduction pipe (61 is pressurized
by the diaphragm of pressure sensor
module (51, the diaphragm shape changes.
A bridge is formed on the opposite face of
this diaphragm by a strain gauge, and the
Oil pressure P (kg/cm? deflection of the diaphragm is converted
205FO5161
from a resistance value of the strain gauge
l Relationship between output voltage V (v) to the bridge output voltage and is sent to
and pressure P (kg/cm2). the voltage amplifier (amp).
V = 0.008 x P + 1 .O The voltage is further amplified by the
amplifier, and is output to the controller.
’o-‘i4-3
8) WORK EQUIPMENT OIL PRESSURE SWITCH, SWING OIL PRESSURE SWITCH,
TRAVEL OIL PRESSURE SWITCH
123456 7
202FO5 I65
1. Plug SPECIFICATIONS
2. Diaghragm Actuation pressure: 5.0 2 1 .O kg/cm2
3. Back up spring Reset pressure: 3.0 f 0.5 kg/cm2
4. Pin
5. Guide pin
6. Movable contacts
7. Connector
EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)
Monitor panel Relay Electrical parts
Sensor signal Engine throttle controller
Warming-up signal
I=
Q=
II Pump controller
Sensor Power
source Buzzer signal
II
Switch signal
1
Coolant temp. signal
Buzzer
Battery
205FO5162
l The electronic monitor and control console l Various modes selector switches are built
(EMACC) observes the condition of the ma- into the monitor panel, and it acts as the
chine through the sensors installed to vari- control portion of the machine control
ous parts of the machine, and processes system.
this information quickly. The system informs
the operator of the condition of the machine
by displaying the condition on the panel.
The content of the panel displays can be
broadly divided into the following.
1. Monitor portion that gives warnings
when any abnormality occurs in the
machine.
2. The gauge portion (coolant temperature,
fuel level) that always informs the condi-
tion of the machine.
1. MONITOR PANEL
205FO5 163
OUTLINE
l The monitor panel has the switch functions
for the electrical parts, mode selection, and
monitor display functions.
It has a built-in CPU (Central Processing
Unit), and processes the data and outputs
the display.
The monitor display uses a liquid crystal dis-
play (LCD). The switches are flat sheet
switches.
MONITOR
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
1. Coolant temperature gauge

2. Engine oil level caution lamp
3. Coolant level lamp
4. Coolant temperature caution lamp
5. Coolant level caution lamp
6. Engine oil pressure caution lamp
7. Fuel level caution lamp
8. Charge level caution lamp
9. Engine preheat pilot lamp
10. Hydraulic oil level caution lamp
11. Fuel level guage
Classifi-
i ’ P7
Condition for displaying

205FO5164
cation of Symbol Item Description

indicatior
abnormalities
Coolant level Below low level indicates when placing the starting
switch to ON before starting the
engine.
Engine oil level Below low level
If it is normal, the lamp goes off.
If it is an abnormality, the lamp
Hydraulic oil level flashes.
Below low level
Engine oil pressure 0.5 kg/cm2 max. Indicates while the engine is running
and the starting switch is set to ON.
Coolant level Below low level If it is normal, the lamp goes off.
flashes and the buzzer sounds.
Coolant temperature 107°C min.
Indicates when the engine is running

Charge level When charging system fails. and the starting switch is set to ON.
Fuel level Below low level
flashes.
67 76 83 90 97 102 107°C
Appropriate place (one place)

Coolant temperature
lights up.
All light up below appropriate

Fuel level
level
When the starting switch is turned to

HEAT position, this pilot lights for 30
Preheat When prehe’ating seconds, then flashes (for 10
seconds) to indicate the preheating
is finished.
’o-227
1 2 3 4 5
1. Coolant temperature gauge
2. Engine oil level caution lamp
3. Coolant level lamp
4. Coolant temperature caution lamp
5. Coolant level caution lamp
6. Engine oil pressure caution lamp
7. Fuel level caution lamp
8. Charge level caution lamp
9. Engine preheat pilot lamp
10. Hydraulic oil level caution lamp
11. Fuel level guage
1 205FO5164
Classifi- Condition for displaying

cation of Symbol Item Description
abnormalities
indication
: Coolant level Below low level Indicates when placing the starting
8
switch to ON before starting the
%
;I= engine.
0 Engine oil level Below low level If it._.is normal, the lamp goes off.
Ifs - _ I
VI- - 1 If it is an abnormality,thk lamp
Z” flashes.
0 Hydraulic oil level Below low level
c G
8
b Engine
Coolant
oil pressure
level
0.5 kg/cm2
Below low level
102°C (Flash)
max. Indicates while
and the starting
If it is normal,
the engine
If it is an abnormality,
flashes
switch
and the buzzer

is running
is set to ON.
the lamp goes off.
the lamp
sounds.
Coolant temperature 105°C (Buzzer)
Q
Indicates when the engine is running
m Charge level When charging system fails. and the starting switch is set to ON.
Fuel level Below low level
@ flashes.
67 76 83 90 97102 105°C
I /
.;.
.:. Appropriate place (one place)
Coolant temperature :.:.
j: lights up.
8 ai:d 0:j: d 00
0-10
C t-l
9 57 76 98 122 145 176 192215 236 31OP
All light up below appropriate

Fuel level
level
When the starting switch is turned to

HEAT position, this pilot lights for 30
Preheat When preheating seconds, then flashes (for 10
-00- seconds) to indicate the preheating
is finished.
’O-k2*
SWITCH
1. Heater fan switch

2. Power set selection switch
3. Working mode selection switch
4. Buzzer cancel switch
5. Travel speed switch
6. Lamp switch
7. Auto-deceleration switch
8. Wiper switch
9. Swing lock lamp
9 8 7 205FO5165
l The switches consist of four mode selector Switch actuation table

switches and four electrical component
switches; every time the switch is pressed, Item Action
the condition of the machine changes. The Working mode G.0 - H.0 - L.0 - F.0
present condition is displayed by the light-
ing up of the LED above the switch. Power set S -H-L
Auto decel ON -OFF
Travel speed Lo -Hi
Fan OFF-Lo-Hi
Wiper OFF-Lo-Hi
Lamp OFF-l -2
Buzzer cancel OFF -ON
* The bold letters indicate the default values

when the starting switch is truned ON.
lo-129
0
2. SENSOR
0 The signals from the sensors are input
directly to the monitor panel.
One of the contact points of the sensors
with contacts is always connected to the
chassis GND.
Classification I
Type of sensor Sensing type Normal Abnormal
of indicatinn
Coolant level Contact type ON (close) OFF (open)

CHECK
MONITOR Engine oil level Contact type ON (close) OFF (open)
GROUP
Hydraulic oil level Contact type ON (close) OFF (open)
CAUTION Engine oil pressure Contact type OFF (open) ON (close)
Coolant temperatrue Resistance type - -

GAUGE GROUP
Fuel level Resistance type - -
1) COOLANT LEVEL SENSOR
1. Sub-tank
2. Float
3. Sensor
4. Connector
205FO5166
10-130
2) ENGINE OIL LEVEL SENSOR
1. Connector
2. Bracket
3. Float
4. Switch
205FO5167A
3) HYDRAULIC OIL LEVEL SENSOR
1. Connector
2. Plug
3. Switch
4. Float
205FO5168
4) ENGINE OIL PRESSURE SENSOR
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
205FO5169
10-131
5) COOLANT TEMPERATURE SENSOR
2 3
1. Connector
2. Plug
3. Thermister
205FO5170A
6) FUEL LEVEL SENSOR
Float
Connector
Cover
Variable resistance
EMPTY
8
1 \
i ;I
Section A- A
205FO5171
lo-132
20 TESTING AND ADJUSTING
Table of judgement standard value ........................ ...................... 20- 2

Standard value table for electrical system .................. ...................... 20-I 8
Tools for testing, adjusting, and troubleshooting ............. ...................... 20-29
Adjusting valve clearance ............................... ...................... 20-30
Measuring compression pressure ......................... ...................... 20-31
Testing and adjusting fuel injection timing .................. ...................... 20-32
Testing and adjusting travel of governor motor lever ......... ...................... 20-33
Inspection of swing circle bearing clearance ................ ..................... 20-33-I
Adjusting engine speed sensor ........................... ...................... 20-34
Testing and adjusting hydrauic pressure in
work equipment, swing, travel circuit ................... ............ ........ 20-35
Testing and adjusting charging pump pressure .............. ............ ........ 20-38
Testing and adjusting main pump control pressure ........... ............ ........ 20-40
Measuring stroke of servo piston ......................... ............ ........ 20-47
Measuring output pressure of PPC valve ................... ............ ........ 20-48
Adjusting work equipment, swing PPC valve ................ ............ ........ 20-49
Testing PPC shuttle valve ................................ ............ ........ 20-50
Measuring solenoid valve output port pressure .............. ............ ........ 20-51
Testing locations causing hydrauic drift of work equipment .... ............ ........ 20-52
Bleeding air ........................................... ............ ........ 20-54
Releasing remaining pressure in hydraulic circuit ............ ............ ........ 20-56
Troubleshooting ....................................... ............ ........ 20-57
ABefore performing inspection, adjustment or faultfinding, park the machine on level ground and
check the safety pin and chock.
A When performing joint work, make appropriate signals and allow only authorized personnel near
the machine.
A When checking the water level, allow the engine to cool down before removing the radiator cap to
prevent the risk of being scalded by hot water which may spurt out if the engine is hot.
A Take great care to avoid getting caught in rotating parts such as the fan, etc.
TABLE OF JUDGEMENT STANDARD VALUE
. FOR ENGINE
Machine model PC200-5 PCZZO-5
Engine S6D95L-1 SA6D95L-1
‘““.” Standard Permissible

Item Measurement conditions Unit WI ue value
High idling 2,250 i 70 2,410 + 70 -

rpm
Engine speed Low idling rpm 870 + 50 870+ 50 -
Rated speed rpm 2,050 2,200 -
Bosch
At sudden acceleration Max. 5.5 7.5 Max. 5.5 7.5
index
Exhaust gas color
Bosch 2.0
At high idling Max. 1 .O 1 .o 2.0
index
Valve clearance Intake valve mm 0.35 - 0.35 -

(normal temperature) Exhaust valve mm 0.50 - 0.50 -
I
Compression pressure Oil temperature: 40-60°C kg/cm’ Min. 28 Min. 28

(SAE 30 oil) (Engine speed) (rpm) (320 - 360) (3202-0360, (320 - 360) (320 y360)
N;_lj
(Coolant temperature:
Blowby pressure
Operating range) mmH,O Max. 75 150
(SAE oil)
At rated output
I I
(Coolant temperature:
Operating range)
At high idling (SAESO) kg/cm’ 3.5 - 6.0 2.4 3.5 - 6.0 2.4
Oil pressure
At low idling (SAE30) kg/cm’ Min. 1 .O 0.7 Min 1 .O 0.7
At low idling (SAElOW) kg/cm’ Min. 0.8 0.7 Min 0.8 0.7
Oil temperature Whole speed range

OC 80- 110 120 80- 110 120
(inside oil pan)
Fuel injection timing 0 18*1 18~ 1

B.T.D.C. 18*1 18i 1
Deflection when pressed

Belt tension (alternator) with finger force of mm 8 6- 10 8 6- 10
approx. 6 kg.
0 FOR CHASSIS
* The standard values and permissible values shown in this table are all values for H.0 (heavy-duty
operation) and H mode.
Machine model
1 PC200 - 220-5
Classif i-
Item Measurement conditions Unil Standard value
cation
-
Hydraulic oil temperature: 45 _ 55”1
Engine oil pressure: PC200 PC220
At l-pump relief
Within operating range
. Coolant temperature:
Within operating rangr - -
At 2-pump relief
Speed when CO
. l-pump relief: Bucket relief
2pump relief: Arm relief
* H.0 and H mode
I
- Engine at high idling
function canceled
* Arm relief
-
Speed when auto-
Fuel control dial at MAX.
deceleration is 1,400t 120
actuated
. Control lever at neutral
Boom-Lo control
valve P a b
Boom-Hi control
valve I P
r
Arm-Lo control valve
Arm-Hi control valve mm - 9.5to.5 9.520.5
Bucket control valve
202F2302
Swing control valve
Travel control valve
Center of lever knob Max. 75

Boom control lever 65*10 Min. 55
Read max. value to end of travel
Engine stopped
Max. 75
Arm control lever Except for neutral play 65+10
Min. 55
Bucket control lever
Swing control lever

1 mm
65rlO
65-clO
Max. 75
Min. 55
Max. 75
Min. 55
Travel control lever Max. 131

120*11
Min. 119
Play of travel lever Max. 10 Max. 15

-
2.3iO.3 Max. 3.1
1.8*0.3 Max. 2.6
travel
Bucket control lever 1 .BiO.3 Max. 2.6
kg
Swing control lever 2.3i0.4 Max. 3.1
1
Lever 2.5r0.7 Max. 4.0
Pedal 7kl.8 Max. 11
i
Machine model PC206 .226-5
Item Unit Standard value Permissible value
. Oil temperature: 45 - 55’C pc200 pc200

Boom
. Relief pressure with engine at
high idling
(Relieve only circuit to be Max. 340
325:;,
Arm measured) Min.310
’ H.0 and H mode
. ( ) : When using power (340:;“)
maximizing (reference)
Bucket At outlet of pump
*I: Oil pressure when travel is re- Max. 300

Swing lieved on one side. 29o;;o
Min. 285
*2: When the travel lever is ope-
rated, the CO is canceled.
Max. 365
Trave I 34o+‘O
-15 Min. 325
Max. 36
Charging pump 32;:
Min. 25
. Oil temperature:
45 - 55°C
. Engine at high
T
Control lever at
neutral
23*1 24tl Max. 18
I
Max. 18
idling 1 -pump relief

. H.0 and [2pump average
TVC valve output H mode oil pressure1
pressure
P, +P Max. 17 Max. 18
1 = 160-l 7c 16+1 17+1
2 kg/cd Min. 14 Min. 15
g/cm I
. Oil temperature: Control lever at
45 - 55°C neutral
. Engine at high Max. 5.5 Max. 5.5
idling E;;!z;J
. Ii.0 and H mode
. Measure at NC
valve outlet port Travel lever at
full, track rotating
CO - NC valve freely Min. 17 Min. 17
output pressure
1
(actuated J
Pump relief
Max. 5.5 Max. 5.5
. Oil temperature: 45 - 55°C

Lever at Max. 19
neutral . Engine at high idling 16*3
Min. 13
. Control lever at neutral
et sensor
ifferential
ressure
. Oil temperature: 45 - 55’C
Lever at end . Engine at high idling
of travel . Control lever at end of travel Max. 2 Max. 2
(Pump discharge pressure as
desired)
Classi,
Item Measurement conditions Unit Standard value Permissible value
cation
Working equipment Max. reach
pas-
PC200 PC220 PC220
Swing brake angle Engine at high idling

Hydraulic oil temperature: 45 - 55’~ Max. 90 Max. 130 Max. 120 Max. 160
Stop after swinging one turn
and measure distance that swing
circle moves
( 1: Distance of movement on
outside circumference of
swing circle
Nork equipment Max. reach 1
90” 2.8 ? 0.3 3.2 i 0.3 Max. 3.4 Max. 3.8
Time taken to start 20x2123

sec.
swing Engine at high idling
Hydraulic oil temperature:
45 - 55Oc
H.0 and H mode 180’ 4.2 + 0.4 4.6 ? 0.5 Max. 5.1 Max. 5.5
Time taken from starting
position to swing 90’ and
180”
Work equipment Max. reach

posture
Time taken to swing sec. 25 ? 2 24 + 2 Max. 30 Max. 30
Engine at high idling 202~2~~

Hydrau lit oil temperature:
45 - 55Oc
H.0 and H mode
Swing one turn, and measure time
taken to swing next 5 turns
Hydraulic dri!t of
Engine stopped
swing mm
45 - 55Oc
Set machine on 15’ slope, and set
upper structure at 90” to the side.
Make match marks on swing circle
outer race and track frame.
Measure distance that match
marks move apart after 5 minutes.
Engine at high idling
Leakage from swing Hydraulic oil temperature:

45 - 55Oc Max. 5 Max. 10
motor
Swing lock switch ON
Relieve swing circuit.
Classifi- Unit Standard value Permissible value

Item Measurement conditions
cations
PC200 PC220 PC200 PC220
‘C200: PC220: PC200: PC220:

18.1 t3 47.3i3 Max. 54.1 Max. 53.5
LO ‘C2OOLC: PC22OLC: Min. 45.1 Min. 44.3
j2.4*3 51.3*3 PC200 LC : PC22OLC:
Max. 58.6 Max. 57.3
Min. 49.4 Min. 48.3
Travel speed (I)
sec.
‘C200 : PC220: PC200: PC220:
28.0*2 29.2*2 Max. 32.0 Max. 33.2
45- 55Oc
?C2OOLC: PC22OLC Min. 26.0 Min. 27.2
H.0 and H mode
Hi 30.5+2 31.7?2 PC200LC: PC22OLC:
t Raise track on one side Max. 35.7
Max. 34.5
at a time, rotate one turn,
Min. 28.5 Min. 29.7
then measure time taken
for next 5 turns.
Max. 26.5 Max. 25.2

Lo 22.522 21.2i2
Min. 20.5 Min. 19.2
Travel speed (2) sec.
. Engine at high idling

0”
45- 55°C Max. 17.1 Max. 17.1
::
H.0 and H mode Hi 13.1?2
13.1*2 :
Min. 11.1 Min. II .I
Run up for at least IO m,
and measure time taken to
travel next 20 m on flat
ground.
-
205F2409

. Hydraulic oil temperature:
45 - 55°C
Travel deviation Run up for at least 10 m, and mm Max. 200 Max. 220
measure deviation when travel-
ing next 20 m on flat ground.
*Use a hard horizontal surface
205F2402
l Measure dimension x
Classifi
Measurement conditions Unit Standardvalue Permissible value
cation
-
Hydraulic drift of
travel 0 0
. Engine stopped
45- 55Oc
‘Stop machine on 12’ slope
with sprocket facing straight
up the slope.
Measure the distance the
machine moves in 5 minutes.
Leakage of travel !/mir Max. 13.6 Max. 27.2

motor

45-555Oc
. Lock shoes and relieve travel
circuit.
Work equipment posture

Total work equip-
ment (hydraulic
drift at tip of Max. 600 Max. 900
bucket teeth)
Boom cylinder
(amount of
retraction of Max. 18 Max. 27
cylinder)
Place in above posture and
measure extension or retraction
of cylinder and downward
mm
movement at tip of bucket teeth.
Bucket: Rated load
Arm cylinder Horizontal, flat ground
(amount of Levers at neutral
Max. 160 Max. 240
extension of Engine stopped
cylinder) Hydraulic oil temperature:
45 - 55Oc
Start measuring immediately
after setting.
Measure hydraulic drift for each
Bucket cylinder 5 minutes, and judge from results
(amount of for 15 minutes.
retraction of Max. 35 Max. 53
cylinder)
Classif
cation T Measurement conditions Unit Standard value Permissible value
PC200 PC220 PC200 PC220

Boom
Bucket teeth in
3.1 to.3 3.1kO.3 Max. 3.9 Max. 3.9
contact with
ground
s
cylinder fully Engine at high idling
extended 2.7i-0.3 3.OkO.3 Max. 3.4 Max. 3.3
. Hydraulicoil temperature:
45-55°C
H.0 and H mode
Arm 3.8t0.4 4.1 io.4 Max. 5.0 Max. 4.8

Cylinder fully
retracted
4
fully extended
Hydraulic oil temperature: 2.8kO.3 3.1to.4 Max. 3.8 Max. 3.7
45-!xc
H.0 and H mode
3.610.4 4.oto.4 Max. 4.3 Max. 4.8

But ket
Cylinder fully
retracted ::
Sec.
0”
s 205F2423
h.illy extended z
2.1 kO.3 2.420.3 Max. 2.7 Min.3.1
45 - 55%
H.0 and H mode
i
Boom
Max. 1 .O Max. 1.2
Lower bucket to ground and

measure time taken for chassis
to rise from ground
. Engine: Low idling
45-555OC
Arm
Max. 1.0 Max. 2.8
Amount of time when arm stops

for a moment.
Engine: Low idling
. Hydraulic oil temperature: ’
45-55Oc
20-8
0
Unit Stand value Permissible value
P
i Sec. Max. 1 .o Max. 3.6
F
. Amount of time when bucket

stops for a moment.
Engine: Low idling
45 - 55OC
-
Cylinders 4.5 20
45-555Oc
Center swivel
. Relieve circuit to be measured
10 50
joint

45-55Oc
l Use a hard horizontal surface.
20m
Travel deviation
(travel and work Max. 200 Max. 220
equipment)
205F2402
l Measure dimension x
-
PC200 PC220

45-555Oc
. Measure with engine running at
Charging pump rated speed.
flin. 43.3 Min. 47.0 vlin. 39.5 Min. 429
. At relief valve set pressure
lmin
(32 kg/cm’ )
Piston pump See next page See next page
20-9
Classifi-
cation Discharge volume of PC200 main piston pump (H.0 + H mode)
IWO Luo 300
Pump discharge pressure = v (kg/cm?
F20505459
Pump rated speed: 2,050 rpm
Discharge pressure Discharge pressure Average Pressure Standard value Judgement standard
for discharge value
Check point of test pump of other pump
amount
(kglcm* 1 (kg/cm’ 1 (kg/cm’) Q WminJ 0 (Urnin)
PI + P, See graph
As desired P, P, See graph (Lower limit)
f Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure
when measuring.
The error is greatest around the area where the graph bends, so avoid measuring at these points.
* When measuring with the pump mounted on the machine, if it is not possible to set the engine
to the specified speed with the fuel control dial, use the engine speed and pump discharge
amount as a base to calculate the pump discharge amount at the specified speed.
Clanifi-
cation Discharge volume of PC200 main piston pump (H.0 + S mode)
Upper limit
Lower limit
100 200 300
F’20505460
I I I
p, See graph
As desired PI P, See graph (Lower limit)
2
k Bring discharge pressure P, and P? for the pump as close as possible to the average pressure
when measuring.
k When measuring with the pump mounted on the machine, if it is not possible to set the engine
Classifi-
cation Discharge volume of PC200 main piston pump (H.0 + L mode)
Upper limit
Lower limit
loo 200 300
Pump discharge pressure = 2” + ” (kglcn-?)
F20505461
Standard value Judgement standard

Discharge pressure Discharge pressure Average Pressure for discharge value
Check point of test pump of other pump amount
(kg/cm2) 0 (Urnin d (Urnin)
(k&m2 I (kg/cm*)
PI + P, See graph
As desired P, P, See graph (Lower limit)
2
* Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure
when measuring.
20; 2
Classifi-
cati on Discharge volume of PC220 main piston pump (H.0 + H mode)
100 200 300
F20505462

Discharge pressure Discharge Pressure Average press& for discharge
Check point of test pump of other pump value
amount
(kg/cm* ) (kg/cm’) (kg/cm’ 1 Q (Urnin) Q bUmin)
P, + P, See graph
As desired P, P, see graph (Lower limit)
2
t Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure
when measuring.
The error is greatest around the area where the graph bends, so avoid measuring at these points:
20;’ 3
L
Clatsifi-
cations Discharge volume of PC220 main piston pump (H.0 + S mode)
100 200 300
Pump discharge pressure = v (kg/cm2)
F20505463
Standard value
Discharge pressure Discharge pressure *“erage p;essure Judgement standard
for discharge
Check point of test pump of other pump value
amount
(kg/cm* ) (kg/cm* 1 (kg/cm’ ) Q (Qlmin) Q (Qlmin)
P +P See graph
As desired PI P, 1 See graph
2 (Lower limit)
* Bring discharge pressure P, and P, for the pump as close as possible to the average pressure
when measuring.
20-14
0
Classifi-
cations Discharge volume of PC220 main piston pump (H.0 + L mode)
100 200 300
PI + P2
Pump discharge pressure = 2 (kg/cm’)
F20505464
Pump rated speed: 2.200 rpm

Discharge pressure Discharge pressure Average Pressure
of test pump of other pump for discharge value
Check point amount
(kg/cm’) (kg/cm’ ) (kg/cm,) Q (Urnin) Q (Urnin)
PI + P, See graph
As desired P, P* See graph
2 (Lower limit)
* Bring discharge pressure P, and P, for the pump as close as possible to the average pressure
when measuring.
20-15
0
TABLE OF SPEEDS FOR S, L MODES
* The values in this table are reference values for the speed of the work equipment, swing, and travel when switching from H.0 and
H mode to other modes
Classifi-
Item Measurementcondition Unit ?C200-5 PC220-5
cation
.
;.O+S F.O+S L.O+L
node mode mode
Boom
(Bucket teeth in . Measure full stroke for each 3io.4 3.3+0.4 4.3f0.4 5Ito.4 3.5kO.4 4.5*0.5
contact with cylinder (for boor” only, t
I I
ground *cylinder measure time taken to lower
to the ground)
I I
fully extended)
. Setthe machine on a flat 9f0.3 2.9rto.3 3.4*0.: .2f0.33.2*0.3 3.710.4
horizontal surface.
. No load in bucket
i
I
I I I
. Hydraulic oil temperature: 1f0.4 6.8 f0.7 7.6z!cO.8
Arm 45-55Oc SW.
(Cylinder fully . When measuring boom: arm, I I
I I
retracted tf fully bucket cylinders fully retracted
extended) . When measuring arm: top .0*0.3 3.0f0.3 3.3*9.: .5f0.4 3.5*0.4 4.1 f0.4
surface of boom horizontal
bucket cylinder fully
I II I 1
I
retaracted I I
. When measuring bucket: top .8*0.413.8f0.414.610.t .3*0.4 4.3kO.4 5.3f0.5
Bucket surface of boom horizontal,
(Cylinder fully arm cylinder fully retracted I I
retracted +
fully extended) .3f0.2 2.3kO.2 2.8fO.Z .6*0.3 2.610.3 3.2kO.3
I I I I
No load in bucket
. Swing one turn, then measure 0.8 10.8 13.2 0.3 10.3 12.6
Time taken to Sec.
time taken to swing next lto.5 f0.5 *0.7 *0.5 10.5 10.6
swing
two turns.
I I
I
. Engine at high idling 11.4
. Hydraulic oil temperature: .6&1.4 9.6jz1.4 “;“1,, .2*1.3 9.2i1.3
11.6
45.- E&oc 1 I t I /
Travel speed Raise track on one side at a time, Sec.
rotate one turn, then measure
time taken to rotate the next m.2*0.916.2kO.9j7.6kl
.l
two turns.
. Amount of deviation when

traveling 20 m as shown below
* Us a hard horizontal surface.
20m
Travel deviation mm Max. 200

Max. 200
205F2402
t Measure dimension3
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
+ Note 1: (Male) and (Female) in the Connector No. column indicates the matina at the terminal
(pin). (For details, see CONNECTION TABLE FOR CONNECTORS).
2: The figure in ( ) in the Judgement table column indicates the pin number.
ClassiIfi- Measurement
1
Connector No Judgement table
catiol ns conditions
If the condition is as shown in the I) Turn starting

table below, it is normal switch OFF.
2) Disconnect
Connector.
Fuel control dial E6 (Male)
7

2) Disconnect
connector.
Potentiometer E4 (Male)
1

table below, it is normal switch OFF
Between (1) - (2) 4-9.Q 2) Disconnect

connector
Between (3) - (4) 4-9R
Motor E5 (Male)
Between (1) - (3) No continuity
(1 ) - chassis No continuity
(3) - chassis No continuity
If the condition is as shown in the 1) Turn starting

table below, it is normal switch ON.
Power source 2) Insert

voltage T-adapter.
WI
1) Turn starting
switch ON.
2) Insert
Fuel control dial T-adapter.
(Throttle signal)
El
If the condition is as shown in the I) Turn starting _

table below, it. is normal switch ON.
2) Insert
T-adapter.
Governor Fi
Potentiometer
Between (6) - (16) 4.75 - 5.25V

Classi Measurement
Connector No. Judgment table
catior conditions
If the condition is asshown in the

1) Turn starting
tabe below, it is normal
No. 2 throttle switch ON.
signal 2) Insert
Between (9) - (19) 0.25 -44.75V
T-adapter
If the condition is as shown in 1) Turn starting

the table below, it is normal switch ON.
Warming-up 2) Insert
signal T-adapter.

Auto-deceleration 2) Insert
signal When decelerating Max. 1 V
Between T-adapter.
(11) - (12)
When canceled 8- 12v
If the condition is as shown in 1) Turn starting

the table below, it is normal. switch ON.
El 2) Insert
Governor motor Between (3) - (14) 2.8 - 6.3V Tdapter
Between (4) - (15) 2.8 - 6.3V

2) Insert
Between (13) - (12) 20 - 3ov T-adapter
Battery relay
*This is only for 2.5 seconds after

turning the starting switch ON -+ OFF.
At other times, it is 0 V.
If the condition is as shown in the ) Turn starting

!I Disconnect
Model selection PC200 Continuity
Between connector.
(17) - (12)
PC220 No continuity
Classif i- Measurement
Component Connector No. Judgment table
cation conditions

Throttle signal table below, it is normal. switch ON.
(engine throttle c2
controller) Between (20) - (10) 0.25 - 4.75 2) Insert
T-adapter

table below, it is normal. switch OFF.
2) Disconnect
Between (1) - (2) 500 - 1,000.Q
connector.
Between (2) - chassis Min. 1 Ma
1) Start engine
Measure at AC range
Engine speed sensor E7
2) Insert T-
I adapter.
Between (I) - (2) 0.5 - 3.ov
1) Screw in speed sensor until it contacts

ring gear, then turn back one turn.
2) Work normally after carrying out above

adjustment.
Nork equipment oil

If the condition is as shown in the 1) Start engine.
xessure switch
table below, it is normal (Charge
‘PCZOO, ZOOLC-5
accumulator)
No.: 45001 - 49706
For boom, arm, bucket, and swing control levers
PC220, 220LC-5 2) Disconnect
,No.: 35001 - 35661 1 connector.
All levers at neutral Min. 1Mn
Nork equipment . Sl (Male) Between (I) - (2)
One or more levers Max, , n
wing oil pressure
operated
switch
‘C200,2OOLC-5
\lo.: 49707 and up
‘C200, 2OOLC-5 MIGHT’
Between (1). (2) chassis Mtn. 1 MS2
‘C220,22OLC-5
\o.: 35662 and up

table below, it is normal (Charge
accumulator)
For swing control lever
Swing oil pressure 2) Disconnect
switch connector.
Lever at neutral Min. 1 MR
PC200,2OOLC-5 S2 (Male) Between (1) - (2)
No.: 45001 - 49706 ‘1 Lever operated Max. la
PC220,22OLC-5
No.: 35001 - 35661 1
Min. 1 Ma
Between (1). (2) - chassis I

table below, it is normal. (Charge accumu-
For travel control lever lator).
2) Disconnect
connector.
Travel oil pressure
swicth S4 (Male)
Between (1). (21 - chassis Min. 1 Ma

I
20620
IllSpeC-
Classifi- Measurement
Component Connector No. tion Judgment table conditions
cations
method

table below, it is normal.
2) Fuel control
dial at MAX.
Between (1) - (2) 18 - 28V
3) Insert
T-adapter
c7 (Rear)
Pump pressure sensor All levers
C8 (Front)
at neutral
If the condition is as shown in the I) Turn stan-

table below, it is normal. ing switch
OFF.
Swing lock switch C2 (Female)
Switch OFF Min. IMR
Between (81 - (41 21 Disconnect
Switch ON Max. IR connector
CN2.
If the condition is as shown in the 1) Turn TVC

table below, it is normal. prolix switch
OFF.
TVC solenoid valve C4 (Male)

I Between (1) - (2)
I
10 - 22Q
I 2) Turn
ing
start-
switch
OFF.
Between (2) - chassis Min. 1MQ I
3) Disconnect
connector C4
PCZOO, 2OOLC-5 Serial No.: 45001 - 52783 I) Turn stan-

PC220,22OLC-5 Serial No.: 35001 - 36023 ing switch
If the condition is as shown in the OFF.
table below, it is normal. 21 Disconnect
r Between (1) - (2)

I 10- 350
I
connector
VI.
Swing brake Between (2) - chassis Min. IMR

Vl (male)
solenoid valve
If the condition is as shown in the
Between (1) - (2) 24 - 4662
Between (2) - chassis Min. 1MQ
PC200,2OOLC-5 Serial No: 45001 - 52783 I) Turn start-

PC220,22OLC-5 Serial No: 35001 - 36023 ing switch
table below, it is normal. 21 Disconnect
connector
Between (1) - (2) 50 - IOOR v2.
Travel speed Between (2) - chassis Min. IMQ

V2 (male)
solenoid valve
PC200; 2OOLC-5 MIGHTY
I Between (1) - (2)

I 24 - 46R
I
Between (21 - chassis Min. IMR
Classifi
cation! Connector No. I IllSPt?C-
tion
nethod
Judgment table
Measurement
conditions
PC200,200LC-5 Serial No: 45001 - 52783 I) Turn stan-

table below, it is normal. 2) Disconnect
connector
Between (I) - (2) 50 - 1000 v7.
Z-stage relief l
Between (2) - chassis Min. 1MR
co cancel V7 (Male)
solenoid valve
table below, It is normal.
Between (1) - (2) 24 - 46R
Between (2) - chasiis Min. 1MR
PC200,200LC-5 Serial No: 45001 - 52783 1) Turn start-

table below, it is normal. 2) Disconnect
connector
Between (I) - (2) 10-350 v5.
Between (2) - chassis Min. 1MR

Arm half flow
V5 (Male)
solenoid valve
Between (I) - (2) 24 - 46R
Between (2) - chassis Min. IMR
20622
hpec-
Classifi Measurement
Connector No. tion Judgment table
cation: conditions
nethod
If the condition is as shown in the I) Turn start-

Power source
Cl OFF.
voltage
1Between (12). (13) - 13). (4)l 20 - 3ov 2) Insert
I T-adapter.
If the condition is as shown in the li Turn start-

ON.
Between (8) - (14) 10 - 13v 21 Insert

H.0 mode T-adaoter.
Between (8) - (151 O-IV
Between (8) - (14) IO - 13v

G.0 mode
Working mode
c2 Between (8) - (15) 10 - 13v
switch
Between 18) - (14) 0 - 1v

F.0 mode
Between (8) - (15) 10 - 13v
1 L.0 mode -1
If the condition is as shown in the 1) Turn start

ON.
2) Insert
T-adapter.
) H mode -1
Power set switch c2
l10 - 13V when working mode is L.0 mode
If the condition is as shown in the 1) Turn start-

ON.
Auto-deceleration 2) Insert
c2 Switch OFF 10 - 13v
switch Between T-adaoter.
(8) - (7)
Switch ON o- 1v

ON.
Travel speed
c2 Switch at Lo 10 - 13v 2) Insert
switch Between T-adapter.
181 - (3)
Switch at Hi o- 1v
If the condition is as shown in the 1) Turn stan-

ON.
Power maximizing
c2 Switch OFF 20 - 28V 2) Insert
switch Between
T-adaoter.
(8) - (12)
Switch ON 0 - 1v
Connector No. Judgment table
cation: conditions
PC200,2OOLC-5 Serial No: 45001 - 58018 1) Turn start-

If the condition is as shown in the ON.
table below, it is normal. 21 Insert
T-adapter.
5xJant temperature
c2 I I I
signal
Between (8) - (17) O-IV

Coolant temperature
above 105’C
Between (8) - (18) o- 1v

Wodel ON.
c2
xlection 2) Insert
T-adapter.

ON.
<erosene mode c2 2) Insert
T-adapter.

table below, it is normal. 2) Insert
T-adapter.
kto-deceleration Auto-decelera-
c2 8- 12v
utput signal tion switch OFF Between 3) All levers
(21) - 1191 at neutral
Auto-decelera-
0 - 1v
tion switch ON
IllSPfX-
Classifi
Component Connector No. tion Judgment table
cation: nethod
T PC200,200LC-5
PC220,22OLC-5
Serial No: 45001 - 58018
Serial No: 35001 - 36613
11 Turn
ing switch
start-
If the condition is as shown in the ON.

table below, it is normal. [Coolant
temperature
Between
PC200 PC220 gauge is within
(21) - (11)
green range]
H.0 mode 2) Insert
0.75 - l.OV 0.75 - l.OV
or H mode
T-adapter.
G.0, F.O. L.0
and S mode,
1.25 - 1.55V 1.35 - 1.65V
G.0, F.0 and
L mode
L.0 and L mode 2.06 - 2.36V 2.18 - 2.48V
When coolant
temperature is 4.0 - 4.25V 4.0 - 4.25V
No. 2 throttle signal c2 above 107~C

Between
PC200 PC220
(211 - (11)
H.0 mode
0.75 - l.OV 0.75 - l.OV
or H mode
G.O. F.O. L.0

and S mode,
1.25 - 1.55V 1.35 - 1.65V
G.O. F.0 and
L mode
L.0 and L mode 2.06 - 2.36V 2.18 - 2.48V
When coolant
temperature is 4.0 - 4.25V 4.0 - 4.25V
above 105~C
If the condition is as shown in the I) Start engine

table below, it is normal. !I Turn swing
lock switch
Approx. 4 set after I
I!
OFF.
swing brake placing swng lever 1 20-30V /
Cl at neutral $1 Turn swing
;olenoid Between
lock prolix
Swing lever (8) - (121, (13)
0 - 3v switch OFF.
operated
1) Insert
T-adapter

table below, it is normal. 2) Insert
T-adapter
Travel speed Travel speed
Cl switch at Lo
20 - 3ov 3) Fuel control
solenoid Between dial at MAX.
Travel speed (161 - (12). (13)
0 - 3v 4) Travel on
switch at Hi
flat ground

table below, it is normal. Ing switch
Z-stage relief * CO ON.
Travel lever
cancel solenoid Cl at neutral
20 - 3ov 2) Insert
Between T-adapter.
(2.stage relief) (15) - (12). (13)
Travel lever
0 - 3v
operated

2-stage relief. CO ON.
cancel solenoid Cl Swing lock
20 - 3ov
2) Insert
switch OFF Between T-adapter.
(CO cancel)
(7) - (121, (131
Swing lock
0 - 3v
switch ON
Il-lSpeC-
Classif
Connector No. tion Measurement
cation conditions
method

ON.
Arm half flow
Cl 2) Insert
H.0, G.O. mode 20 - 3ov
Between T-adapter
(6) - (12), 113)
F.O. L.0 mode 0 - 3v
InSpeC-
Classi Measurement
catior
Component ConnectorNo. tion Judgment table
conditions
method
CHECK, CAUTION the condition is as shown in Table 1, Table 2, and Table 3, the monitor panel is I) Start engine.
group 0mlal. 21 Insert T-adapter.
Buzzer signal able 1 (CHECK, CAUTION group)
kgnai_i
The voltage for H Monitor auxiliary signal input
it~;~~~or
and L in the table
are as follows. Monitor
display
*l. Engine oil

item I
pressure signal
PI (16) PI (8) Pl (7)
H: 3.5 - 30V
L: Approx. OV Flashing
Zoolant lever
‘I (17)
*2. Starting signal OFF
H: 7 - 30V
lngine oil Flashing
L: Approx. OV
ever
‘1 (18)
The starting signal
is H once,
that
However,
starting
turned
it becomes
but
until
switch
OFF, the
after
L.
the
is
---I
hydraulic
ever
‘1 (IO)
‘reheat
oil
Engine oil pressure signal

Flashing
OFF
Flashing
Starting signal is ‘1 (9) L and starting signal L

OFF
held in the memory
inside the monitor
Flashing
panel as H.
OFF
*3. Alternator
signal Flashing
H: 20 - 30V
OFF
L: Max. 5v
Flashing
*4. Sensor signal :uel level
H: 3.5 - 30V ‘1 (5) I OFF
L: Approx. OV
Flashing
:harge
‘1 (7)
OFF
Engine oil pressure signal
H and starting signal H
Flashing
:001ant level
OFF
Flashing
OFF
Flashing
OFF
ble 2 (Buzzer signal)
Pl (4) Open (no connecting wiring)

P2 II), (2). (14). (15)
Pl (1) - (3) Starting switch ON

(+24V input) 20 - 3ov
Starting switch OFF

ov
PI (11) (Alarm buzzer output) - (3) Remove connector, and buzzer sounds
Disconnect P8 (coolant level sensor) or the following cycle is repeated.
I
Connect short connector to P8 Over 20V: 0.8 set
3V: 0.8 set
When short connector is connected,

buzzer stops or voltage is OV.
IllSpeC-
Classifi
cation!
ConnectorNo.
I tion
method I Judgment table
Measurement
conditions
GAUGE group able 3 (GAUGE group) 1) Turn starting

t switch OFF,
insert dummy
Position of Display level resistance (kR)
gauge display resistance, or
(Monitor panel input resistance)
measure resist-
Starting switch Starting switch OFF ance (kni
ON (Monitor panel
input resistance)
Measure resistance Min. - Max. 2) Turn starting
between coolant
Right switch ON, and
temperature gauge All OFF 0 - 0.7
side check display.
Pl (female)
3) Connect socket.
(6) - (3) t 8 0.5 - 3.245
7 3.015 - 3.665
Dis-
play 6 3.419 - 4.222
posi-
tion t 5 3.946 - 5.092
4 4.764 - 6.248
J 3 5.844 - 7.713
7.086 - 10.17
Left
9.455 - Disconnection
side
Measure resistance Right

side 10 0 - 14.24
between fuel
level gauge
9 11.23 - 20.87
PI (female)
(5) - (3)
T 8 17.51 - 27.32
7 23.52 - 34.07
Dis-
play 6 29.98 - 39.55
posi-
tion ! 5 35.15 - 44.38
4 39.70 - 49.45
3 44.47 - 61.60
i
2 55.89 - 79.36
1 72.52 - 691.63
Left
All OFF 611.82 - Disconnection
side
PC200,2OOLC-5 Serial No: 45001 - 58018 1) Turn starting

PC220,22OLC-5 Serial No: 35001 - 36613 switch ON.
If the condition is as shown in the 2) Insert
table below, it is normal. T-adapter.
Coolant temperature P2
20628
IllSpeC.
Classii Measurement
Component Connector No tion Judgment table
cation
n&hoc
PC200,200LC-5 Serial No: 58019 and up 1) Turn starting

PC200,2OOLC-5 MIGHTY switch ON.
2) InsertT-adapter.
Coolant Between (12) - (16) IO-13v

temperature
below 102’C Between (13) - (16) 10 - 13v
Coolant temperatur, P2
Coolant
Between (12) - (16) 0 - 1v
temperature
a hove 102~C.
Between (13) - (16) 10 - 13v
below 105’C
Coolant Between (12) - (16) o- 1v

temperature
above 105X Between (13) - (16) O-IV

table below, it is normal. switch ON.
2) Insert
Narming-up signal P2 Coolant temper- T-adapter.
Max. 1V
ture below IO’C Between
(11) - (16)
Coolant temper-
8- 12V
ture below 5O’C

table below. switch ON.
2) Insert
T-adapter.
Between (8) - (16) 10 - 13v
H.0 mode
Between (9) - (16) o- 1v
Between (8) - (16) 10 - 13v

rVorking mode
:witch
P2 G.0 mode .
Between (9) - (16) 10 - 13v
Between (8) - (16) 0 - 1v

F.0 mode
Between 19) - (16) 10 - 13v

L.0 mode

ON.
Between (5) - (16) 10 - 13v 2) Insert
H mode T-adapter.
Between (6) - (16) IO-13v

f‘ower set switch P2 S mode
Between (6) - (16) IO-13v
Between (5) - (16) *o-w

L mode
Between (6) - (16) o-1v ’
* 10 - 13V when working mode is L.0 mode
r If the condition
table below,
is as shown
it is normal.
in the 1) Turn
ing switch
ON.
stan-
I
I ’\uto-deceleration P2 ON Max. 1V
2) Insert
witch Between T-adapter.
1. OFF
(7) - (16)
8- 12V
20-;8- 1
Connector No. tibn Judgment table
cations conditions
nethod
If thecondition is as shown in the I) Turn start-

ON.
P2 2) insert
T-adapter.
Between When engine is running (112 throttle or above): 1) Start engine.

alternator 27.5 - 29.5v
terminal R * If the battery is old, or after starting in cold areas,
- chassis the voltage may not rise for some time.
20;$8-2
Classifi
cations Connector No. Measurement conditions and standard values
1) Turn starting switch OFF.

2) Disconnect connector P8.
3) Insert T-adapter into connector at sensor end and measure resistance value
Coolantlevel sensor P8 (Male)
Sub-tank water level at LOW level

Max. 1R
or above
Sub-tank water level at LOW level
nr hnlnw, Min. IMR

3) Drain oil and remove sensor.
4) Insert T-adapter into sensor and measure resistance value.
Engine oil level
P7 (Male)
sensor * Connect the
T-adapter to the ; zs ? Raise
Max. 1Q
connector and float
sensor flange.
$ p_. Lower
Min. IMR
1 float

3) Insert T-adapter into connector at sensor end and measure resistance
Coolant temperature value
P7 (Male)
sensor
Normal temperature (25-C) Approx. 37 - 50kQ
100x Approx. 3.5 - 4.0kQ
1) Install oil pressure measurement gauge.

2) Remove wiring harness terminal.
3) Start engine.
4) Put tester in contact between chassis and sensor terminal screw, and measure
Engine oil pressure
- resistance value.
sensor
Engine oil pressure: 0.7 kg/cm2 or above Min. IMR
Engine oil pressure: 0.3 kg/cm’ or below Max. 10

3) Drain fuel and remove sensor.
4) Insert T-adapter into sensor and measure resistance value.
* Connect the
Fuel Raise
level sensor P6 (Male) T-adapter to the
float to Max. approx. 12Q
connector and f
stopper
sensor flange.
Lower
-; float to Approx. 85 - 1 lo<>
J stopper

2) Disconnect P9.
3) Drain oil and remove sensor.
4) Insert T-adapter into sensor and measure resistance Value.
Hydraulic oil level

P9 (Male)
4,
gauge c3 Raise
Max. lL1
“4 float
=Jt
J- Lower
w Min. 1MQ
float
3 1
20-;8-3
J
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or
measurement item S;ym bol Part No. Part Name Remarks
1 799-203-8000 Multi-tachometer Digital display L: 60 - 2,OOOrpm

H: 60 - 19,999rpm
Engine speed A 799-203-8901 Clamp set

2
6210-81-4111 Gear box
Water and oil Degital temperature _50 _, 2ooC

temperatures gauge
I
Pressure gauge
799-101-5001 Hydraulic tester
20, 60, 400, 600 kg/cm*
l--
790-261-1201 Digital hydraulic
Pressure gauge 700kg/cm2
tester
C . 790-261-1310 Both male and female:

Hydraulic pressure
14 x 1.5 (female PT l/8)
2 . 790-261-1320 Adapter Both male and female:
Both male and female:

. 790-261-1330
1 795-502-I 590 Compression guage 0 - 70 kg/cm*

Kit Part No. 795-502-1205
Compression pressure D -
2 l 795-502-1370 Adapter
Blow-by pressure E 799-201-1504 Blow-by checker 0 - 500mmH,O
Commercially -
Valve clearance F Feeler gauge
available
Handy smoke Discoloration 0 - 70%
799-201-9000
checker (with standard color)
Exhaust color G
Commercially (Discoloration % x l/IO
Smoke meter
available = Bosch index)
Operating force -. H ‘-,

I-79A-264-0020 Push-pull scale
I
-
Commercially -
Stroke, hydraulic drift I Scale
available
Commercially -
Work equipment speed J Stop watch
available
Pump performance K 790-303-I 002 Flowmeter Kit
I I 1 799-601-2600 T-adapter box
Troubleshooting of
wiring harnesses and
sensors
Troubleshooting of
voltage and resistance M 79A-264-0210 Tester
values
Engine oil pressure N 799-401-2320 Hydraulic guage 1 Okg/cm*
20629
ADJUSTING VALVE CLEARANCE
1. Remove the cylinder head cover.

2. Rotate the crankshaft in the normal direction to
align pointer (2) with 1.6 TOP line (I) on the
crankshaft pulley. When rotating, check the
movement of the intake valve of No. 6 cylinder.
3. When No. 1 cylinder is at top dead center,
adjust the valves marked l. Next, rotate the
crankshaft one turn (360”) in the normal direc-
tion and adjust the valve clearance of the re-
maining valves marked o.
205FO521C
* Valve arrangement
4. To adjust the valve clearance, loosen locknut

(6). then insert tool F between rocker arm (3)
and valve stem (4). and turn adjustment screw 0”
0”
(5) until the clearance is a sliding fit. Then tight- ’ 205FO5211
z
en locknut (61 to hold the adjustment screw in
position.
w Locknut: 4.5 f 0.5 kgm
* After adjusting No. 1 cylinder at top dead
center, it is also possible to turn the crankshaft
120” each time and adjust the valve clearance
of each cylinder according to the firing order.
l Firing order: 1 - 5 - 3 - 6 - 2 - 4
0 After tightening the locknut, check the clear-
ance again.
20-30
0
‘A When measuring the compression pressure,
be careful not to touch the exhaust mainfold
or muffler, or to get your clothes caught in
the fan, fan belt or other rotating parts.
1. Adjust the valve clearance.

For details, see ADJUSTING VALVE
CLEARANCE.
2. Warm up the engine to make the oil temperature
40 - 60°C.
3. Remove the nozzle holder assembly from the
cylinder to be measured.
4. Install adapter D2 in the mount of the nozzle
holder, then connect pressure gauge Dl.
5. Set tachometer A in position.
6. Disconnect the fuel control rod, place the con-
trol lever of the injection pump in the NO INJEC-
TION position, then crank the engine with the
starting motor and measure the compression
pressure.
Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
After measuring the compression pressure, in-
stall the nozzle holder assembly.
20-3 1
TESTING AND ,ADJUSTING FUEL INJECTION TIMING
1. Rotate the crankshaft in the normal direction to

align pointer (2) with 18” line (1 I on the crank-
shaft pulley.
2. Disconnect fuel injection pipe (3) of No. 1
cylinder.
3. Remove delivery valve holder (41, take out deliv-
ery valve (51 and spring (61, then install delivery
valve holder (4) again.
4. Place the governor lever at the FULL position.
5. Loosen the nut in the oblong hole of the mount-
- ing flange of the fuel injection pump, then
loosen injection pump mounting bolts (7). 205FO5214
6.Move the fuel injection pump towards the out-

side, then move the injection pump towards the
cylinder block a little at a time while operating
the priming pump, and stop at the point where
the fuel stops flowing from the delivery valve
holder.
* If the fuel does not stop whichever way the
injection pump is moved, rotate the crank-
shaft one more turn.
* Adjust the fuel injection timing by moving
the fuel injection pump as follows.
L
To RETARD timing, move towards
OUTSIDE.
To ADVANCE timing, move towards CYLIN-
DER BLOCK.:
7.Tighten injection pump mounting bolts (7) in
turn.
8. Tighten the nut in the oblong hole of the mount-
ing flange of the fuel injection pump.
9. Remove delivery valve holder (4). assemble
delivery valve (5) and spring (61, then install
delivery valve holder (4) again.
m Delivery valve holder: 3.3 * 0.2 kgm
10. Connect fuel injection pipe (3).
m Sleeve nut: 2.4 f 0.1 kgm
I I
205FO5216
F2050539r
c.
TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR
LEVER
1. Inspection
1) Set each switch in the following condition
* Condition Starting switch: ON
Working mode: H.0
Power mode: H
Auto-deceleration: OFF
Fuel control dial: MAX
2) In the above condition, check the two fol-

lowing points regarding the governor lever
and spring rod.
i) Check that the injection pump gover-
IL 205F05220A
nor lever is contacting the FULL

stopper.
ii) Check that there is a clearance of at Engine at high idling
least 1 mm between the yoke welding
bead and the end face of spring rod
(2).
+ If the clearance is too small, grind
the welding bead to ensure a clear-
ance of at least 1 mm. --c-- Min. 1mm
Adjusting
Ir Carry out adjustment Detail P
with the starting FO20205032
switch OFF.
Pull out pin (I), and disconnect spring rod
(2) from the injection pump governor
lever.
Set governor motor lever (3) and injection
pump governor lever (4) in contact with
the FULL stopper, adjust the length of spr-
ing rod (2), and connect again.
From the above position, turn back rod (5)
3.5 turns (approx. 4.4 mm) (extend the
rod), then secure with locknut (6).
INSPECTION OF SWING CIRCLE
Method of inspecting swing circle bearing clear- Revolving frame Revolving frame
ance on machine I G=l
1. Fix a dial gauge equipped with a magnet to the
outer race (or inner race ) of the swing circle, and
put the probe in contact with the end face of the
inner race (or outer race).
Set the dial gauge at the front or rear.
Ime
F20505395
2. Set the work equipment to the maximum

reach with the tip of the bucket at the height
of the bottom surface of the frame.
In this condition, the front of the upper struc-
ture will go down, and the rear will go up.
3. Set the dial gauge to the 0 point.
F20505396
4. Set the arm at 90” perpendicular to the

ground surface, then lower the boom until
the front of the track comes off the ground.
The front of the upper structure will go up,
and the rear will go down.
5. With the machine in this condition, read the
value on the dial gauge.
This reading of the dial gauge is the clear- F20505397
ance of the swing circle bearing.
AWhen carrying out the measurement, do

not put your hands or feet under the un-
dercarriage.
6. Return the machine to the condition in Step
2, and check that the dial gauge has returned
to the 0 point. If the dial gauge has not re-
turned to the 0 point, repeat Steps 2 - 5.
20$3-l
ADJUSTING ENGINE SPEED SENSOR
1. Screw in so that the tip of sensor (I) contacts

gear (2). Engine speed sensor
2. When sensor (I 1 contacts gear (21, turn it back \L%
one turn.
3. Tighten locknut (3).
Ir When connecting the wiring, be careful to
prevent any excessive force from bearing
on the wiring of the sensor.
* Be careful not to scratch the top of the
sensor or to get any metal powder stuck to
it.
205FO5221
205FO5222 j
20-34
0
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
EQUIPMENT, SWING, TRAVEL CIRCUIT
1. Measuring
* Oil temperature when measuring:
45 - 55°C
Y Y
Lower the work equipment to the ground
*
and stop the engine. Operate the control
levers several times to release the remaining
pressure in the hydraulic piping. Then
loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
Put the safety lock lever in the LOCK
i i 205FO5223
position.
11 Remove pressure pick-up plug (I) or (2)
(Thread dia. = 1 Omm, Pitch = 1.25mm)
from the circuit to be measured, then install
oil pressure gauge Cl (600 kg/cm2).
2) Start the engine, set to the H.0 and H mode,
and measure the main relief pressure with
the engine at high idling.
l Condition of actuator to be measured
i) For the work equipment, set each
cylinder to the end its stroke.
ii1 For swing, turn the swing lock
switch ON.
I 205FO5224
iii) For travel, fit block 0 under the
track shoe grouser. Or fit block @
between the sprocket and frame to
lock the track shoe. Measure one
side at a time.
Table 1
‘lug Pump Actuator controlled
l Arm cylinder
I
l Boom cylinder
1 Front pump
0 Swing motor %
l R.H. travel motor 205FO5225 205FO5226
l Arm cylinder
1 l L.H. travel motor
% The set pressure of the safety valve for the

boom head end and swing motor is lower
than the set pressure of the main relief valve,
so be careful.
2. Adjusting
Main relief valve
I) Adjusting high set pressure
i) Loosen locknut (3) and turn holder (4)
to adjust.
+ Adjust the holder as follows.
l To INCREASE pressure, turn
CLOCKWISE
l To DECREASE pressure, turn
COUNTERCLOCKWISE
l-4 For\front / pump
w Locknut: 6.0 f 0.5 kgm For rear pump
205FO5227
* When the high set pressure is ad-
justed, the low set pressure also
changes so always adjust the low
set pressure also.
2) Adjusting low set pressure 3 4 Pa 5
i) Loosen locknut (5).
+ Check that elbow (6) moves.
ii) Loosen locknut (7) and turn holder (8)
to adjust.
CLOCKWISE
COUNTERCLOCKWISE 205FO5664
+ Amount of adjustment for one turn
of holder: 128 kg/cm2
m Locknut: 4.5 +- 0.5 kgm 1
Ir Normally, the pressure applied to port PR is
approx. 13 kg/cm2 or less, and at high set
pressure, is approx. 30 kg/cm2.
Swing motor safety valve

1) Loosen locknut (9) and turn adjustment
screw (I 01 to adjust.
+ Adjust the adjustment screw as follows.
CLOCKWISE
205FO522:
COUNTERCLOCKWISE
* After adjusting, repeat the procedure in
Step 1 to check again.
m Safety valve: 18.0 + 1 .O kgm

* Adjustment of the safety valve set pressure
is only for the swing motor. Do not try to
adjust the safety valve set pressure for any
other part.
205FO5230 ,
20-36
0
Precautions when measuring hydraulic pressure
I) Measuring hydraulic pressure under normal
operation
Relieve the boom, arm, and bucket cylinders
when measuring.
* Do not operate the power max. switch.
2) Measuring hydraulic pressure when 2-stage
relief is actuated
Relieve the travel circuit to measure.
* When the travel circuit is relieved, the
2-stage relief solenoid valve and the CO
cancel solenoid valve are actuated.
+ When the CO valve is canceled, the relief
pressure is different when one side is
relieved and when both sides are relieved.
TESTING AND ADJUSTING CHARGING PUMP PRESSURE
1. Measuring
* Oil temperature when measuring: 45 -
55°C
I) Remove pressure pick-up plug (I) (Thread
dia. = 1 Omm, Pitch = 1.25mm), and install
2) Start the engine and measure with the
engine at high idling.
* When testing for internal leakage of the

equipment in the control circuit, use the
205FO5231
parts given below to shut off the circuit for
the following sections when measuring the
relief pressure.
,,c. Section of hydraulic Component that

circuit shut off canbechecked
Piston pump inlet
1 Piston pump
Port
2 Charging pump
Charging pump
outlet port
3 Solenoid valve Solenoid valve
4 IT ravel PPC valve Travel PPC valve
+ For Items No. 2 and below, it is possible

to check if the equipment above it is
normal.
* Use the following parts to shut off the
circuit. Sleevie
l For elbow
Sleeve nut:
07221-20210,07221-20315
0722 I-20422
Plug:
205FO5233
07222-00210,07222-50315
07222-00414
l For hose
Plug: Travel PPC valve
Piston pump Solenoid valve
07376-50210,07376-50315
07376-50422 Ih
(0 :@ R.H. PPC valve
Charging pump
2
r-
t
Safety lock
valve L.H. PPC valve
205FO5234
20-38
0
2. Adjusting
I) Loosen locknut (2) and turn adjustment
screw (3) to adjust.
Sr Adjust the adjustment screw as follows.
CLOCKWISE
COUNTERCLOCKWISE
Sr Amount of adjustment for one turn of
adjustment screw: 5.4 kg/cm2
m Locknut: 6.5 + 1 .O kgm
205FO5235
+ After completion of adjustment, repeat
the procedure in Step 1 to check the set
pressure again.
20-39
0
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE
1. TVC valve output pressure

Measuring
45 - 55°C
* Measure the relief pressure of the charging
pump first, and check that it is normal.
sr The TVC valve output pressure varies ac-
cording to the average pressure for the
L
PI + P2
pump discharge pressure ( =
2
average pressure), so before measuring,
always adjust the main relief pressure to the 205FO5236
specified pressure.
1) Remove pressure pick-up plug (I) (Thread
dia. = 1 Omm, Pitch = 1.25mm), and install
2) Set to heavy-duty and H mode, run the
engine at high idling, and measure the hy-
draulic pressure with the control lever at
neutral and at pump relief.
[Reference]
a) The average pressure at one pump relief is
approx. 170 kg/cm2. (The discharge pres-
205FO5237
sure of the pump being relieved is 320
kg/cm2, and the discharge pressure of the
pump not being relieved is approx. 20 Graph 1
kg/cm2.)
b) For the relationship between the change in
the TVC valve output pressure and the
pump discharge amount, see graphs 1 and
2.
100 200 300

Pl +P2
Pump discharge pressure - = Average pressure (kg/c,+)
2
205F0523E
1Graph 2
TVC valve control area
When CO function is canceled
co valve
control area
Pl +P2 _
Pump discharge pressure - - Average pressure (kgicr+)
2
205FO5239
20-40
0
Adjusting
Ir If the results of the measurement show that the
hydraulic pressure is not within the standard,
adjust as follows.
I) Loosen locknut (2).
2) Turn adjustment screw (3) to adjust.
* If the adjustment screw is stiff, do not use
excessive force. If excessive force is used
to turn the screw, the tip may break.
3) Adjust the adjustment screw as follows.
l To INCREASE pressure, turn CLOCKWISE
205FO5240
l To DECREASE pressure, turn COUNTER-
CLOCKWISE
It Amount of adjustment for one turn of ad-
justment screw: Approx. 3.5 kg/cm2
f After adjusting with the adjustment screw,
repeat the procedure in measuring to check the
3
output pressure.
* If the adjustment screw is stiff and excessive
force is used to turn it, the tip may break, so in
this case, remove the TVC valve assembly,
remove the cover assembly, and put lubricant
on the screw before trying to move it.
: -
0
205FO5241
g
20-4 1
a
Output pressure of CO valve and NC valve
[Reference1
The output pressure of the NC valve controls
the discharge amount of the piston pump flow-
ing to the servo valve.
The oil flows TVC valve - CO valve -NC valve -
servo valve, and the ouput pressure changes as
follows according to the movement of the con-
trol lever or work equipment.
* Control levers at neutral
The NC valve is actuated by the differential
205FO5242
pressure of the jet sensor, and the output
pressure drops below 5.5 kg/cm2.
(The pump discharge amount is the minimum)
+ When hydraulic cylinder is relieved
The CO valve is actuated, and lowers the
pressure of the oil entering the NC valve to
below 5.5 kg/cm2. The NC valve supplied
this pressure as it is to the servo valve.
(The pump discharge amount in this case is
the minimum)
+ Work equipment, swing, travel actuated
The output pressure of the TVC valve is not
affected by the CO valve and NC valve, and
I i 205FO5243
is supplied as it is to the servo valve.
(The discharge amount of the pump varies
between the maximum and the point where
the CO valve is actuated.)
Measuring
+ Olil temperature when measuring:
45 - 55°C
l Remove pressure pick-up plug (41 (Thread
dia. = 1 Omm, Pitch = 1.25 mm), and install
Ir This is at the body side of the servo
valve. 205FO5244
1) Pressure when NC valve is actuated
Set to H.0 and H mode, run the engine at
high idling, and measure the pressure when
all control levers are at neutral.
* Turn the auto-deceleration switch OFF.
* If the output pressure is more than 5.5
kg/cm2, measure the differential pres-
sure of the jet sensor.
2) Pressure when CO valve is actuated
Run the engine at high idling and measure
the hydraulic pressure when any of the
boom (except LOWER), arm, or bucket are
relieved.
3) Pressure when work quipment or swing are
actuated
A The work equipment is actuated

when the pressure is measured, so
be careful of the surrounding area.
Measure the hydraulic pressure when reliev-
ing the swing (front pump) or when rotating
the track under no load (front, rear pump) at
the same time as measuring the output pres-
sure of the TVC valve.
Sr Measure the swing relief with the swing
lock switch OFF.
j, Rotate the track under no load one side
at a time.
* If there is a big difference from the TVC
valve output pressure, the operation of
the CO valve or NC valve is probably
defective.
Adjusting
I) CO valve
* If the set pressure of the CO valve is high,
the discharge amount is not reduced when
the circuit is relieved, so the relief pressure
becomes high. For this reason, always
adjust the pressure to the specified
pressure.
i) Loosen locknut (5) and turn adjustment
+ Adjust the adjustment screw as follows.
INCREASE
co valve 205FO5245
J
l To pressure, turn
CLOCKWISE
COUNTERCLOCKWISE
+ Amount of adjustment for one turn of
adjustment screw: 41.25 kg/cm2.
+ If the hydraulic pressure does not drop
even when the adjustment screw is ad-
justed, there is probably a defect inside
the CO valve.
ii) After adjusting, repeat the procedure in
measuring to check the set pressure again.
205FO5246
2) NC valve
* The NC valve is actuated by the dif-
ferential pressure of the jet sensor, so
when adjusting it, always check first
that the differential pressure of the jet
sensor is correct.
i) Loosen locknut (7) and turn adjustment
* Adjust the adjustment screw as
follows.
CLOCKWISE 205FO5247

CLOCKWISE
* Amount of adjustment for one turn
of holder: Approx. 4.3 kg/cm2.
20-44
3. Defferential pressure of jet sensor
[Reference] Relationship between travel of
control lever and differential
High pressure and low pressure (high pressure
pressure of jet sensor
- low pressure = differential pressure) is
formed at the outlet port of the control valve,
and this differential pressure controls the NC
valve.
The differential pressure is at its maximum
when the control levers are at neutral, and is at
its minimum when the control levers are operat- I
ed to the end of their travel. O Control lever travel (mm)
205FO5249
Measuring
*y Loosen the oil filler cap slowly to

release the pressure inside the hydraulic
tank.
+ Oil temperature when measuring:
45 - 55°C
1) Remove pressure pick-up plugs (91 (high
pressure side) and (I 0) (low pressure side)
(PT l/8).
* For both front and rear, the side nearest
the engine is the high pressure side.
* The clearance between the pressure / ’ /
iO5FO5250
pick-up plug and cover is small, so use
one of the following adapter.
l Adapter:
790-261-1231
(PT l/8 x PT l/8 90” elbow)
790-261-1310
(Type to insert between hose
and elbow)
2) Install oil pressure gauge Cl (60 kg/cm2 at
high pressure side, 25 kg/cm2 at low pres-
sure side).
3) Set to H.0 and H mode, run the engine at
high idling, and measure the differential I Elbbws 205FO5251
pressure with the control levers at neutral.
Sr High pressure (Pt) - low pressure (Pd)
= Differential pressure
4) Using the work equipment, raise the track
frame on one side, and measure the dif-
ferential pressure with the track rotating
freely (control lever operated to the end of
its travel).
* Any actuator can be measured, but it is
easiest to measure the free rotation of
the track because the measurement
time can be chosen as desire.
* The differential pressure is the minimum
(below 1 .O kg/cm2).
20-45
0
Adjusting
* If the results of the measurement show that
the differential pressure is not within the
standard value, adjust as follows.
I) Loosen locknut (I I) and turn adjustment
* Adjust the adjustment screw as follows.
CLOCKWISE
COUNTERCLOCKWISE
Sr Amount of adjustment for one turn of 205FO5252
adjustment screw:
Approx. 16.6 kg/cm2
m Locknut: 7.0 f 1.0 kgm
* After adjusting the adjustment screw,
repeat the procedure in measuring to check
the differential pressure again.
F2050539E
20-46
@
MEASURING STROKE OF SERVO PISTON
* If the output pressure of the NC valve is normal,

and it is considered that the pump performance
is defective, inspect as follows to determine if
the servo valve is defective or not.
1. Prepare the tool

Make up gauge 0 from the following parts.
1) Servo piston cap (side which has spring)
2) Dump truck brake wear measurement
gauge (566-98-41120)
3) Tap PT l/4 threads in the center of the cap,
and install the gauge. I 205FO5254
2. Measuring
1) Remove the cap (with the spring) from the
side to be measured.
t The cap is pushed by the spring, so use
bolt (01016-31070) and a nut.
21 Fit the shims that were removed, and install
gauge @.
4 Do not let the shims catch on the
threaded portion of the bolt.
3) Stop the engine, push the rod in fully, then
measure the dimension of the rod.
205FO5255
4) Raise the track shoe on the side where the
gauge is installed, and measure the dimen-
sion of the rod when the engine is run at
high idling and the track is rotated freely.
t Standard stroke: Approx. 7.2 mm
* When the track shoe is rotated freely,
push the rod by hand, and check at the
same time that the rod moves smothly
in accordance with the travel of the con-
trol lever.
20-47
0
TESTING AND ADJUSTING TRAVEL DEVIATION
* When traveling on fiat ground

Travel posture
1. Measuring when traveling
1) Set the machine in the travel posture.
J, When setting the machine in the travel
posture, extend the bucket and arm cyl-
inder rod fully, and hold the boom at 45”.
2) Travel for 10 m, then measure the deviation
when traveling for the next 20 m.
* Set to the H.0 and H mode, and measure
with the engine at high idling.
202F2322
20 m 0 Travel for 10 m
Travel straight
through without
stopping
\ \ \
Make a mark Make a mark at Make a mark
the 10 m midpoint
~~r~~n?Jn~~~‘:I-^.rk
Mark
this deviation 202F5258
2o-i7-1
2. Adjusting
If the result of the measurement shows that the
value is not within the standard value, adjust as
follows.
t Adjustment procedure
. If the travel deviation is still not within the

standard value even after carrying out this
adjustment, see TROUBLESHOOTING, Travel
deviation is excessive.
1) Loosen 4 bolts (I).
Ir The shims are split shims, so do not
remove the cap.
2) Add shim (2) of a thickness that matches the
amount of deviation, then tighten bolts (1).
* Add maximum of 0.3 mm of shim.
W Mounting bolt: 6.75 2 0.75 kgm
F205C5117
* Amount of travel deviation and thickness
of shim to add
PC200
20
15
10
0
Thickness of shim to add (mm)
F205C5118
PC220
Thickness of shim to add (mm)

F205C5119
2047-2
MEASURING OUTPUT PRESSURE OF PPC VALVE

45 - 55°C
1. Disconnect the hose (see diagram below) from
the circuit to be measured.
2. install adapter C2 between the hose and elbow.
3. Install oil pressure gauge Cl (60 kg/cm7 to
adapter C2.
4. Run the engine at high idling, operate the con-
trol lever for the circuit to be measured, and
measure the hydraulic pressure.
205F05684
PC200,2OOLC-5 Serial No: 45001 - 52783
PC220,22OLC-5 Serial No: 35001 - l
R.H. PPC valve P,
205FO5266B
* Color code
B: Black, Br: Brown, W: White, Y: Yellow
BU: Blue, G: Green, R: Red
PC220,22OLC-5 Serial No: l and up
R.H PPC valve I D
L.H
205FO5880
20649
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
PC200,2OOLC-5 Serial No: 45001 - 58018

PC220,22OLC-5 Serial No: 35001 - 36613
* If there is excessive play in the work equipment
or swing lever, adjust as follows.
*y Lower the work equipment to the ground

and stop the engine. Operate the control
Set the safety lock lever to the LOCK po-
sition.
1. Remove the boot, loosen the lever mounting

bolt, then remove the lever.
2. Hold down disc (I 1, and loosen locknut (2).
3. Turn disc (I 1 and adjust the clearance.
sr Adjust the clearance with the disc as
follows.
l To DECREASE clearance, turn
CLOCKWISE
l To INCREASE clearance, turn
COUNTERCLOCKWISE
i) When adjusting the clearance, adjust four
pistons (3) separately. (Two pistons in the
front-to-rear direction (A - a) and two pis-
tons in the left-to-right direction (B - b)).
ii) Set disc (I) so that it contacts one of the
pistons in the front-to-rear direction (A - 0.3 - 0.5 mm
1
a), then adjust the clearance between disc
(I) and piston (3) on the opposite side to
0.3 - 0.5 mm.
3
iii) After adjusting in the front-to-rear direction,
adjust in the left-to-right direction (B - b).
iv) If the clearance exceeds 0.5 mm, change
the position of disc (I) or change the
mounting position of piston (31, then check
again.
w Locknut: 11.5 * 1.5 kgm

* If no clearance is made, even when the lever
is at neutral, the work equipment will move,
or the hydraulic drift will increase, so
always provide a clearance.
20-$9-l
PCZOO, 2OOLC-5 Serial No: 58019 and up
f- If there is excessive play in the work equip-

ment or swing lever, adjust as follows.
*qLower the work equipment to the ground and

stop the engine. Operate the control levers
several timesto release the remaining pressure
in the hydraulic piping. Then loosen the oil
filler cap slowly to release the pressure inside
the hydraulic tank. Set the safety lock lever to
the LOCK position.
1. Remove the PPC valve.

2. Remove boot (1).
3. Loosen locknut (2), and screw in disc (3) until
it contacts the head of 4 pistons (4).
Ir When adjusting, do not operate the pis-
tons.
4. Hold disc (3) in position and tighten locknut
(2) to the specified tightening torque.
w Locknut: 11 & 1 kgm
5. Install boot (I).
* With this adjustment, the clearance between

disc (3) and piston (4) is made 0.
z
z
8
20TF011.29
20-&9-2
TESTING PPC SHUTTLE VALVE
* If the auto-deceleration does not work, the

swing brake is not canceled, the travel lacks
power, or if there is any other problem, and the
pressure switch is normal, check the operation
of the PPC shuttle valve as follows. (Check first
that the electrical system is normal.)
-k Oil temperature when testing:
45 - 55°C
1. Remove the pressure switch from the circuit to
be tested.
I) Work equipment, swing pressure switch (I)
2) Travel pressure switch (2)
2. Install pressure gauge Cl (60 kg/cm?.
3. Run the engine at high idling, operate the fol-
lowing control lever, and measure the hydraulic
pressure.
In the case of switch (1). operate the work
equipment or swing lever.
In the case of switch (21, operate the travel
lever.
205FO5259
20-50
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE
Measure each solenoid valve at the following

places.
INO.
I Solenoid Measurement location I
Solenoid valve
outlet port
205FO5260
Disconnect the hose, and install adapter C2 be-

tween the measurement point and the hose.
* Adapter
Size Part No.
02 790-261-1310
03 790-261-I 320
04 790-261-I 330
205FO5261
Install oil pressure gauge Cl (60 kg/cm21 to the
adapter.
Run the engine at high idling and measure the
hydraulic pressure under the following
conditions.
1) Arm half flow solenoid valve
If the working mode switch is set to heavy-
duty or general mode, and the arm is operat-
ed, the PPC valve output pressure is sup-
plied; if the working mode switch is set to
finishing or lifting mode, the pressure
should be 0 kg/cm2.
21 Swing brake soleoid valve
205FO5262
Operate the swing.
3) Travel speed solenoid valve
Set the travel speed switch to Hi.
4) 2-stage relief *CO cancel solenoid valve
Turn the swing lock switch ON or push the
power max. switch ON.
205FO5263
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF
WORK EQUIPMENT
* If there is any hydraulic drift in the work equip-

ment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
1. Checking for defective cylinder packing

I) Checking boom and bucket cylinders
i) Set in the same posture as when PC200: 1,260 kg (. 1
measuring hydraulic drift, and stop the PC220: 1,620 kg -7
r
engine.
ii) Operate the boom control lever to
205FO5264
RAISE or the bucket control lever to
CURL.
l If the lowering speed increases, the
packing is defective.
l If there is no change, the holding
valve (boom) or the control valve
(bucket) is defective.
2) Checking arm cylinder
i) Operate the arm cylinder to move the
arm in fully, then stop the engine.
ii) Operate the arm control lever to IN.
l If the lowering speed increases, the
packing is defective.
205FO5265
l If there is no change, the control
valve is defective.
* If the pressure in the accumulator has been
lost, run the engine for approx. 10 seconds
to charge the accumulator again before
operating.
[Reference1
If the cause of the hydraulic drift is in the
packing, and the above operation is carried
out, the downward movement becomes
faster because of the following reasons.
I) If the work equipment is set to the above 3) When the pressure is balanced, the down-
posture (holding pressure applied to the ward movement becomes slower. If the
bottom end), the oil at the bottom end leaks lever is then operated according to the
to the head end. However, the volume at the procedure given above, the circuit of the
head end is smaller than the volume at the head end is opened to the drain circuit (the
bottom end by the volume of the rod, so the bottom end is closed by the check valve),
internal pressure at the head end increases so the oil at the head end flows to the drain
because of the oil flowing in from the circuit and the downward movement be-
bottom end. comes faster.
2) When the internal pressure at the head end
increaes, the balance is maintained by a cer-
tain pressure (this differes according to the
amount of leakage) in proportion to it.
20-52
Checking boom holding valve
*y Set the work equipment at the maximum

reach, and the top of the boom horizon-
tal, then stop the engine.
Lock the work equipment control levers
and release the pressure inside the hy-
draulic tank.
1) Disconnect pilot hose (I) of the boom hold-
ing valve, and install a blind plug in the hose.
* Blind plug: 07376-50315
* Leave the holding valve end open.
2) Start the engine, charge the accumulator,
then stop the engine.
3) Operate the boom control lever to the
LOWER position.
* If any oil leaks from the port that is left
open, the holding valve is defective.
Checking PPC valve

If the hydraulic drift differs when the safety
lock lever is in the LOCK or FREE position,
(engine running), the PPC valve is defective.
20-53
BLEEDING AIR
Procedure for bleeding the air
Air bleeding item Air bleeding procedure
Bleed air from Bleed air from Bleed air from Bleed air from
Start operations
Neutral of work travel motor
l Charge hydraulic oil

l Clean strainer ’ + o + ’ + ’ (Note? ’ (Not$+ ’
I
l Replace return filter element 0 > 0
I
l Replace or repair pump
l Remove suction piping
* Replace or repair control valve
- Replace cylinder
l Remove cylinder piping 0 J+ 0 ) 0
I
l Replace Swing motor
l Remove swing motor piping 0 -0 -0
. Replace travel motor or swivel
l Remove travel motor or swivel 0 ) 0 + 0
piping
Note: Bleed the air from the swing and travel motors only when the oil inside the motor case
has been drained.
1. Bleeding air from pump

I) Loosen air bleed plug (II, and check
that oil oozes out from the plug.
2) When oil oozes out, tighten plug (I).
m Plug: 1.75 * 0.25 kgm
* If oil does not ooze out from the air
bleed plug:
3) Leave plug (I) loosened, then remove
hose (2) and elbow (3).
4) Add oil through the elbow mounting
hole until oil comes out from plug (I 1.
5) Fit elbow (31, install hose (2).
6) Tighten air bleed plug (I 1.
m Plug: 1.75 f 0.25 kgm
* Precautions when starting the engine
When starting the engine after carrying
out the above operation, run at low
idling for 10 minutes.
* If the water temperature is low and
warming-up operation is carried out,
cancel the automatic warming-up with
the fuel control dial after starting the
engine.
2. Bleeding air from cylinders
1) Start the engine and run it at low idling
for approx. 5 min.
2) Run engine at low idling, and raise and
lower boom 4 - 5 times in succession.
* Stop the piston rod approx. 100
mm before the end of the stroke. Do
not relieve the circuit.
3) Run the engine at full throttle and repeat
Step 2). After this, run the engine at low
idling and operate the piston rod to the
end of its stroke to relieve the circuit.
4) Carry out the procedure in Steps 2) and
3) for both the arm and bucket cylinders.
* If the hydraulic cylinder has been re-

placed, it is better to bleed the air be-
fore connecting the work equipment
again.
(In particular, for the LOWER end of
the boom cylinder, if it contacts the
boom, the cylinder cannot be operat-
ed to the end of its stroke.)
3. Bleedina air from swing motor I 1

I) Run the engine at low idling, loosen air
bleed plug (41, and check that oil oozes
out from the plug.
* If oil does not ooze out from the air
bleed plug :
2) Stop the engine, and fill the pump case
with oil through plug (4).
3) Tighten air bleed plug (4).
w Plug: 17.0 + 2.0 kgm
4. Bleeding air from travel motor

I) Run the engine at low idling, loosen air
bleed plug (51, and if oil flows out, tight-
en the air bleed plug again.
w Plug: 0.9 f 0.1 kgm
s 205FO5608
sr If the piping between the hydraulic cylinder and
the control valve is disconnected, remove the
remaining pressure from the circuit as follows.
The travel circuit is an open circuit, so there is
no remaining pressure. It is enough to remove
the oil filler cap.
1. Loosen the oil filler cap slowly to release the
pressure inside the tank.
2. Operate the control levers.
t When the levers are operated 2 - 3 times,
the pressure stored in the accumulator is
removed.
3. Start engine, run at low idling for approx. 5 mi-
nutes, then stop the engine and operate the
control levers.
+ Repeat the above operation 2 - 3 times to
release all the remaining pressure.
TROUBLESHOOTING
Points to remember when troubleshooting. ................................. .. 20- 58

Sequence of events in troubleshooting ..................................... . 20- 59
Precautions when carrying out maintenance ................................ .. 20- 60
Checks before troubleshooting ............................................ . 20- 67
Electrical circuit diagram .................................................. . 20- 68
Position of connectors for troubleshooting ................................. . 20- 72
Connection table for connector ............................................ . 20- 90
Explanation of functions of control mechanism of electrical system ........... . 20- 98
Display method for monitor panel, pump controller and engine throttle controller .. 20-I 01
Action of self-diagnostic function and symptoms on machine ................ . 20- 105
Method of ,using judgement table .......................................... . 20- 108
Method of using troubleshooting charts .................................... .. 20-I 10
Troubleshooting of engine throttle controller system ................
(E mode) .. 20-I 13
Troubleshooting of pump controller system (C mode) ....................... .. 20-I 39
Troubleshooting of pump controller input signal system (F mode) ............. .. 20-I 69
Troubleshooting of hydraulic and mechanical system (H mode) ............... .. 20-I 81
Troubleshooting of monitor system (P mode) ............................... .. 20-213
20-57
0
POINTS TO REMEMBER WHEN TROUBLESHOOTING
a l Stop the machine
securely fitted.
in a level place, and check that the safety pin, blocks, and parking brake are
l When carrying out the operation with two or more workers, keep strickly to the agreed signals,
and do no allow any unauthorized person to come near.
l Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
l When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
*A,o When removing the plug from a location which is under pressure from oil, water, or air, always
4 release the internal pressure first. When installing measuring equipment, be sure to connect it
properly.
l The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs
swiftly, and to prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the struc-
ture and function. However, a short cut to effective troubleshooting is to ask the operator vari-
ous questions to form some idea of possible cases of the failure that would produce the report-
ed symptoms.
1. When carrying out troubleshooting, do not 3) Check the travel of the control levers.
hurry to disassemble the components. 4) Check the stroke of the control valve
If components are disassembled immediate- spool.
ly any failure occurs: 5) Other maintenance items can be
l Parts that have no connection with the checked externally, so check any item
failure or other unnecessary parts will that is considered to be necessary.
be disassembled. 4. Confirming failure
l It will become impossible to find the l Confirm the extent of the failure your-
cause of the failure. self, and judge whether to handle it as a
It will also cause a waste of manhours, real failure or as a problem with the
parts, or oil or grease, and at the same time, method of operation, etc.
will also lose the confidence of the user or * When operating the machine to re-
operator. enact the torubleshooting symp-
For this reason, when carrying out trou- toms, do not carry out any investiga-
bleshooting, it is necessary to carry out tion or measurement that may make
thorough prior investigation and to carry the problem worse.
out troubleshooting in accordance with the 5. Troubleshooting
fixed procedure. l Use the results of the investigation and
2. Points to ask user or operator inspection in Items 2 - 4 to narrow
I) Have any other problems occured apart down the causes of failure, then use the
from the problem that has been troubleshooting flowchart to locate the
reported? position of the failure exactly.
2) Was there anything strange about the * The basic procedure for troublesh-
machine before the failure occurred? ooting is as follows.
3) Did the failure occur suddenly, or were 1) Start from the simple points.
there problems with the machine condi- 2) Start from the most likely points.
tion before this? 3) Investigate other related parts or
4) Under what conditions did the failure information.
occur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before l Even if the failure is repaired, if the root
the failure? cause of the failure is not repaired, the
When were these repairs carried out? same failure will occur again.
6) Has the same kind of failure occurred To prevent this, always investigate why
before? the problem occurred. Then, remove the
3. Check before troubleshooting root cause.
I) Check the oil level.
2) Check for any external leakage of oil
from the piping or hydraulic equipment.
20-58
SEQUENCE OF EVENTS IN TROUBLESHOOTING
a Jobsite
\
step 1
[Examination. confirmation of symptoms 1
1) When a request for repairs is received,

first ask the following points. Ring! Ring!
--------
* Name of customer
----____ 3
’ Type. senal number
of machine
. Details of jobsite, etc.
2) Ask questions to gain an outline of the
problem.
+ Condition of fallure
’ Work being carried out at the time
of the failure
’ Operating environment
’ Past hlstory, details of maintenance,
etc.
step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
ca”SeS
step 3
[Preparation of troubleshooting tools]
Look at the table of troubleshooting tools

in the shop manual and prepare the
necessary tools.
* T-adapter
* Hydraulic pressure gauge kit, etc.
Look in the parts book and prepare the
* Decide action to take
necessary replacement parts.
1) Before starting troubleshooting, locate and
repair simple failures. n 0,
* Check before starting items
* Other check items
2) See the Troubleshooting Section of the
shop manual, select a troubleshootinq
flowchart that matches the symptonx. and
carry out troubleshooting_
Step 6
Reenacting failure
I f Driveand operate the machine to confirm
the condition and judge if there is really a
failure I
20-59
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine

over a long period, and to prevent failures or
other troubles before they occur, correct opera-
tion, maintenance and inspection, troubleshoot-
ing, and repairs must be carried out. This section
deals particularly with correct repair procedures
for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sec-
tions on “Handling elecric equipment” and
“Handling hydraulic equipment” (particlularly
hydraulic oil).
1. PRECAUTIONS WHEN HANDLING

ELECTRIC EQUIPMENT
I) Handling wiring harnesses and

connectors
Wiring harnesses consist of wiring connect-
ing one component to another component,
connectors used for connecting and discon-
necting one wire from another wire, and
protector or tubes 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 vi-
bration. Furthermore, during inspection and
repair operations they are frequently re-
moved and installed again, so they are likely
to suffer deformation or damage. For this
reason, it is necessary to be extremely care-
ful when handling wiring harnesses. F20505201
Main failures occurring ir! wiring harm-

(1) Defective contact of connect&
(defective contact between male and
female)
Problems with defective contact are ‘Improper insertion
likely to occur because the male connec-
tor is not properly inserted into the
female connector, or because one or
both of the connectors is deformed or
the position is not correctly aligned, or
because there is corrosion or oxidization
of the contact surfaces. F20505202
20-60
(2) Defective compression or soldering of
Improper compression
connectors
The pins of the male and female
connectors are in contact at the
compressed terminal or soldered
portion, but there is excessive force on
the wiring, and the plating peels to F56103079
cause improper correction or breakage.
(31 Disconnections in wiring

If the wiring is held and the connectors
are pulled apart, or components are
lifted with a crane with the wiring still
connected, or a heavy object hits the
wiring, the compression the of
connector may be lost, or the soldering
may be damaged, or the wiring may be
broken.
(4) High pressure water entering connector

F2050520A
The connector is designed to make it
difficult for water to enter (drip-proof
structure), but if high-pressure water is
sprayed directly on the connector,
water may enter the connector depend-
ing on the direction 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 diffi-
cult for it to be drained. Therefore, if
water should get into the connector, the
pins will be short-circuited by the water,
so if any water gets in, immediately dry
F20505205
the connector or take other appropriate
action before passing electricity
through it.
(5) Oil or dirt stuck to connector

If oil or grease are stuck to the connec-
tor and an oil film is formed on the
mating surface between the male and
female pins, the oil will not let the elec-
tricity pass, so there will be defective
contact.
If there is oil or grease or dirt stuck to
the connector, wipe it off with a dry
cloth or blow dry with air, and spray it
with a contact restorer.
* When wiping the mating portion of
the connector, be careful not to use
excessive force or deform the pins. F20505206
20-61
0
* If there is water or oil in the air, it
will increase the contamination of
the points, so clean with air from
which all the water and oil has been
removed.
2) Removing, installing, and drying connec-

tors and wiring harnesses
Disconnecting connectors
(I) Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors and not the wires. Lock
For connctors held by a screw, loosen
the screw fully, then hold the male and
female connectors in each hand and pull v F20505207
apart. For connectors which have a lock
stopper, press down the stopper with
your thumb and pull the connectors
apart.
(2) Action to take after removing

connectors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
F20505208
Connecting connectors
(I) Check the connector visually.
a. Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portionI.
b. Cherr. that there is nn ~dwcoa~~,?~,
defective contact, corrosion, or
damage to the connector pins.
c. Check that there is no damage or
breakage to the outside of the
connector.
* If there is any oil, water, or dirt stuck
to the connector, wipe it off with a
dry cloth. If any water has got inside
the connector, warm the inside of
the wiring with a dryer, but be care-
ful not to make it too hot as this will
cause short circuits.
* If there is any damage or breakage,
replace the connector.
20-62
(2) Fix the connector securely.
Align the position of the connector cor-
rectly, then insert it securely.
For connectors with lock stopper
Push in the connector until the stopper
clicks into position. Cliks into position
(3) Correct any protrusion

any misalignment
of the boot and
of the wiring hanress
II F20505209
For connectors fitted with boots, correct

any protrusion or the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.
* When blowing with dry air, there is
danger that the oil in the air may
cause improper contact, so clean
with air from which all the water
and oil has been removed.
I I F20505210
Drying wiring harness
If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
(I) Disconnect the connector and wipe off
the water with a dry cloth.
+ If the connector is blown dry with
F20505211
air, there is the risk that oil in the air
may cause defective contact, so
avoid blowing with air.
(2) Dry the inside of the connector with a

dryer.
If water gets inside the connector, use a
dryer to dry the connector.
Ir Hot air from the dryer can be used,
but be careful not to make the
connector or related parts too hot,
as this will cause deformation or
damage to the connector.
F20505212
2043
0
(3) Carry out a continuity test on the
connector.
After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits be-
tween pins caused by water.
* After completely drying the connec-
T-adapter
tor, blow it with contact restorer
and reassemble.
\\\’
F20505213
3) Handling control box

(I) The control box contains a micro-
computer and electronic control circuits.
These control all of the electronic cir-
cuits on the machine, so be extremely
careful 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 con-
trol box.
F20505214
z
(4) Cover the control connectors with tape _
0
or a vinyl bag. z
(5) During rainy weather, do not leave the
control box in a place where it is ex-
posed to rain.
(6) Do not place the control box on oil,
water, or soil, or in any hot place, even
for a short time. (Place it on a suitable
dry stand)
(7) Precautions when carrying out arc
welding
When carrying out arc welding on the
body, disconnect all wiring harness F20505215
connectors connected to the control
box. Fit an arc welding ground close to
the welding point.
F20505216
20-64
2. POINTS TO REMEMBER WHEN
HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of

hydraulic equipment, the most common cause
of failure is dirt (foreign material) in the hydrau-
lic cirucit. When adding hydraulic oil, or when
disassembling or assembling hydraulic equip-
ment, it is necessary to be particularly careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters,
or repairing the machine in rain or high
winds, or places where there is a lot of dust.
21 Disassembly and maintenance work in

the field
If disassembly or maintenance work is car-
ried out on hydraulic equipment in the field,
there is danger of dust entering the equip-
ment. It is also difficult to confirm the per-
formance after repairs, so it is desirable to
use unit exchange. Disassembly and mainte-
::
z nance of hydraulic equipment should be car-
cv ried out in a specially prepared dustproof
0
workshop, and the performance should be
confirmed with special test equipment.
F20505217
3) Sealing openings
After any piping or equipment is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left
open or is blocked with a rag, there is
danger of dirt entering or of the surrounding
area being made dirty by leaking oil so
never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose
of it, or take it back with you for disposal. F20505218
41 Do not let any dirt or dust get in during

refilling operations.
Be careful not to let any dirt or dust get in
when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil con-
tainers. If an oil cleaning device is used, it is
possible to filter out the dirt that has collect-
ed during storage, so this is an even more
effective method. F20505219
20-65
5) Change hydraulic oil when the tempera-
ture is high.
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can also
be drained out easily from the circuit togeth-
er with the oil, so it is best to change the oil
when it is still warm. When changing the oil,
as much as possible of the old hydraulic oil
must be drained out. (Do not drain the oil
from the hydraulic tank; also drain the oil
from the filter and from the drain plug in the
circuit.) If any old oil is left, the contaminants
and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the
equipment, or changing the oil, use flushing
oil to remove the contaminants, sludge, and
old oil from the hydraulic circuit.
Normally, flushing is carried out twice: pri-
mary flushing is carried out with flushing
oil, and secondary flushing is carried out
with the specified hydraulic oil.
F20505220
7) Cleaning operations
After repairing the hydraulic equipment
(pump, control valve, etc.) or when running
the machine, carry out oil cleaning to
remove the sludge or contaminants in the
hydraulic oil circuit.
The oil cleaning equipment is used to
remove the ultrafine (about 34 particles
that the filter built into the hydraulic equip-
ment cannot remove, so it is an extremely
effective device.
F20505221
20-66
CHECKS BEFORE TROUBLESHOOTING
(1. Checks before starting, 2. Other check items)
T Item
Judgement
standard
Remedy
1. Check fuel level - Add fuel
2. Check for dirt or water in fuel Clean, drain
3. Check hydraulic oil level - Add oil
4. Check hydraulic oil strainer - Clean, drain
5. Check swing machinery oil level Add oil
6. Check engine oil level (Level of oil in oil pan) - Add oil
7. Check cooling water level - Add water
8. Check condition of dust indicator Clean or replace
9, Check for loose or corroded battery - Tighten or replace

terminals
Check for loose or corroded alternator
IO. Tighten or replace
terminals
, ,. Check for loose or corroded starting motor
Tighten or replace
terminals
12. Check for abnormal noise or smell - Repair
13. Check for oil leakage - Repair
14. Bleed air from system - Bleed air
15. Check battery voltage (engine stopped) 20 - 3OV Replace
16. Check level of battery electrolyte - Add or replace
17. Check for discolored, burnt, or bare wiring Replace
1 8. Check for missing wiring clamps, hanging - Repair

wires
Checks for water leaking onto wiring Disconnect

19. (check carefully water leakage at connector: connector and
and terminals) dry connection
20. Check for broken or corroded fuses - Replace
21. Check alternator voltage

27.5 - 29.6V Replace
(engine running at over half throttle)
22. Noise when battery relay is operated
Replace
(switch starting switch from on to off)
20-67
ELECTRICAL CIRCUIT DIAGRAM
ENGINE THROTTLE CONTROLLER SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 48283

PC220,22OLC-5 Serial No: 35001 - 35447
Starting switch
Fuse
0.85GY
0.85WR
I
(NSl20)
I Battery relay
Ml468)
1
Governor motor
controller
E6(M3) Fuel control dial
l--In PC200 only
“.Jvv
-I- 5 Power set a
0.518 6
__._.
__._ _____ Power set b
Auto-deceleration \ ,.; 0.5L
0.5w
0.5L
0.5LW .
7 Auto-deceleration
Throttle (+I ~ 8 Working mode a
r\ GWD 05G g
Working mode b
Coolant 102’C signal

Coolant 107’C signal
16 \GND
--
PC200,2OOLC-5 Serial No: 48284 - 58018
PC220,22OLC-5 Serial No: 35448 - 36613
Starting switch
starting motor Alternator
Governormotor
Fuel control dial
p&
3
205FO5757
Starting switch
Fuse
M37CMI) M38L2)
2WR
Fusible link
0 85GY IOA 2 5WR
Iti- I
608
Fusible link
Banery relay
DIO
2
%,b
E6CM3
Kerosene mode
--A
205FO5757
20-&O
PUMP CONTROLLER SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 49706

PC220,22OLC-5 Serial No: 35001 - 35661
1 tuse “&,
Swing lock switch
l-l
M6EIO)
Arm half flow
L-stage relief CO
T"C prolix cancel solenoid valve
reslstor
L-ITilw
Travel speed
) solenoid valve
_
_
_
_
_
_
_
_
_
_
_
_
-izing swit .h
PC200,2OOLC-5 Serial No: 49707 - 58018
PC220,22OLC-5 Serial No: 35662 - 36613
Swing lock Battery (NSl20)

Battery relay
prolix switch
Fusible link
D9
M3(Sl6)
r-i&J 2-stage relief . CO
/e
r
I I I I I I I I '-IL1 Travel weed
Swing brake
solenoid valve
I Enqine throttle controller
-I -_-
Monitor panel
J
B switch
_- I I
I
1,
Engine speed sensor
20-&2
Swing lock Battery (~~120)

prolix switch
Swing lock switch r-----l I I
’ I M6(SIO)
IllI/
IIIII
-85-l Arm half flow
solenoid valve
Z-stage relief . CO
V7(X2) cancel solenoid valve
I I I L\ Travel soeed
V2(X2) solenoid valve
Swing brake
Engine throttle controller

I-1
i 4 0.5GW I I I I I I I I I I I-I
05w
5 nK,L1 Monitor panel
1
Power maximizing switch
Engine speed sensor

..”,.”,“._,,, 8YR
tiaunmi+r, 8 0.5GR
205FO5761B
MONITOR SYSTEM
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
Service meter
M7lL2) Mll(L2)
WR w/R
Wlper motor
J g motor
Alternator
Light
relay
air heater
Heater
Engine oil level sensor
Hi relay P5(Xl)
Heater
III Overload
warnmq dewce
I
P7(x2j Coolant temperature sensor
Lo relay r-1
L!.rr!i
Wiper III Engine oil pressure sensor
relay
oo,y~~ Coolant level sensor
Tl I i IIIIIII P6IXI)
is I I
Pump controller
I
R
r-1
P4(M2) B:dy
earth
Warn-T
Startina switch
Window washer
R.H. head lamp
205FQ5705
Service meter
_
Wiper motor IYCEA,
D3
Light
relay
intakel
Heater
II Electrical
air heater
Hi relay P5(X,) Engine oil level sensor
R2
Heater P7(X2) Coolant temperature sensor
Lo relay r-1
Overload warning device l.T?_i
y-1
Engine oil pressure sensor
Wiper _
relay
-
Fuel level sensor
P6(XI) r-2--
Pump controller
-_-
05GW I ]
0%” Engine loom lamp
ZsLp 1.258
Startinq switch c
Window washer
T@ Boom lamp
R.H.
head lamp
205FO5763
POSITION OF CONNECTORS FOR TROUBLESHOOTING
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
I-
C
air conditioner
No. o M TYPE CONNECTOR
pins
Male connector Female connector
205FO5317 205FO5318
i
205FO5319 205FO5320
205FO5321 205FO5322
1 3
el
205FO5323 205FO5324
20-9 1
0
No. o f T M TYPE CONNECTOR
pins Male connector Female connector
1 4
ci 6 6 3
205FO5325 205FO5326
20-92
No. ( S TYPE CONNECTOR
pin:
205FO532: 205~05328
6 1
10
h I
205FO5329
12
! s’ i
205FO533’
l$ 5 205FO5332
16 7 8 1
16
1; Ii
205FO5333 205FO5334
20-93
No. o fl AMP040 TYPE CONNECTOR
pins
16
i il
205FO5335 205FO5336
\ w
20
i il 1’1 i
205FO5337 205FO5338
20-94
No. cIf I SWP TYPE CONNECTOR
pins
1 4 1
\ ! \
6 II
/ \ H
3 6 6 3
205FO5339 205FO5340
4 8 8 i
205FO5341 205FO5342
20-95
No. o fl MIC CONNECTOR
pins Female connector Male connector
205FO5343 205FO5344
.I7
142F414 142F415
21
142F416 142F417
20-96
No. of 1 X TYPE CONNECTOR
205FO5309 205FO5310
205FO5311 205FO5312
205FO53 13 205FO5314
205FO53 15 205FO5316
HANDLING CONNECTORS
1. When removing the connectors from the

clips, pull the connector in a parallel direc-
tion to the clip.
* If the connector is twisted to the left
and right or up and down, the housing
may break.
205FO5609
I 205FO5610
2. When disconnecting male and female

connectors, release the lock and pull in
parallel with both hands.
Ir Never try to pull out with one hand.
205FO5611
3. When the wiring harness clamp of the

connector has been removed, always return
it to its original condition and check that
there is no looseness of the clamp.
205FO5612
20-27-l
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM
OF ELECTRICAL SYSTEM
This section gives the functions and details of checks for the monitor panel, pump controller, and
engine throttle controller needed to carry out troubleshooting of the electrical system.
1. Explanation of functions
The control mechanism for the electrical system consists of the monitor panel, pump controller,
and engine throttle controller. It carries out control by changing the absorption torque of the pump
(power mode) or by changing the output of the engine (working mode).
Monitor panel and both the controllers i) each input the necessary signals, and ii) combined with
the signals selected by the monitor panel, the controllers input and output the necessary signals to
control the absorption torque of the pump and the engine output.
l Input and output signal system of monitor panel and both controllers (Fig. I)
PC200,2OOLC-5 Serial No: 45001 - 49706

PC220,22OLC-5 Serial No: 35001 - 35661
Monitor panel
r 3
Eng,ne 011level
Worktng mode watch signal
-A CL
Power mode swatch slgnal
@
Swng Oli
pressure swtch
@
Travel 011
pressure switch
@
Pump
pressure sensor
Power max
swtch signal
Engine
throttle ~
controller L
205F05345A
The pump controller and engine throttle controller have a self-diagnostic display function and if any
electrical abnormality (disconnection, contact with ground, internal short circuit, or short circuit be-
tween wires) occurs in the output signals (input signal for the receiving controller) for numbers 0 -
@ in Fig. 1, the content of the abnormality is displayed.
l If 01 - 09, or 25 are displayed (if a short circuit or other fault causes a current above the
specified level to flow to the controller, the controller stops the operation of that system).
l If 1 1 - 28 are displayed, there is a disconnection (the operation of that system stops) or there
is contact of the No. 2 pin of the solenoid with the ground (the solenoid continues to operate).
Even if there is any abnormality in the input signal system for @ - 0, the abnormality is not displayed
in the display area, but the pump controller has a built-in monitor function to check the input signals.
The controller starts to work only when there is an input signal, and it gives a display on the display
panel.
Therefore, when investigating if the cause is in the electrical system or in the hydraulic or mechanical
system in the case of “There is no abnormality display on the display panel, but there is an abnormality
in the movement of the unit”, the first step when carrying out troubleshooting is to use the method of
checking the operation of the electrical systm in Item 2 to check if the necessary signal is being output
to the pump controller correctly.

Monitor panel
c
1_- _”.=..
_.
Coolant temperaf”re
107”C/105”C signal (Note)
AutomaW
wamxng-up signal
c J
,’ -I
,’
Swng lock sagnal
i
205F05714
Note:
107°C signal PC200, 2OOLC-5 Serial No.: 49707 - 58018 105°C signal PC200, 2OOLC-5 Serial No.: 58019 and up
PC220, 22OLC-5 Serial No.: 35662 - 36613 PC200,2OOLC-5 MIGHTY
PC220, 22OLC-5 Serial No.: 36614 and up
20699
2. Checking operation of electrical system
When the Set of operations given below is carried out in the order given, and the action of the
monitor panel, pump controller, and engine throttle controller are as given in the table, the monitor
panel (EMACCI and both the controllers are normal.
c The IH.1./ and other displays given in the table are the monitor displays given by the controller if
the input and output signals are normal.
o The monitor display of the pump controller is displayed for 1.5 seconds after the signal is
input, and after that the operaton mode is displayed.
c For items 0, 0, and ‘0, the system automatically enters the auto-deceleration mode, so set
the auto-deceleration switch on the monitor panel OFF.
PC200,2OOLC-5 Serial No: 45001 - 49706 PC220,22OLC-5 Serial No: 35001 - 35661
Operation procedure and condition of Items for confirmation (when normal)

machine Monitor panel Pump Controller Engine throttle controller
* Turn starting switch OFF.

\I: All lamps OFF All lamps OFF All lamps OFF
* Turn fuel control dial to MlN
Display lamps light up

2_’ Turn starting switch ON. G.0 and S mode is a is displayed
display
start engine
If coolant temperature is below 30°C. After 5 s?c. normal display
3‘ +
carry out automatx warming up and 10 l (\ is displayed
[Operating model
increase engine speed.
Decimal pant flashes
. Turn fuel control dial to MAX

Engme speed rises (fuel
Raise engine speed I” FULL speed of
4 control dial, governor
G.0 mode.
potentiometer systems normal1
. Set auto-deceleratlo” swtch OFF
* Set working mode to H.0 mode

Raise engine speed from FULL speed of
- :~,:,“~y~,“““’ m is displayed ~i+~~~~~~~~t!$ 2
5, G.0 mode to FULL speed of H.0 mode.
( Set auto-deceleratlo” switch OFF
. Set working mode to L.0 mode
6‘ Lower engine speed from FULL speed - Ldi~p~~~e~mode ‘* j:_.‘-:l is displayed ~[~{;~~~:~I?~~:? 2
of H 0 mode to FULL speed of L.0 mode.
* Set working mode to G 0 mode

Raise engine speed from FULL speed of
3 rises agal” ,IUO
7‘ pal system
L.0 mode to FULL speed of G 0 mode
* Set auto-deceleration swtch OFF
8, Press
- power marimwng swatch
Travel speed Hi -Lo

‘!$ Swtch travel speed swtch between HI and Lo )
IS dlsplayed 11 - 1.5 secl
: Opfyk equip-_
Cancel deceleration and raise engine
Operate work equpment lever, and move

sw,ng lever slightly to left and right. m Isdisplayed 1
Switch auto-decelerat!on switch ON.
Iz Engine speed drops to deceleration

speed after a few seconds.
I I
____ Swing lock lamp OFF

@ Switch swing lock switch ON and OFF.
. and ON is displayed
@ Operate travel lever slightly. 4
jj)
Return fuel control dial to MIN
Engine speed drops to low idling. H I Engine speed drops (fuel
control dial system normal)
Engine stops
@ Turn starting switch OFF.
(battery relay system normal)
I
Operation
machine
procedure and condition of
1 Monitor panel
Items for confirmation
1 Pump controller
(when normal1

7
* Turn starting switch OFF
;I; All lamps OFF All lamps OFF
* Turn fuel control dial to MIN.
Display lamps light up pc200,G vll isdisplaved

$ Turn starting switch ON G.0 and S mode IS j is displayed PC220~~a (model displayed
display for 5 set)
Start engine
If coolant temperature IS below 30°C. After 5 sec. normal disblay
9
carry out automatic warming up and &I= is displayed
[Operating model
increase engine speed.
Decimal point flashes
. Turn fuel control dial to MAX.

Engine speed rises (fuel
Raiseengine speed in FULL speed of
n control dial, governor
G.0 mode I-4
. Set auto-deceleration switch OFF potentiometer systems normal
* Set working mode to H.0 mode

Engine speed rise (No. 2
Raise engine speed from FULL speed of H.0 and H mode
3 m 1s displayed throttle signal system
G 0 mode to FULL speed of H.0 mode. IS dIsplayed
normal1
* Set auto-deceleration switch OFF
. Set working mode to L 0 mode Engine speed drops (No. 2

L.0 and L mode 15
Lower engine speed from FULL speed -+ :_.‘-:/ is dIsplayed throttle signal system
B displayed
of H.0 mode to FULL speed of L.0 mode. normal)
* Set working mode to G.0 mode

Engine speed rises again (No.
Rae engme speed from FULL speed of G 0 and S mode
a 2 throttle signal system
L.0 mode to FULL speed of G 0 mode. is displayed
normal)
* Set auto-deceleration switch OFF.
D Press power maximizing switch

I 1
Travel speed Hi -Lo

!$ Switch travel speed switch between HI and LO
is displayed
Operate work equipment or swng levers

B Cancel deceleration and raise engine
speed.
Switch auto-deceleration switch ON

Deceleration is
B Engine speed drops to deceleration
displayed
speed after a few seconds
I
Swing lock lamp OFF

@ Switch swng lock switch ON and OFF.
and ON is displayed
Return fuel control dial to MIN. Engine speed drops (fuel

control dial system normal)
Engine stops
Turn starting switch OFF.
(battery relay system normal)
20401
DISPLAY METHOD FOR MONITOR PANEL, PUMP
CONTROLLER AND ENGINE THROTTLE CONTROLLER
1. MONITOR PANEL
Approximately 2 seconds after the starting . Model code display
switch is turned ON, all monitor and gauge
lamps light up and the buzzer sounds for Model LEDs (Light Emitting Diodes)
approximately 1 second. This is the

Red Green Red
self-diagnostic function of the monitor
PC200 0 0 0
panel. After this, the display returns to OFF OFF ON
normal.
Red Green Red
PC220 0 0 0
2. ENGINE THROTTLE CONTROLLER OFF ON OFF
I) Model code display function (normal
display)
When the starting switch is turned ON,
the model code is displayed for approxi- Red Green Red
mately 5 seconds on the controller dis- Normal display 0 0 0
OFF ON OFF
play panel.
* After 5 seconds, the model code
display changes to the normal
display or the abnormal display
(self-diagnostic display).
Ir The display for the wrist control
type is the opposite (left becomes
right) of the display for the long
lever control type.
2) Self-diagnostic display (abnormal l Self-diagnostic display

display)
l The abnormal display consists of 3 Order of LEDs
Abnormal system
LEDs, and the ON/OFF combination priority (Light Emitting Diodes)
of these displays the type of Red Green Red

Power source system
abnormality (abnormal system). 1 0 0 0
or controller sytem
. If two or more abnormalityes occur OFF OFF OFF
at the same time, the abnormalities Red Green Red Short circuit in
are displayed in the order of priority 2 0 0 0 governor motor
shown in the table on the right. ON OFF ON system
l Once the starting switch is turned Red Green Red

Short circuit in
OFF, the self-diagnostic display is 3 3 0 0
battery relay system
reset. OFF OFF ON
Check the abnormal display with Red Green Red Disconnection in

the starting switch ON. 4 0 c‘ k-j governor motor
ON OFF OFF system
0 When the abnormality is removed,
the display is automatically reset, so Red Green Red Abnormality In gover-
nor motor potentiomete
if the abnormality occurs intermit- 5 0 0 0 sytem, or motor is
tently, the abnormal display and OFF ON ON step out
normal display will appear alternate- Red Green Red

Abnormality in fuel
ly, and the display may appear to be 6 0 0 0
control dial system
ON ON ON
flashing.
Red Green Red
Abnormaltiy in No. 2
7 0 0 0
throttle signal system
ON ON OFF
*O-io2
3. PUMP CONTROLLER
I) Model code display function (normal l Model code display
display)
When the starting switch is turned ON,
the model code is displayed for approxi- mi
mately 0.5 seconds on the controller

display panel.
l Operation mode display

2) Operation mode display function
(normal display) Power set
The operation mode is displayed unless selection system Working mode selection system
there is any change or abnormality in

the input or output system for the pump
mi
controller on controller.
Power source Engine speed signal monitor

monitor
When engine speed signal is
Lights up when
input
power is ON
Flashes
(At 2,000 rpm, approx.
20 times/l 0 set)
3) Input signal display function (normal l Input signal display

display) input signal Code Displa!
When the input signal to the controller Travel speed switch Lo - Hi Hi !I-:. t
is switched, the input signal is displayed Travel speed switch Hi - Lo Lo !I- .cI
for approx. 1 - 1.5 sec. r\ t
Auto-deceleration switch OFF - ON Ad J-u2
* If it is not displayed, there is an
Swing lock switch OFF - ON bS !rB!3-
abnormality in the input signal
Work equipment oil pressure switch
system. OFF - ON P., 17 ,
PCZOO, 200LC-5 No.: 45001 - 49706 .I-. %
Sr After the input signal is displayed
I PC220,220LC-5 No.: 35001 - 35661 I
for 1 - 1.5 set, the display
Swing oil pressure switch
changes to the operation mode PCZOO, 2OOLC-5 No.: 45001 - 49706
display. b C220, 22OLC-5 No.: 35001 - 35661 I
OFF - ON
Work equipment . swing oil
pressure switch
PC200,200LC-5 No.: 49707 and up
1PC220,22OLC-5 No.: 35662 and up 1
Service oil pressure switch 1, 2 OFF - ON
Travel oil pressure switch OFF - ON
Power max. switch OFF - ON UP \ I 1-t

.u.r
Free swing FS :--- .IJ
*O-iAo3
4) Self-diagnostic display function (abnor-
mal display)
l If there is any abnormality in the
controller output signal system and
sensor system, the abnormal display
and operation mode display are
shown alternately.
+ If two or more abnormalities
occur at the same time, all of the
abnormality displays and opera-
tion mode display are shown in
Short circuit in 2
turn.
. If 01 - 09, 25 are displayed, there
is danger that the controller may be
broken, so the controller automati-
cally stops the output to the system
where the abnormality has occurred.
l Once the starting switch is turned
OFF, the abnormal display is reset,
so check with the starting switch
ON.
Ir If the starting switch is turned
OFF, re-enact the abnormal dis-
play as follows.
n System
Turn the starting switch ON.
0 System
Turn starting switch ON
(Engine stopped) and oper-
No. 2 throttle signal system
ate the control lever.
n System
Start the engine and operate
the control lever
l If no signal comes from the engine
speed sensor (engine stopped,
defective clearance at sensor, etc.).
the central decimal point does not
flash.
I Example of display
a) H.0 and H mode when normal
b) Same as a) but “throttle signal

system abnormal”
20- 104
0
POSITION OF SELF-DIAGNOSTIC DISPLAY FOR EACH CONTROLLER
For engine throttle controller

For pump contl
F20505400
0” TROUBLESHOOTING PROCEDURE WHEN ABNORMALITY OCCURS

::
c*l
0 Remedy
Go to troubleshooting for
2 YES
engine throttle controller
Does engine svstem
Engi throttle controller
give abnormal
display?
Problem in engine, mechani
Cal system
Is problem in en-
gine or hydraulic Go to troubleshooting for
system? pump controller system
I
Go to troubleshooting for H
Hydraulic
swtem
L
I Does pump con-

troller g,ve abnor-
mal display’
4 5 YEI
mode hydraulic and me-
chanical system
4
Go to troubleshooting for
applicalble item in C mode
Is monitor display f there is abnormality in
of pump controller
tern 12). (3), 15) - 17). (9J.
NO inputs;q~al
:121, (13)
I 1 Go to troubleshooting for
* See table for checkina NC applable Item in P mode
operation of electrical
system.
Note: Items (1). (4). (15).
(16) do not apply. If there is abnormality in 30 to troubleshooting for
Item (8). 11% 111). (141. Ppplicable (tern in F mode
20-ki?4-’
2. Judgement table for pump controller, hydraulic related parts
l If the self-diagnostic display gives an abnormal display, go to the troubleshooting code (C-c
c) given on the bottom line of the judgement table.
(There is a l given in the column where the failure mode and self-diagnostic display come
together.)
l For any problem where there is no abnormal display given by the self-diagnostic display, check
the chart for the place where the failure mode and input signal display come together (place
marked c).
If the display is normal, go to the troubleshooting code (H-c c) given in the column on the
right of the judgement table.
If the input signal is not displayed, go to the troubleshooting code (F-c c) given on the
bottom line.
<Example > Failure mode “Auto-deceleration does not work”
[Procedure]
Check if an abnormal display is given by the self-diagnostic display, or if the numbers on the side face
of the controller are flashing.
[J
If there is an abnormal display (for example, 28) on the self-diagnostic display:
Go to troubleshooting C-21 of the electrical syste !m.
If there is no abnormal display on the self-diagnostic display, and the auto-deceleration does not work:
Display given: .. ... .. ........... Go to troubleshooting of

I- hydraulic system H-7
l Check the monitor for the pu.mp --I
controller input signal
L No display given: ................ Go to troubleshooting of
electrical system Fl , 2,3, or 6
20- 109
METHOD OF USING TROUBLESHOOTING CHARTS
1. Category of troubleshooting code number
Troubleshooting
Component
Code No.
Troubleshooting of engine throttle

E_cccontroller system
Troubleshooting of pump controller

c-cc system
Troubleshooting of pump controller

F-CC
input signal system
Troubleshooting of hydraulic,
H-cc
mechanical system
P-G c ) Troubleshooting of monitor system
2. Method of using troubleshooting table

Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting code number and the prob-
lem with the machine.
Distinguishing condition
Even with the same problem the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the troubleshooting chart is further divided into sections
z
marked with small letters (for example, a)), so go to the appropriate section to carry out
0”
troubleshooting. CJ
0
If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item.
Method of following troubleshooting chart
Check or measure the item inside the box, and according to the answer follow either the
YES line or the NO line to go to the next box. (Note: The number written at the top right
corner of the box is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right.
Below the box there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the box are correct or the answer to the question
inside the box is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
Below the box is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item I).
General precautions
When using the troubleshooting chart, precautions that apply to all items are given at the top
of the page and marked with +. The precautions marked + are not given in the box, but must
always be followed when carrying out the check inside the box.
Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For
details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
20-110
0 Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection table, so when carrying out troubleshooting, see this chart for details of the
connector pin number and location for details of the connector pin number and locations for in-
spection and measurement of wiring connector number o o appearing in the troubleshooting
flow chart.
< Example >
o E_2 mi
[Short circuit in governor motor1 is displayed
@ (There are cases where the troubleshooting is divided into Sections a), b) etc.)
+ If this happens during operation, because of the force of the spring:
I) Engine speed changes to low idling
2) Engine does not stop
+ If the problem occured when the engine was stopped:
I) Engine starts but remains at low idling
2) Engine starts, but does not stop
A Stop the engine (place the fuel lever of the injection pump in the NO INJECTION posi-
tion) before carrying out any checks.
@ or Before carrying out troubleshooting, check that all the related connectors are properly
inserted.
Sr Always connect any disconnected connectors before going on to the next step.
2 YES
YE
t c
Short circuit in wiring
Red Green led
I* resistance be- harmx* for problem
l 0 0
tween each pin of
E5 (male),and
each pin-chassis
.T”rn starting
pEi;_NEOjj(between
‘See Fig. 7
El-
ON OFF ON snitch OFF.

as shown in Table i Disconnect El:
17
H
I .T”rn starting
switch OFF.
. Disconnect ES.
20-111
POINTS TO REMEMBER WHEN CARRYING OUT
TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER
SYSTEM
The engine on the PC200, 220 is controlled by an engine throttle controller.

The problems that may arise with this system are as follows.
1. Low idling speed in too high (low)

2. High idling speed is too low
3. Auto-deceleration speed is too high (low)
4. Automatic warming-up speed is too high (low)
5. There is hunting
6. Engine does not stop
If an abnormality occurs and the abnormality is displayed by the self-diagnostic display, use the charts
to go to the applicable troubleshooting flowchart G-l - G-7. However, if there is no self-diagnostic
display, and there is an abnormality in the machine, it is necessary to determine if the problem is in the
mechanical system or in the electrical system.
For example, if there is defective adjustment of the linkage between the governor motor and injection
pump, the above problems 1 - 6 may occur.
Therefore, if any of the above problems 1 - 6 occurs, carry out the following troubleshooting
procedure.
YES
_ 2 Defective adjustmenr of governor
dYES mofor linkage
1 Doeroperation
Of See TESTING AND ADJUSTING.
_ governor motor
Does condition beCOme normal
return to normal - when linkage
befwee” governor
when linkage motor and injeCtion
between governor pump is dirconnecred’ Go to troubleshooting of electrical
motor and sYstem E-9 - E-l 1.
NO
injection pump is _ . Set starting switch
di&onnected. and at ON p&ion and
pump governor operate fuel control dial
lever is operated and working mode switch.
by hand or is See Engine shop manual
secured with NO
I If the engine does

not stop. push the
governor lever to
the STOP position
and check if the
engine stops.
After disconnecting or adjusting the linkage as shown above, go to the troubleshooting flow chart for
the mechanical system or electrical system.
* For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
E-l I? %“?I [Abnormality in power source system or controller] is
displayed (All lamps OFF)
PC200,200LC-5 Serial No: 45001 - 48283
PC220,22OLC-5 Serial No: 35001 - 35447
When fuse 9 is not blown
(If it is blown, check for any short circuit with the ground in the circuit to the starting switch.)
If battery is normal.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
3 YES
I I I
Disconnect connect
YES tar El and replace
2- fuse 2. Does it blow
7 again’
YES
Repalce fuse 2. * Turn starting NO
. Does it blow again? - switch ON.
I I
. Turn starting
switch ON.
NO
7 YES
Is there continuity
YES between El
- (female1 (12) and -
!
gqotl
battery relay termi-
6 nal E?
9 Turn starting NO
Y ES Is voltage between swtch OFF.
El (21 and chassis - . Disconnect El.
I
normal7
8 YES
5 * 20 - 3ov
Is voltage between
* Turn starong
starting switch ter-
Is voltage between switch ON.
YES NO
minal BR and
- El (11 and El (12) . chassis normal?
normal?
. 20 - 3ov NO
* 20 - 3ov . Turn starting
. Turn starting switch ON.
4
switch ON.
Does working lamp NC

light up?
NO
* I urn stamng II YES

switch ON.
9s
Is voltage between
battery relay term,-
“al BR and chassis
NO 10 YES
normal’
- Is voltage between
* zo-3ov
L starting switch ter-
* Turn starting
NO minal BR and chas-
switch ON.
sis normal?
* 20 - 3ov NO
* Turn starting
switch ON.
M20lM4)
Starting switch MI(M~)
DIO
I ;
Engine thronle controller
EI(MlCZI)
FUX
Ml4681
Battery
relay I3
M7CL21 Battery relay Battery
BR; b +t-+/~/
774 F20505465
Remedy
Inspect, repair
Replace
Already reset
Defective enigne throttle

controller
Defective contact, 01
disconnection in wiring
Repair or
harness between El
reDlace
(female) (12) - Ml4 (8) -
chassis ground
Defective contact, Or
harness between El
(female) (‘2) - M20 - Ml (21
- starting switch terminal
BR
Defective starbng switch R+3W
Defecwe contact. or
harness between El
(female) 11) and fuse 2
Outlet
Defective battery relay Replace
Defective contact. or
harness between startina Repair or
switch terminal BFi - MleL2) iepk%e
- M20 - D10 - M7 (2) -
battery relay terminal BR
Defective starting switch Replace

PC200,2OOLC-5 Serial No: 48284 - 58018
PC220,22OLC-5 Serial No: 35448 - 36613
+ When fuse 9 is not blown
j, If battery is normal.
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on to the next step.
3 YES
Disconnect connec-
YES tar El and replace
2 - fuse 2. Does it blow
p agan?
‘ES
Repalce fuse 2. . Turn starting NO
Does 11blow again’ switch ON.
* Turn starting
switch ON.
NO
7 YES
Is rhere cont~““~fy
YES between El
- (femalei 112) and -
barrery relay terml
Red Green Red 6 nal ET
000
OFF OFF OFF
is fuse 2 blown? YES
-
Is voltage between
E, (2) and chass,s -
. Turn starting
switch OFF.
* Disconnect El.
NO
!lOKlWi?
fl YES
5-- . 20 3ov Is voltage between
P . Turn starnng sfarnng swtch ter-
Is voltage between swtch ON - m,nai ER and
Yl NO
El (11 and El (121 - chassis normal?
normal?
. 20- 3ov NO
. 20 - 3ov
. Turn starttng
swlrch ON.
4 . Turn starttng
watch ON.
Does working lamp NO

NO
. Turn starttng
switch ON. 9
El
Isvoltage between
L battery relay termi-
nal BR and chassis
10
normal7
10 YES
* 20 - 3ov
* Turn starting
switch ON. I
. 20 - 3ov NO
. Turn staritng
switch ON.
F20505466
20-‘d7-1
Cause Remedy
/ Short circuit I” wiring

harness between fuse 2 and Inspect. repail
Controller
Abnormality in engine
Rf?plaC.?
throttle controller
Already reset
Defecwe enigne throttle

ReplaCe
controller
Defectwe contact.or
disconnection in wring
harness between El
(female) (12) - Ml4 181-
chassis ground
Defective contact, or
harness between El
(female) (‘2) - D14 - M20
- Ml (2) - starting switch
terrmna, BR
Defective starting switch Replace
Defective contact, 01
harness between El
(female) (1) and fuse 2
outlet
Defective battery relay ReplaCe
harness between starting
switch terminal BR - M1 (2)
- M20 - DlO - M7 (2) -
battery relay fermlnal BR
Defective stamng swlfch
20-1cA7-2
* When fuse 9 is not blown
t If battery is normal.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on to the next step.
3 YES
Disconnect connec-
YES mr El and replace
2- fuse 2. Does it blow
1 agan?
YES Repax fuse 2. . Turn starting NO

_ Does it blow again? - switch ON.
. Turn starting
switch ON.
NO
il
6 1 b.;;;; relay term]- 1 Lo
Red Green Red
. Turn starring
000 Is fuse 2 blown? Is voltage between switch OFF.
Y j
OFF OFF - El (21 and chaws - . Disconnect El.
OFF
normal?
8 YES
- 20 - 3ov
Is voltage between
. Turn starting
starnng swtch ter-
Is voltage
between
switch ON
-
NO
m,nal ER and
El Ill and El 112) chaws normal’
. 20 - 3ov NO
. Turn staeing
switch ON.
switch ON.
Does working lamp

light up?
* Turn
switch
starting
ON. I 9 I
YES
* 20 - 3ov NO
. Turn starting
switch ON.
I I/ Stamng switch MI(M~) 010

_
I=20505467
Remedy
Inspect. repaIr
C~XSIS ground
disconnection in wring
harness between El
(female) (21 - D14 - M20 -
Ml (21 - starttng switch
terminal BR
. Defective starting switch
disconnectlon in wtrlng
harness between El
(female) (1) and fuse 2
$1 Defective battery relay
20- !;8’7-4
-2
E-2 m [Short circuit in governor motor] is displayed
sr If this happens during operation, because of the force of the spring:

I) Engine speed changes to low idling.
* If the problem occured when the engine was stopped:
2) Engine starts, but does not stop
A Stop the engine (place the governor lever of the injection pump in the NO INJECTION position)
before carrying out any checks.
CaUSe Remedy
2 YES Defective engine throttle

ReplZXe
cO”trOller
Is resistance bet-
YES ween each pin of
, - El (female), and c
each pin - chassis Short circuit in wirina
1 Red Green Red
Is resistance be- as shown in Table harness for problem -
I.00
Repair or
fween each pin of l? pin No. (between El-
replace
E2- E5)
- E5 (ma’e),and - *Turn starting
each pin- chassis * See Fig. 1
ON OFF ON switch OFF.
as shown in Table
. Disconnect El.
I?
Defective governor
l Turn starting ReplaCe
motor
switch OFF. NO
0 Disconnect E5.
Table 1
E5 (male) El (female) Resistance value
(I) - (2) (3) - (14) 4-9R
(3) - (4) (4) - (15) 4-9.Q
(1) - (3) (3) - (4) Min. 1 Ma
(I) - (4) (3) - (15) Min. 1 Ma
Between pins (1). Between pins (3), (4),

Min. 1 MA?.
(2). (3). (4) -chassis (14), (15) -chassis
Fig. 1
(MIC21) E2(Sl2) E5(X4) Governor

\ 1 motor
A (+I\ ti
205FO5352-2
20-118
0
E-3 m [Abnormality in battery relay] is displayed
PCZOO, ZOOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
Note: This occurs only when the engine is stopped and the starting switch is turned to the OFF position.
* The engine does not stop.
Astop the engine (place the governor lever of the injection pump in the NO INJECTION position)
1 YES
Red Green Red - Defective battery relay
Is resistance between
El (female) (13)-
000 - battery relay terminal - 1) Contact of wiring
BR, wiring harness- harness between El
OFF OFF ON
chassis normal? (female) (13) - M7
Repair or
(2) - battery relay B
I 1
NO I with other wiring
rePlaCe
.Between El (13)-batter” relav BR: Max. lfl I harness

l Between wiring harness - chas&: Min. 1 Ma 2) When lamp is
*Turn starfinq switch OFF. I connected
l Disconnect El and battery relay BR. I
FL?0505468
When ON (approx. 24V)
switch (El (2))
OFF
Voltage output from controller when starting
- switch is OFF
When ON
(approx. 24V)
Controller circuit (Note)
To battery relay 8 R
actuated (El (13)) OFFJ
_ - Min.: 4.0 set
Drive time Max.: 7 set (when it is impossible to set to NO INJECTION
because of failure of the motor)
205FO5354
Note: When the starting switch is ON, the controller is OFF, but a voltage of 20 - 30V is always
flowing from the starting switch BR, so if the measurement is made at El (I 31, the voltage is
20 - 3ov.
20-119
'C
PCZOO, 2OOLC-5 Serial No: 58019 and up
Note: This occurs only when the engine is stopped and the starting switch is turned to the OFF position.
Ir The engine does not stop.
AStop the engine (place the governor lever of the injection pump in the NO INJECTION position)
Defective battery relay ReDlaCe
1) Contact of wiring
harness between El
(female) (13) - M7
Repair or
(2) - battery relay I+)
replace
with other wiring
. Between El (13)-battery relay (+) :
Max. I.$2 harness
l Between wiring harness - chassis: Min. 1 MR 2) When lamp is
*Turn starting switch OFF. connected
. Disconnect El and battery relay (+I
m
N
Ml(M4)
M20
(M 4)
Starting switch
Battery relay
El(MIC21)
voltage from starting

switch (El (2))
To battery relay (+I
OFF
t from controller when starting
Controller circuit (Note)

To battery relay (+I
actuated (El (13)) OFF1
L 4 - Min.: 4.0 set
Drive time Max.: 7 set (when it is impossible to set to NO INJECTION
205FO5354
Note: When the starting switch is ON, the controller is OFF, but a voltage of 20 - 30V is always
flowing from the starting switch BR, so if the measurement is made at El (13). the voltage is
20 - 3ov.
20-A20
E-4 l”;““‘e.” [Disconnection in wiring harness of governor
inotor] is displayed
Sr During operation:
I) If there is disconnection simultaneously in the A phase and B phase:
Engine speed changes to low idling
Engine does not stop
2) If there is a disconnection in either A phase or B phase:
The engine speed stays the same as immediately before the problem occured.
* If the problem occurred when th engine was stopped:
+ Always connect any disconnected connectors before going on to the next step.
Catlse Remedy

I 15rerirtance I I controller
ReplCXe

harness for problem Pin
Repair or
No. (between El - E2
rl3plaCe
-E5)
* See Fig. 1
Defective governor
switch OFF. ReplaCe
m0tor
. Disconnect E5.
Table 1
E5 (male) El (female) Resistance value
(1) - (2) (3) - (14) 4-9$?.
(3) - (4) (4) - (15) 4-9.Q
(1) - (3) (3) - (4) Min. 1 MS2
(1) - (4) (3) - (15) Min. 1 MSt
Between pins (11, (2). Between pins (3). (41,

Min. 1 Ma
(3), (4) - chassis (14). (15) -chassis
Fig 1
E I (MIC21)
205FO5352-2
E-5 m [Abnormality in governor potentiometer] is
displayed
+ If the pump controller displays only “22”, go to troubleshooting C-l 8.

Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+, Always connect any disconnected connectors before going on the next step.
.4.
Is resistance bet-
YES ween El (female)
- (6) - (6), (5) - -
(16). (6) - (16) as
3 shown in Table I?
I* resistance
between E4 - Turn starting
YES (male) (1) - (21, _ switch OFF.
- (1) - (3). (2) - * Disconnect El
(3) asshown in
2 Table 17
Governor motor Is re51stance * Turn starting
potentiometer between El ifemale) switch OFF.
display and pump - (10) - (20). and - * Disconnect E4. ~0
controller between (10). (20)
display [221 -chaws normal?
1
Red Green Red . $$%_l Ma No
Check display of switch OFF.

pump controller. -Disconnect El and C2.
8 YES
OFF ON ON
IS re$i*fa”ce
between each pin
YES Qt El Ifemale)
7 - between
(6’w(1610reach
Pi” - ctla**is as
Is resistance ShDW” in Table 17
Governor motor between E4
potentiometer (male) (1 I- (2). _ - Turn starting NO
- (1) - (31, (2) - switch OFF.
display only (31 as shown in . Disconnect El.
L Table 17
* Turn starting
switch OFF. NO
* Disconnect E4.
E I (lVlIC21)
C2(MIC21)
Pump controller
Fuel control dial
Governor potentiometer
source 5V
E2612) E4(X3)
F20505357
20- 122
0
Replace
Is resistance bet- Controller
ween El (female)
(7) - (81, (8) - -
Wiring harness between
(18). (7) - (18) as
shown in Table I? ND El (female) (7) - E6 Repair or
(female) (I 1 in contact
_ --- with ground, or contact
replace
with other wiring harness
* Turn starting Defective fuel

Replace
switch OFF. NO control dial
. Disconnect E6.
El (female) (6)-~2 (1)
-E4 (female) (1) in Repair or
contact with ground, or replace
NO
contact with other
wiring harness.
Defective governor
motor Replace

harness between E1
(female) (10). (20) - Repair or
reDlace
c2 (f&lalit) (IO), (20).
or contact with ground
Defective engine
Replace
throttle controller
Defective wiring
harness in system where Repair or
resistance value is xplace
defective
Defective governor
Replace
motor
Table I
E4 (male) E6 (male) El (female) El (female) Resistance value (Kn)
Between (I) - (3) Between (1) - (3) Between (6) - (16) Between (7) - (18) 4-6
Between (I) - (2) Between (I) - (2) Between (6) - (5) Between (7) - (8) 0.25 - 7.0
Between (2) - (3) Between (2) - (3) Between (5) - (16) Between (8) - (18) 0.25 - 7.0
- _ B;ty; (6) (5) (16) Between (7) (8) (18) Min. 1 M.Q
- - chassis
20-123
0
E-6 VI [Abnormality in fuel control dial] is displayed
* When the relevant abnormality is displayed, “Pump controller abnormality display 22” is also dis-
played at the same time.
* Always connect any disconnected connectors before going on the next step.
Remedv
3 YE Defective engine throttle

ReplaCe
controller
YI
m=
2 harness between El Repair or
(female) (101, (20) - re!Aace
* Min. 100k.Q NI C2 (female) (10). (20).
ween El (female) * Between wiring or contact with ground
YE
(7) - (8). (7) - harness - chassis:
(18). (8) - (18) as Min. 1Ma
shown in Table l? .* Turn starting
Red Green Red switch OFF.
. Turn starting Defective wiring
* Disconnect El and C:
switch OFF. harness in system where Repair or
. Disconnect El. resistance value is replaCe
\I0
defective
ON ON ON
A . Turn starting
switch OFF. Defective fuel control ReplflCe
. Disconnect E6.
dial
Table 1
Fig. 1

E I (MlC21)
I C2(MIC21)
I I / I
Pump controller
Fuel control dial
m I
Sensor powe
(source kV 1 F20505358
2o-A24
E-7 j”,” [Abnormality in No. 2 throttle signal] is displayed
4 YES
between El
. Turn startingswitch ON.
(female) (9) - + Switch working mode switch.
(19) as shown in
. Turn starting
(female) (9). (19) switch OFF.
NO
- C2 (female) - Disconnect El.
(11). (21) aSShoW”
in Table 17
Red Green Red
Turn starting
switch OFF.
Disconnect El
(19) -chassis as
ON ON OFF and C2.
shown in Table l?
J * Turn startina
switch OFF.-
. Disconnect El.
Table 1
El (female) - Engine throttle controller Pump controller

El (female) Resistance value
C2 (female)
EI(MIC21) C2tMIC21)
Between
(9) - (19) - Min. 1 MO.
Between (9)-chassis - Min. 1 MR

0
Between 119) - - Max. 1R
chassis
Between (9) - (11) Max. 1 s2

- Between (19) - (21) Max. 1 n
205FO5358
Table 2 Voltage (V)
Condition when measuring PC200 PC220

(1) When overheating 4.0 - 4.25 4.0 - 4.25
(4) Heavy-duty mode

or H mode
Engine speed (rpm)

205FO5359
20-A26
r
I Remedy
Replace
Replace
Contact of wiring
harness between El I ReDair or
(female) (91, (19) -
c2 (female) (11). (21)
Disconnection in wiring
I
harness between El Repair or
(female) (9). (19)-C2 replace
(female) (11). (21)

El (female) (9). (19)- Repair or
C2 (female) (11). (21) in replace
contact with ground
20-127
E-8 Engine does not start
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
Sr When the starting motor does not turn.

* Check that fuse 9 is not blown before starting troubleshooting.
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
YEE
. Turn starting
’ p,:Ih tosTA:T;\&[[
- Turn starting switch to START.

. Approx. 24\j
9 YES
battery relay Is there con-

when starting YES tinuity between
switch is turned - battery terminal -
8 (-) - battery
- Turn starting I* resistance of relay terminal-b?
switch ON-OFF wiring harness
YES between starting NO
switch BR-
0”
7 battery relay BR
normal?
Is there ContinuitY * Between starting NO
1 Yl S between starting _ switch BR- batter,,
r switch terminal B relay BR: Max. 1 a
IS battery - terminal
voltage and
6 BR? * Between wiring harness- chassis: Min. 1 Ma
- * Disconnect at both starting switch and battery
specific gravity * Turn starting relay ends.
normal? switch ON.
starting switch
terminal 6 * Remove terminal B. NO
- Voltage: normal?
Min. 24V
Specific
gravity:
tester to (-) ierminz
Min. 1.26
of battery.
.20-29v
NO
M 2(X 2) E8CSWP8) M14CS8)
Fusible link
P?
Starting
motor
Starting
switch
205FO589 I
20-128
8
Defective contact Of
wiring harness between
Repair
battery terminal (+) -
starting motor terminal 6
switch terminal C-Ml
(4)-Ml4 (l)-ES cl)-
M2 (1 j-starting motor
terminal S
1 zictive battery
ReplaCe
switch terminal BR - Ml
I
(2l- M20 - DIO - M7 (2) -
battery relay terminal BR
I
20-129
Cc
* When the starting motor does not turn.
+ Check that fuse 9 is not blown before starting troubleshooting.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted
4 YES
IS voltage between
Yl ; starting motor
terminal B -
chassis normal?
3 NO
Is there any + Turn starting switch ON.
sound of * Approx. 24V
starting motor
pinion moving
out? 5 YES
- Turn starting
Is voltage between
switch to START.
starting switch
ND terminal c -
chassis normal?
NO
* Turn starting switch to START.
. Approx. 24V
9 YES
battery rebf Is there con-

when starting YES tinuity between
switch is turned 8 r battery terminal -
(-) - revolving
- Turn starting Is resistance of
wiring harness
frame ground?
switch ON-OFF YES NO ::
between Starting
r switch ER-
g
7 battery rew (+I r*I
normal? 0
Is there continuity * Between starting NO
YES between starting _ switch BR - battery
switch terminal B relay (+) : Max. 1 Cl
El
Is battery 6 - terminal BR? *
Between wiring harness- chassis: Min. 1 MO_
voltage and - *
Disconnect at both starting switch and batterv
specific gravity IS voltage at * Turn starting relay ends.
normal? starting switch _ switch ON.
. Voltage:
i
P1( terminal B * Remove terminal B. NO
normal?
Min. 24V
Specific
. connect (-) Pole ot
gravity:
tester to (-) terminal
Min. 1.26
of battery.
NO
- zo-29v
M 2(X 2) E8CSWP8) M14CS8)
/ I pT”9 :usible link
Starting M37CMl) Fuse

M l(M 4)
motor
aanery
Starting
I, M 7 CL 2)
switch
205FO5892
20-1$9-l
1 Defective contact of
Repair
Repair or
replace
Defective starting
ReplaCe
switch (between
terminals B- C)
Defective battery ?eDlaCe

relay
Defective contact of
wiring harness between 3epair or
battery terminal i-1 - eplace
revolving frame ground?
harness between starting Repair or
switch terminal BR - Ml .ep lace
(2) - M20 - DlO - M7 (21
battery relay terminal (+I
Defective starting
SWlfCh
,.
,between Replace
terminal B- BR)
Defective contact, Or
harness between battery FIepair Or
termnal(+I- M38 - -ep1ace
M37 (1) -Ml (1) -
starting switch terminal
B (including fusible link)
. Battery capacity too low
20-
l=i9-2
E-9 Engine rotation is irregular
PC200,2OOLC-5 Serial No: 45001 - 48283
PC220,22OLC-5 Serial No: 35001 - 35447
al Idling rotation is irregular

* Before starting troubleshooting, check the model code.
* Always connect any disconnectd connectors before going on to the next step.
2 YES
Adjust linkage
between governor
YI motor and injec-
tion pump. IDOe5
it become
nOrlTlal? NO
l See TESTING AND
ADJUSTING.
Warming-up signal 6 YES
1 IS voltage I
position when
linkage is dis-
connected?
* Turn starting switcl Potentiometer 1

OFF.
H zo-3oti _ LO
- (16) normal
between El PC200: 2.8V

pc220: 2.9v NO
normal and
stable?
. At MIN.: ‘I
4.0 - 4.75v
I
. At MAX.: Lln
0.25 - l.OV ‘“”
M20(M4)
Fuel control dial
205FO5722
*O-A30
F
CaUSe Remedy
t--Defective adjustment
Adjust
of linkage
Defective injection ;ee Engine sho

Pump nanual
Defective governor
motor
See E-12
Defectwe contact of
starttng switch BR - Ml
(2) - M20 14). (3) -
El (female) (2). or
defective starting swtch
See E-5
see E-6
20-131
a
b) There is hunting
2 YES
Adjust linkage
between governor
(ES motor and in&x-
tion pump. Does
it become
normal?
r
YES
Starting signal 7
IS voltaae
IS “lwtclr lever
aligned with dial
position when
linkage is dis- Y
connected?
No. 2 throttle
I normal and 11
* Turn starting signal 5 stable?
switch ON.
* Move fuel control Is voltage between - When auto-decele- ‘I
dial from MIN. to YES El (9) - (19) stable ration operating: A
MAX. and stop on and as shown in Max. 1 V NO
the way. Table 21 . When auto-deceleration
Potentiometer 4
canceled: 8 - 12V
Is voltage between
El 15) - (161 normal
and stable, and as
shown in Table 17
Fuel control dial 3
IS voltage
between El
(8) - (18)
NO
normal and
stable?
At MIN.:
4.0 - 4.75.v
At MAX.:
0.25 - l.OV
Table 1 Voltage (V)
Condition PC200 PC220
At high idling 2.6-3.0 1 2.7-3.1
At low idling 0.5 - 0.9 0.5 - 0.9
When decelerating Approx. 1.9 Approx. 2.1
When warming-up Approx. 2.2 Approx. 2.4
Table 2 Voltage (V)
Condition when measuring PC200 PC220

(1) When overheating 4.0 - 4.25 4.0 - 4.25
(2) 1L.0 and L mode 2.06 - 2.36 2.18 - 2.48
G.O.F.O. L.0 and

I I
(3) S mode
1.25 - 1.55 1.35 - 1.65
G.O. F.0 and L mode
(4) H.0 mode or H mode 0.75 - 1 .o 0.75 - 1 .o
Engine speed (rpm)
205FO5362
20-A32
Remedy
Defective adjustment Adj usf

of linkage
Defective injection jee Engine she

pump nanual
Warming-up signal 8 YES Defective governor

ReplaCe
IS voltage motor
between El
- (21) - (12) -
normal and
stable?
See E-l 2
. When warming-up NO
operating: Max. 1V
. When warming-up Defective contact of
canceled: 6 - 12V wiring harness between
starting switch BR - Ml
Repair or
12) - M20 (4). (3) - El
replace
(female) (2) - starting
switch, or defective
starting switch
see P-19
See E-7
See E-5
See E-6
Fuel control dial
20-133
'7
a) Idling rotation is irregular
Ir Before starting troubleshooting, check the model code.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted
* Always connect any disconnectd connectors before going on to the next step.
2 YES
1 Adjust linkage II
H
between governor
motor and injec-
tion pump. Doe*
it become
ADJUSTING.
Warming-up signal 6 YES
IS Voltaue II
* Turn starting switct

OFF.
1 Is voltage II * ‘A’h-- ooeratina: I
between El (51 _
.“llrlI
YES 20-3( Iti - ho

rl - (16) normal
and stable?
At low idling
between El PC200: 2.8V
PC220: 2.9v NO
h normal and
4.0 - 4.75v
. At MAX.:
I
NO
0.25 - l.OV
Starting
Ml(M4) Switch Ml(M4)
Engine throttle
Controller
El (MIC21)
Start signal
ISig)
Dial
potentiometer
PotentioniSig)
meter
(6)
F20505470
20-iz3-1
Remedy
Defective adjustment
Adjust
of linkage
Defective injection See Engine sho

Pump nanual
Defective governor Replace

motor
See E-l 2
starbng switch BR - Ml
(2) - M20 141. (3) - D14 -
El (female) (2). or
defective starting switch
-, See E-5
see E-6
20-133-2
b) There is hunting
PC200 I PC220
1 I I
? YES
Adjust linkage
betwean governor
YES motor and injec-
tion pump. Doer
it become
normal?
I 7,r
YES
Starting signal
Is voltage
between El
Deceleration (2) - (12)
aligned with dial

position when
linkage is dis- YES
connected?
No. 2 throttle r
. Turn starting
switch ON.
signal
I 5, I 1 ::czand 11
. Move fuel control Is voltage between - When auto-decele-
dial from MIN. to YES El (9) - (19) stable ration operating: a
MAX. and stop on c and as shown in Max. TV NO
the way. Potentiometer 4 Table 2? * When auto-deceleration
canceled: 8 - 12V
Is voltage between
YES El (9) - (16) normal _ ‘
and stable, and as
shown in Table l?
Fuel control dial 3
Is voltage
between El
- 18) - (181
NO
’ normal and
stable?
At MIN.:
4.0 - 4.75v
At MAX.: I
0.25 - 1 .OV NO
Table 1 Voltage IV)
Condition PC200 1 PC220
2 4.0 -
%
Table 2 Voltase (V)
: 3.0 -
% Condition when measuring PC200 PC220
.-k (1) When overheating , 4.0 - 4.25 4.0 - 4.25
; 2.0 - (2) L.0 and L mode 2.06 - 2.36 2.18 - 2.48
i; (3) G.0, F.O. L.0 and S mode 1.25 - 1.55 1.35 - 1.65
; G.O. F.0 and L mode
4
P l.O- (4) l-l.0 mode or H mode 0.75 - 1 .o 0.75 - 1 .o
Engine speed kpm)
205FO5362
20-‘23-3
CalEe Remed,
Defective adjustment Adjust

of linkage
Defective injection See Engine

pump lU”UZ4l
Warming-up signal 8 YES Defective governor

motor ReDlace
Is voltage
between El
- (21) - (12) -
normal and
stable?
See E-l 2
. When warming-up NO
operating: Max. 1 V
* When warming-up
canceled: 8 - 12V
starting switch BR - Ml Repair or
(2) - M20 141. (3) - Dl4 replace
- El (female) (21 -
starting switch, or defec-
tive starting switch
see P-19
see E-7
See E-5
See E-6
Fuelcontrol dial
F20505471
E-10 Lack of output power (max. engine speed is too low)
PC200,2OOLC-5 Serial No: 45001 - 48283
PC220,22OLC-5 Serial No: 35001 - 35447
mi
-k Always connect any disconnected connectors before going on to the next step.
YES
Deceleration
Yl Is voltage between
El (1:) - (12)
No. 2 throttle
normal and stable,
signal 5
contact with
FULL stopper? Yt El (9) - (19) stable ration operating: L
and as shown in Max. 1V NO
. Start engine. * When auto-deceleration
- Fuel control dial
Potentiometer 4
canceled: S-12V
at MAX
- Heavy-duty Is voltagebetween
+H mode YES El (6) - 116) normal
and stable, and as IO
Fuel control dial 3 shown in Table 17
Y Is voltage between
‘El (8) - (18)
normal and stable?
n
L * At MIN.:
4.0 - 4.7511
Is adjustment of
. At MAX.: 1
linkage between
0.2.5 - l.OV NO
governor motor
- injection Pump
normal? I
YES
I Adiustlinkaqe II
be;ween go&w
motor - iniec- Ll
. See TESTING AND

ADJUSTING.
Table 1 Voltage (V)
I Condition I PC200 I PC220 I

At high idling 2.6 - 3.0 2.7 - 3.1
At low idling 0.5 - 0.9 0.5 - 0.9
When decelerating Approx. 1.9 Approx. 2.1
When warming-up Approx. 2.2 Approx. 2.4
Table 7 Voltage (V)
Engine speed (rpm)

205FO5364
20-ik34
Cause Remedy
Defective injection ee Engine sho

pump IanUal
Defective governor
qeplace
motor
See E-l 2
Defectwe contact of
starting switch BR - Ml Repair or
12) - M20 (4). (31 - ,eplaCe
El (female) (2). or
defective starting switch
see P-19
See E-7
See E-5
See E-6
Defective adjustment of Adjust

governor motor linkage
;ee Engine sto

Defective injection Pump
nanual
Starting
Engine throttle
controller
E I,MIC2,)
, I1
205F05723A
20-135
0
t Before starting troubleshooting, check the model code.
YES
Deceleration r
signal 6
YES lS Voltage between

r No. 2 throttle
- El (ll)-(121 -
normal and stable,
signal 5
Is voltage between * When auto-decele-

YES El (9) - I191 stable _ ration operating: _
and as shown I” Max. 1v NO
* start engine. Potentiometer 4 Table Z? . When auto-deceleration
. Fuel control dial canceled: 8- 12”
at MAX I I I
- Heavy-duty Is voltage between
in mclae
YI El (5) - (16) normal t
and stable, and as NO
Fuel control dial 3 shown in Table 17
YESIsvoltagebetween
-El (8) - (18)
normal and stable?
2- . At MIN.:
_ 4.0 - 4.75v
Is adjustment of
linkage between
. At MAX.:
IO
- governor motor - o.*5 - 1.0”
’ - injection pump
normal?
YES
Adjust linkage
between 9o”er”or
L motor - injec- _
NO fion Pump. Does
it becqme
normal? NO
l See TESTING AND
ADJUSTING.
Table 1 Voltage (V)
I When decelerating Approx. 1.9 Approx. 2.1

; 4.0
When warming-up 1Approx. 2.2 1 Approx. 2.4
P
Table 2
z 3.0
- 1
Engine speed (rpm)
205FO5364
2o-‘25-1
CaLI Remedy
/ Defective injection ;ee Engine she

pump WlllUal
Warming-up signal fl YES

Defective governor
3ep1ace
IS voltage II IllotCIr
See E-l 2
Defective contact of wiring

switch BR -Ml (2) - M20
(4). (3) - D14 - El Ifemale)
IZ), or defective ?.tart~ng
switch
see P-19
See E-7
See E-6
idjust
;I Defective injection pump ee Engine sto

1aIlual
Fuel control dial
Pump controller
F20505471
20-1,352
7,
E-l 1 Engine does not stop.
PC200,2OOLC-5 Serial No: 45001 - 48283
PC220,22OLC-5 Serial No: 35001 - 35447
I PC200 I PC220 I
YES
1
YES
Has lever of
governor stopped
in c~ntacf with
STOP stopper?
2
* Starting switch Potentiometer 5 YES
ON-OFF . Does engine When starting
return to normal YES switch is OFF, is
_ when linkage is _ - voltage between -
adjusted? Relay drive 4
NO El (5) - (16)
. Is loose spring When afarting - normal?
free of twisting? switch is OFF,
YES doe5 voltage . When engine is NO
between El (13) stopped:
’ ~~J~SST~~G~ AND Starting signal 3 - (12) change as pc200: 3.7-4.1v
shcw” in Table l? PC220: 3.8-4.2V
When starting
switch is OFF, is
- voltage between - NO
NO El (2) - (12)
normal?
. Max. 1v
NO
Table 1
y;kta;e”“(::“;l;;arting ~(pprox’ 24v) To battery re,ay BR
OFF
(Note) _ Voltage output from controller when starting switch is OFF
-----___
When ON
(approx. 24V)
Controller circuit
To battery relay BR
actuated (El (13))
Min.: 4.0 set
OFF_
-Max.: 7 set (when it is impossible to set to NO INJECTION
Drive time
205FO5366
Note: When the starting switch is ON, the controller is OFF, but a voltage of approx. 20 - 30V is
always flowing from the starting switch BR, so if the measurement is made at El (I 31, the vol-
tage is 20 - 30V.
20-T 36
8
GUSEZ Remedy
Defective injection i See Engine shol

Pump nanu.3
Defective adjustment Adiust

of linkage
Defective governor Replace

motor
see E-5
Defective engine
ReplaCe
throttle controller
Defectwe contact of
w,r,“g harness between
starmg switch BR - Ml
12) - M20 (41. (31 -
El (female1 121. or
defectwe startmg swttch
M20 (M4)
El (MIC21)
Ml(M4)
Start signal 2. 4 -2 Starting switch
Battery relay
13
drive
Governor (Sig) 5 Governor potentiometer

potentiometer
(6) 16
IC
DlO
Battery relay
F20505472
PC200,2OOLC-5 Serial No: 48284 - 58018
PC220,22OLC-5 Serial No: 35448 - 36613
Before starting troubleshooting, check the model code.
PC200 PC220
ES
YES
L-t
Has lever of
governor stopped
in contact with
1
STOP stopper?
* Starting switch Potentiometer 5 YES

ON-OFF Does engine
return to normal
when linkage is
\I0 adjusted?
Is loose spring
free of twisting? I
. See TESTING AND

Starting signal 3
ADJUSTING.
switch is OFF, is
voltage between
h El (2) - (12)
. Max. 1V I
NO
Table 1
~;~;;;e~~;;;;arxi”g .~(pprox~ 24v’ To battery relay BR
OFF
(Note)
______~_ _ Voltage output from controller when starting switch is OFF
When ON
(approx. 24V)
Controller circuit
To battery relay BR
~_ -‘--1 (El (13)) OFF
I Min.: 4.0 set
- Max.: 7 set (when it is impossible to set to NO INJECTION
205FO5366
Note: When the starting switch is ON, the controller is OFF, but a voltage of approx. 20 - 30V is
always flowing from the starting switch BR, so if the measurement is made at El (I 31, the vol-
tage is 20 - 30V.
20-137-l
Remedy
Defective injection see Engine sho

pump nanuai
Defective adjustment Adiust

of linkage
Defective governor
FieplSX
motor
see E-5
Defective engine
throttle controller

switch BR - Ml (2) - M20
(4). (3) - D14 - El (female)
121, or defective starting
switch
014 M2OCM4)
El (MIC21)
Start signal
Battery relay
E2612) E4(X3)
drive
Governor (Sigl 5 Governor potentiometer

-2
potentiometer
(-) 16 3
GND I
2 M7(L2)
L
DlO
1 : Battery relay
F20505473
*O-g7-*
Sr Before starting troubleshooting, check the model code.
YES
governor stopped
in contact with
STOP stopper?
ON-OFF . Does engine

I Potentiometer
When starting
5 YES
return to normal YES switch is OFF, is

when linkage is - voltage between -
NC , adjusted? Relay drive 4_ El (5) - (16)
. Is loose spring When starting normal?
free of twisting? switch is OFF,
YES_ does voltage - When engine is NO
between El (13) stopped:
l ~&~ssT~~G. *ND Starting signal 3 - (12) change as pc200: 3.7-4.1v
- show” in Table I? PC220: 3.8-4.2V
When starting
switch is OFF, is
- voltage between - NO
NC El (2) - (12)
normal?
f Max. IV
Table 1

Voltage from starting -,
switch (El (2))
I
- To battery relay (+j
OFF
(Note)
--_--___ - Voltage OUtPUt from controller when starting switch is OFF
1When ON
(approx. 24V)
Controller circuit
To battery relay I+)
actuated (El (13))
Min.: 4.0 sac
OFF_
Drive time - Max.: 7 set (when it is impossible to set to NO INJECTION
205F053E
Note: When the starting switch is ON, the controller is OFF, but a voltage of approx. 20 - 30V i
always flowing from the starting switch BR, so if the measurement is made at El (13). the vol
tage is 20 - 30V.
L
20-‘27-3
Defective injection See Engine she
pump nanual
Defective adjtistment
of linkage
Defective governor ReDlace

motor
See E-5
Defective engine
ReplaCe
throttle controller

harness between start,ng
switch BR - Ml (2) - M20 Repair or
14). (3) - D14 - El (female) replace
12). or defective stafling
switch
D14 - -M2O(M4)
Engine throttle controller 1 2 @@
El(MIC21) I h”1,I.” n\
111 I \“’ 7,
,I -
-
Startsignal 4 A\ 1-Q Starting switch
relay
lv/
i7
Battery
E2 612) E4(X3)
dri”e 1
1 Governor (Sig) 1*
=kBI
2
7
2
3 25 Governor potentiometer
M7(L2)
\ I
F20505474
20-137-4
0
E-l 2 Automatic warming-up operation is defective
* Warming-up is not carried out when the coolant temperature is under 3O”C, or does not stop when
the coolant temperature goes above 30°C.
(When it is canceled by the fuel control dial, there is no change in the voltage.)
Sr Conditions for carrying out warming-up:
I) Coolant temperature below 30°C
2) Fuel control dial set at about 50% or below (warming-up signal: Max. 1 VI
* Conditions for canceling warming-up:
1) Coolant temperature above 30°C
2) Fuel control dial raised to above 70% and kept there for at least 3 seconds in power set switch
H or S mode (see Note I)
+r Always connect any disconnected connectors before going on to the next step.
Note 1 :When the fuel control dial is turned up to cancel warming-up, warming-up will not start again
unless the starting switch is turned OFF and then turned ON again.
2:When the fuel control dial is turned up to cancel warming-up, the voltage of El (211 does not
change.
CtW.ES Remedy
YES Defective engine throttle

FC3plWX
(See Note2) 21 controller
Warming-up
operation is not
canceled see P-21
Disconnection in wirina
harness between El ” Repair or
(female) (21)- P2 replaD
* Start engine. - Turn startina switch (female) (11). or contact
operation does OFF. - with ground
- Disconnect El and
c2.
R@Z!Ce
controller
see P-2 1
* Warming-up: Max. 1V
* Fuel control dial at MIN.
* Start engine.

Table 1 E I (MIC21)
Monitor panel
Wiring harness
Between El (feti6le) (21) P2(04016)

- chassis
Between El (female) (21)

- P2 (female) (11)
1 Max. 1 SL 1
205FO5368
20-l 38
0
PCZOO, 2OOLC5 Serial No: 58019 and up
Ir Check if fuse 1 is blown. If the fuse is blown, check if the wiring harness between the fuse 1 - Cl
(3) (4) is in contact with the ground.
YES Defective pump

ReplXe I
controller
OFF
* 20-30V ,s “o,ta__ ^. _..*1,.*

. Turn starting end of .___ I
switch ON.
Is voltage berween M7 (1) - fuse 1

* 20-30V
_ I.._^ r*..l+:.%n I-l I ‘z1 - I
Defective contact, or discon-
switch ON. nection in wiring harness
’ _“’ =‘-’ L”‘y Repair or
replaCe
. 20- 3ov (female) (1) - battery relay -
- Turn starting
&itch ON.
n Fusible
relay
link
Pump controller
Battery
205FO57 ‘7 I
*o-122-1
c-2 [. .-.
‘? ‘,I [Short circuit in 2-stage relief . CO cancel
solenoid valve, 2-stage relief system] is displayed
When an abnormality occurs, [Oil and LO71 are displayed.
If the starting switch is turned OFF after the abnormality occurred, turn the starting switch ON, set
the power max. switch to ON, and check that 1011 and 1071 are displayed. (If they are not displayed,
the system has been reset.)
It is also possible to operate the travel lever (in this case, with the engine at high idling), or to turn
the swing lock switch ON.
Cause Remedy
Defective pump ReplaCe

controller
To P
* Disconnect Cl.
Contact between wiring

3 YES yarness of power source
qepair or
and wiring harness
Is resistance .eplXe
setween Cl (female)
between VJ :15j - v7 (female) (2)
A- (male) (1) - (2) -
as shown in
Table 17 NO 3efective 2-stage relief *
3eL3lace
* Turn starting switch :O cancel solenoid valve
OFF.
* Disconnect V7.
Table 1
Serial No. Cl (female) VJ (male) Resistance value
PC200: 4500, _ 52JB3 Between 13)(4) - (15) Between (I) - (2) 50 - IOOR
PC220: 3500’ - 36023 Between (15) - chassis Between (2) - chassis Min. 1MR
I
PC200: 52784 and up Between (3K4) - (15) Between (1) - (2) 24- 46Q
PC200 MIGHTY
PC220: 36024 and up Between (15) -chassis Between (2) - chassis Min. ‘IMR
M20(M4)
2-stage
relief. CO
cancel
solenoid
valve
Z-stage
relief
solenoid D9
C-3 Is.3 1 [Sh or t circuit in arm half flow solenoid valve
I
’ system] is displayed
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set
the working mode switch to F.0 mode, and check that the display is [031. (If it is not displayed, the
system has been reset.)
-k Always connect any disconnected connectors before going on to the next step.
CaW.e Remedy
2 YES Defective pump
\-\
Replace
Interchange with Controller
c
1
ween Cl (female)
(31 (4) - (6). (6)
1
* I “terchange V5 and V4.
- chassis as shown
.\A a Turn starting
* Turn working
switch
switch
mode
to finishing
ON.
mode.
* Turn starting switch
OFF. To A
* Disconnect Cl. VO
Contact between
wiring harness of
power so”rca and
YES wiring harness qepair or
41 between Cl (female) ‘ePlaCe
(6)- M3 (female) (5)

Iharness of power sourca
j and wiring harness
qepair or
eplace
Ibetween M6 (female)
(6) - V5 (female) (2)

Iharness of power source ?epair or
and wiring harness Wace
. Turn starting NC
Table I?
switch OFF.
’ Ibetween M3 (male) (5)
-M6 (male) (6)
* Turn starting - Disconnect M6.
switch OFF.
* Disconnect V5. I3efective arm half flow
NC siolenoid valve ?eplace
Table 1
I Serial No. I Cl (female) I M3 (female) I M6 (female) I V5 (male) / Resistance value I

Pc200: 45001 _ 52783 Betwee” (3)(4) - (6) 1 Between (3) - (5) Between (7) - (6) Between (1) - (2) 10 - 35Q
Pc220: 35001 - 36052 Between (6) _ chassis Between (5) - chassis Between (6) - chassis Between (2) - chassis Min. IMQ
PC200: 52784 and up Between (31(4) - (6) Between (3) - (5) Between (7) - (6) Between (I) - (2) 24 - 46R
PC200 MIGHTY
PC220: 36053 and up Between (6) - chassis Between (5) - chassis Between (6) - chassis Between (2) - chassis Min. 1MR
Pump controller
205FO5371-1
20-144
0
c-4 [.I-\.--\
m \I [Short circuit in swing brake solenoid valve
system] is displayed
* If the starting switch is turned OFF after the abnormality occurs, start the engine, operate the
swing, and check that the display is [04l. (If it is not displayed, the system has been reset.)
CXSe Remedy

ReplXe
controller
~,
operate swing.
* Turn starting
switch OFF. 1 WTOA
- Disconnect Cl. NO

harness of power source
and wiring harness Repair or
i \ ‘EL
between Cl (female) (8)- .eplace
M3 (female) (9).

and wiring harness
in Table l? between M3 (female) Repair or
between M3 I [
YE
(male) (1) - (9). NC , cl)-VI (female) (2) -qace
or between (1) switch OFF.
or (9) -chassis * Disconnect M3. ’ Defective swing lock Replace
switch
a Contact between wiring
- harness of power source
Repair or
and wiring harness
* Between (11 or (91 replace
between M3 (male) (l)-
chassis: Min. 1MR
lock switch-M3 (male)
. Turn starting switch OFF.
(9)
* Turn starting . Disconnect M3.
’ switch OFF. NO IDefective swing
*
Disconnect VI. . Set swing lock switch OFF zrake solenoid RePlaCe
. Set swing lock
~1
lalve
switch OFF
fl
PC220: 35001-36023 between (8) -chassis
PC200: 52784 and up Between (3)(4) - (8)

PC200 MIGHTY
PC220: 36024 and up Between (8) - chassis
Swing lock Swing lock

prolix switch switch
ON ~9 OFF ON 99 OFF
VI(X2)
I-
Fuse
M20(M4)
205FO5372- IA
c-5 1s.q [Short circuit in travel speed solenoid valve system] is
displayed
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set
the fuel control dial to MAX. and the travel speed switch to Hi, and check that the display is [OS].
(If it is not displayed, the system has been reset.)
A- Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 YES Defective pump ReDlaCe

Interchange with controller
-. I^
-IIIS resistance bet- 1

relief solenoid
valve.
IsLO51
HLIA
H
I””
ween CI (female) H ’
(3) (4) - (16). (16)
- chassis ground as
shown in Table 17
* Turn starting
. Interchange V2 and V3.
- Turn starting switch ON.
- Place travel speed switch at Hi.
I
7
switch OFF. t cToA
a Disconnect Cl. No
Sontact between wiring

3 YES ,arness of power source
3nd wiring harness
Is resistance xw.ween Cl (female)
between V2 116)-V2 (female) (2)
A- (male) (1) - (2) -
as shown in
Table I? 3efective travel speed
. Turn starting NO zolenoid valve
switch OFF.
- Disconnect V2.
Table 1
~~220: 36024 and up Between (16) - chassis Between (2) - chassis
- M20IM4)
(i)@
Pump controller M3Bl6) Fuse
I I 1
I
Cl (MICl7)
3 L
I _ r-u I
solenoid
205FO5373-1
2o-A46
C-6 [.‘$-\][Short circuit in 2-stage relief CO cancel l
solenoid valve, CO cancel system] is displayed

* When an abnormality occurs LO11 and 1071 are displayed.
* If the starting switch is turned OFF after the abnormality occurred, turn the starting switch ON, set
the power max. switch to ON, and check that 1011 and [071 are displayed. (If they are not displayed,
the system has been reset.)
It is also possible to operate the travel lever (in this case, with the engine at high idling), or to turn
the swing lock switch ON.
Defective pump FilZplaCe

llnterchange with *[ v controller
\-\ \-\
~ ~TOA
i
J-L \
* Disconnect Cl. No-
3 YES and wirina harness
between cl (female)
(7) - v7 (female) (2)
Defective 2.stage relief .

1 CO cancel solenoid
* Turn starting NO valve
switch OFF.
* Disconnect V7.
Table 1
Serial No. I Cl (female) I V7 (male) Resistance value I

PC200: 45001 _ 62783 Between (31(4) - (7) Between (1) - (2) 50 - IOOR
PC220: 35001 - 36023 Between (7) _ chassis Between (2) - chassis Min. 1MR
PC200: 52784 and up Between (3)(4) - (7) Between (1) - (2) 24 - 460
PC200 MIGHTY
PC220: 36024 and up Between (71 - chassis Between (2) - chassis Min. 1MR
M20(M4)
Pump controller P3’5’9’ Fuse

I I
12-stage
205FO5725
C-7 [.z:‘:] [Short circuit in TVC solenoid sysem (I)] is displayed
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
check that the display is 1081. (If it is not displayed, the system has been reset.)
* Turn the TVC prolix switch OFF.
Cause Remedy
Defective pump controlls RePlXe
Defective TVC solenoid ReDlXX
switch OFF Wirino harness between

. Disconnect C4. Cl (female) (9)-c5
(female) (1) in contact
4 YE! j with ground, or in contac
with GND wiring
between C5 * Wiring harness between
(male) (1) -(3). C5 (male) (I)-prolix
(2) - (4) as shown switch-C5 (male) (3)
in contact with g;ound, Repair or
- Turn starting NC or in contact with GND replace
*._&~
switch OFF. wiring
* Disconnect C5. * Defective TVC prolix
switch
* Turn starting ,Wiring harness between Repair or
switch OFF. C5 (female) (3)-C4
IO ‘eplXe
* Disconnect C5. (female) (1) in contact
with ground, or in confac
with GND wiring
Table 1
Cl (female) C5 (female) C4 (male) Resistance value

Between (9) - (17) Between (3) - (4) Between (1) - (2) lo-222a
Between (17) -chassis Between (4) - chassis Between (2) - chassis Min. 1 MR
Between C5 (male) (1) - (3). (2) - (4) Max. 1 D
n
I I
TVC prolix switch
ON OOFF
. C5(M6)
Fuse
I:( (3 Resistor
o $)
5:
I
4
$g
C4fX7)
lVC valve
CI(MICl7)
1 t-1 (4, 1
205FO5375-1
Pump controller
20-148
0
C-8 [.z!z] [Short circuit in TVC solenoid valve system (211
is
displayed
+ If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
check that the display is [091. (If it is not displayed, the system has been reset.)
+ Turn the TVC prolix switch OFF.
Remedy
2 YES
Replace
Defective pump ContrOllE
YE
1 lZjZJH__,.,
H
Is resistance
between C4
\-\
.,_, .
\-\1, (male) (1). - (2)
. Turn starting switch
es shown I” -.
ClFF
Table l? - Disconnect Cl.
. Turn starting
switch OFF. Defective TVC solenoid Replace
* Disconnect C4.
Cl (female) (9)-C5
4 YE! with ground, or in contac Repair or
with GND wiring X?Pl?G?
Is resistance bet-
YES ween C5 (female)
3 - (I) -(3),(2) - -
* Wiring harness between
C5 (male) (1 )-prolix
(4) es shown in
1s resistance * switch- C5 (male) (3)
Table I? N
between C5 in contact with ground, Repair or
(female1 13) - a Turn starting switch or in contact with GND reDlace
A -
chassis. (3) - (5) - OFF. wiring
es shown in
Table I?
* Disconnect C5. * Defective TVC prolix
switch
OFF. Niring harness between qepair or
NO 35 (male) (3)-C4 (fernall x!place
. Disconnect C5.
‘1) in contact with groum
)r in contact with GND
wiring
Table 1
I Cl (female)
I
I
C5 (female)
I
I
C4 (male) 1
I
Resistancevalue 1
Between (9) - (17) Between (3) - (4) Between (1) - (2) lo-22s1
Between (17) - chassis 1 Between (4) - chassis Between (2) - chassis I Min. 1 Ma
I Between C5 (male) (1) - (3). (2) - (4) Max. 1 n
TVC prolix switch tzzlM20(M41
CI(MICl7)
I I 20%05375-l
Pump controller
20-149
0
c-9 [. \. :] [Disconnection in 2-stage relief . CO cancel
solenoid valve, 2-stage relief system] is displayed
* Display and location of abnormality
1) When [I 71 is displayed at the same time
i) If there is a disconnection in the solenoid or up to portion (a) of the wiring harness, the sole-
noid does not work.
ii) If solenoid pin (2) is in contact with the ground, the solenoid remains actuated.
2) When [I 11only is displayed
If there is a disconnection in portion (b) of the wiring harness, the solenoid works normally.
check that the display is [I 1 I. (If it is not displayed, the system has been reset.)
* If [I 11 is displayed, start the engine, and if there no difference in the digging force between when
the power maximizing is actuated and when the switch is not actuated, start troubleshooting from
Item “4” in the flow chart below.
CaLIS? Remedy
2 YES
Defective pump controller
YE
ElT
1 Already reset
H
\ \ Is voltagebetweer
Cl (15) - chassis
normal?
YES
. 1. I
NO 3
. Lever at neutral: 20 -30v
Is resistance
- Lever operated: Max. 3V 3isconnection in wiring
between Cl
. Turn starting switch ON. _ (female) (3) (4) _ ,ar”ess between Cl
l Travel lever operated, - (15). (15) -
chassisasshown ~
4 YE
-
:female) (3). (4). (15)-
power maximizing switch V7 (female) (1) (2). or
ON, or set swing lock in Table 17 Is resistance
Niring harness between Cl
switch ON. ~ between V7
. Turn starting switch, Ifemale) (15)-V7 (female
(male) (1) - (2) - I2) in contact with ground
OFF. NO as shown in
* Disconnect Cl.
Table l? I\ Iaefective 2-stage relief *
. Turn starting switch :o cancel solenoid valve
OFF.
* Disconnect V7.
Table 1
I Serial No.
’ C1(female’ ‘4
PC200: 52784 and UP Between (3)(4) - (15)
2220: 36024 e,,d up &.tWeen(15) -chassis Between (2) - chassis Min. ‘IMQ
Pump controller
CI(MICl7)
V7(X2)
205FO5377-1
c-1 0 [. :.s]
[Disconnection in arm half flow solenoid valve
* If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (2) of the solenoid is short circuiting with the ground, the circuit up to the solenoid
stays actuated.
check that the display is [I 31. (If it is not displayed, the system has been reset.)
* If [I 31 is displayed, start the engine, and if there is no difference in the ARM IN speed between F.0
mode and G.0 mode, start troubleshooting from “A” in the flow chart below.
jr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Remedv
2 YES
Defective pump
Replace
controller
$$jZ?LJ~
voltage - Turn starting switch . Already reset
1 -\ _ Is
between
- chassis
Cl (6) _,
ON.
nor”lal?
,. LX NO 3 YES
. Turn starting switch ON. Is resistance
. Finishing, lifting between c1
mode: Max. 3V _ (female) (3) (4)
- (6). (6) -
. Heavy-duty, general chassis as show” Disconnection in wiring
mode: 20 - 30V in Table 17 NO
- To A harness between Cl
’ Turn starting switch (female) (3)(4)-M3
OFF (female) (3)(5), or
- oi&“..t 0,. wiring harness between
Cl (female) (6)-M3
(female) (5) in contact qepair or
with ground ep1ace
between M3 Disconnection in wiring
YES (male) (3) - harness between M3
5- (5). (5) - chassis (male) (3)(5)-~6
as show” in
Is resistance bet- Table I? (male) (7)(6), or wiring
&
YES wee” MS (female) harness between M6
a Turn starting switch (female) (5)- M6 (male)
I- (7) - (6), (6) - - OFF.
chassis as shown in (6) in contact with
4 * Disconnect M3. ground
- Table l?
Is resistance bet- Disconnection in wiring
ween V5 (male) - Turn starting switct- qepair or
larness between M6
A--r (I) - (2). (2) - - OFF. NO eplace
Ifemale) (7) (6) - V5
chassis as shown in * Disconnect M6.
[female) (1) (2). or wiring
Table l? harness between M6
. Turn starting switch Ffemale) (7) - V5 (female
OFF. 2) in contact with grounc
* Disconnect V5. ND Defective arm half leplace
flow solenoid valve
Table
Serial No. Cl (female) M3 (female) M6 (female) V5 (male) Resistance value
PC200: 45001 _ 52783 Between (3)(4) - (6) Between (3) - (5) Between (7) - (6) Between (1) - (2) 10 - 350
PC2201 35001 - 36052 Between (6) _ chassis Between (5) - chassis Between (6) - chassis Between (21 - chassis Min. 1MR
PC200: 52784 and up Between (3)(4) - (6) Between (3) - 15) Between (7) - (6) Between (1) - (2) 24 - 46R
PC200 MIGHTY
PC220: 36053 and up Between (6) - chassis Between (5) - chassis Between (6) - chassis Between (2) - chassis Min. lM62
Pump controller
205FO5371.1
r ,
C-l 1 /_ \J-\ i [Disconnection

c
in swing brake solenoid valve system]
’ is displayed
If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (21 of the solenoid is short circuiting with the ground, the circuit up to the solenoid
stays actuated.
If the sta,rting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
Always turn the swing lock prolix switch OFF, and set the swing lock switch at OFF before starting
to check.
If [I 41 is displayed, start the engine, and if the swing holding brake is not released when the swing
is operated, start troubleshooting from Item “4” in the flow chart below.
CaUSe Remedy

=i‘?plaCe
tn same condi- I 1 A controller
Already reset
IS voltage ON.
\\ \_ between Cl (8) _ . Turn swing lock
switch 0 F F.
. \ . -\ ;os%; YES
3
- Lever at neutral: 20 - 3ov
Is resistance
* Lever operated: Max. 3v
between Cl
* Turn swing lock switch OFF.
* Turn starting switch ON. NG -(fema’e)
(8). (8) (3)- (4) -
chassis a* show”
4 YE: j TO A
in Table l? 15 resistance
A
between “1
* Turn starting switch OFF. (male) (1) -
: ;e%;v$gal~; switch OFF. NC (2). (2) -
chassis as shown
in Table 17 N c I3efective swing brake
qi?plaCe
. Turn starting switch ;olenoid
OFF.
* Disconnect Vl. [Jisconnectio” in wiring
t,amess between Cl
female) (8)- M3 (female)
6 YE: 7epair or
it 9). or contact with
ep1ace
Is resistance be-
c
Iround
YES_ tween M3 (male) _
’ ~;~c;tive swing lock
5 (1) - 19). (1) or (91
Is resistance - chassis normal?
between M3
Nl 3. Disconnection in wiring
harness between M3
(female) (3) - * Turn staning switch OFF.
(male) (I) - lock switch
A- (1). (1) - - . Disconnect M3.
chassis as shown * Between (11 - (9): Max. lr - M3 (male)
contact
(9). or
with ground
in Table 17 \ . Between (1) or (91 -
. Turn Startina switch chassis: Min. 1Mn
OFF. -
5 - 1>isconnection in
* Disconnect M3. No Yviring harness between
Fd3 (female) (1). (3)
-Vl (female) (l)(2),
)r wiring harness
etwee” M3 (female)
l)-Vl (female) (2)
Table 1 n contact with ground
Serial No. Cl (female) M3 (female) VI (male) Resistance value
PC200: 45001 _ 52783 Between (3)(4) - (8) Between (3) - (1) Between (I) - (2) 10 - 35R
PC220: 3500’ - 36023 Between (8) _ chassis Between (1) - chassis Between (2) -chassis Min. IMQ
PC200: 52784 and up Between (3K4) - (8) Between (3) - (1) Between (1) - (2) 24 - 46R
PC200 MIGHTY
PC220: 36024 and up Between (8) - chassis Between (I) - chassis Between (2) - chassis Min. IMR
swng lock ;v$;t l0Ek

pro,,x 5Wleh
ON QJ OFF
c-12 [. :.q [Disconnection
L
in travel speed solenoid valve system]
’ is displayed
If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (2) of the solenoid is short circuiting with the ground, the circuit up to the solenoid
stays actuated.
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set
the travel speed switch to Lo, and check that the display is [I 51. (If it is not displayed, the system
has been reset.)
If II 51 is displayed, start the engine, and if the speed does not become Hi when the travel speed
switch is set to Hi and the engine is at high idling, start troubleshooting from “A” in the flow chart
below.
Cause Remedy
2 YES Defective pump Qplace

30”tr011er
I” same condition
YES as when measuring
r Item 1, is [151
t
1 1
displayed7
NO A Already reset
1 \- Is voltage between
- Cl (16) -chassis -
ON.
.
--t L,\ nromal?
Is resistance
3 YES
* At Lo: ZO-30V
between Cl
* At Hi: Max. 3V
I (female) (3) (4)
- Switch travel
NO - (16). (16) - -
speed switch. chassis as show”
. Turn starting switch in Table 17 NO
ON. - To A
OFF. Disconnection in wiring
* Disconnect Cl. -,arness between Cl
(female) (3) (4) (16) -
4 YE V2 (female) (1) (2). or Repair or
airing harness between .eplace
Cl (female) (161 - V2
A----El with ground
Defective travel speed

* Turn starting switch SeplXe
.olenoid valve
OFF.
. Disconnect V2.
Table 1
PCZOO: 52784 and UP Between (3)(4) - (16)
pC220: 36024 and up Between 116) - chassis
M20tM4)
Pump controller M3(Sl6) Fuse
Cl (MICl7)
TGWel
speed
solenoid
205FO5373-1
20-;53
d
C-l 3 1 :J-:] [Disconnection in Z-stage relief CO cancel l
c’ . J
solenoid valve, CO cancel system] is displayed

Display and location of abnormality
1) When [I 11 is displayed at the same time
i) If there is a disconnection in the solenoid or up to portion (a) of the wiring harness, the sole-
noid does not work.
ii) If solenoid pin (2) is in contact with the ground, the solenoid remains actuated.
2) When [I 71 only is displayed
If there is a disconnection in portion (b) of the wiring harness, the solenoid works normally.
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, turn
the swing lock switch ON, and check that the display is [I 71. (If it is not displayed, the system has
been reset.)
If [I 71 is displayed, start the engine, and if there no difference in the digging force between when
the swing lock switch is ON and when the swing lock switch is OFF, start troubleshooting from
“A” in the flow chart below.
CaUSe Remedy
Defective pump Replace

controller
Item 1, is 1171
displayed?
1 NO
Alreadv reset
- Turn starting switch
Is voltage between ON.
\ \-\
. \. \ - ::r::,; chassis - NO
3 YES
* At swing lock switch 15 resistance
ON: Max.3V tx?*ween Cl
’ At swing lock switch _ (female) (3) (4) _
OFF: 20 - 30V - (7). (71 -
chassis as show”
in Table 17 NO
ON. c TOA
OFF. Disconnection in wiring
. Disconnect Cl. larness between Cl
ifemale) (3) (4) (7) -
4 YE v7 (female) (1) (21, or
miring harness between
A~-----~[ Cl (female)
rfemale)
Nith ground
(7) - V7
(2) in contact
Zlefective 2-stage relief .

:O cancel solenoid valve
a Turn starting switch
OFF.
* Disconnect V7
Table 1
Serial No. I Cl (female) I v7 (male) I Resistance value
pC200: 4500, _ 52763 Between (3)(4) - (7) Between (I) - (2) 50 - loon
PC220: 35001 - 36023 Between (7) _ chassis Between (2) - chassis Min. IMQ
‘PC200: 52764 and “p Between (3)(4) - (7) Between (I) - (2) 24 - 46Q
PC200 MIGHTY
Min. 1MQ
n
PC220: 36024 and up Between (7) - chassis Between (2) - chassis
Pump controller
mq-g
CIwICl7)
\ I
V7(X2)
I5 D9
205FO5381-1
C-M- [. \ -\ m] [Disconnection
displayed
in TVC solenoid valve system] is
Sr If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (2) of the solenoid is short circuiting with the ground, the current (approx. IA) con-
tinues to flow to the solenoid.
Sr If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
* Turn the TVC prolix switch OFF.
Remedy

controller
TO A
harness between C5
(female) (3). (4)-C4
(female) (l), (2), or Repair or
wiring harness between replaCe
C5 (female) (4)-C4
I
* Turn starting switch a Disconnect C5.
with ground
OFF.
- Disconnect C4.
Defective TVC solenoid Replace
NO
harness between C5
(female) (1). (2kCl
(female) (9). (17). or Repair or
wiring harness between replace
C5 (female) (2)-Cl
with ground
Defective TVC prolix Repair or

switch, or defective replace
* Disconnect C5. switch-C5
I
Table 1
Resistance value
Cl (female) c5 (female) c4 (male)
cs2,
Between (9) - (17) Between (3) - (4) Between (1) - (2) 10-22
Between (17) - chassis Between (4) - chassis Between (2) - chassis Min. 1 MS2
Between C5 (male) (1) - (3). (2) - (4) Max. 1
M20(M4)
TVC prolix switch
ON
Resistor
205FO5375-1
Pump controller
20-155
0
c-15 [.2. q [Abnormality in No. 2 throttle signal system] is
displayed
check that the display is 121 I. (If it is not displayed, the system has been reset.)
i Always connect any disconnected connectors before going on to the next step.
CC+JSE! Remedy
3 YE Defective pump
ReplaCe
COntrOllar
Is same condition
- Item 2, is [211
displayed?
2 h
Already wsaf
IS voltage
ON.
Yl , between C2(11) _
- (12) as show”
in Table 11
4 YE Defective engine ReplaCe
- Turn starting switch Remove El. Is throttle ContrOller
ON. voltage between
* Switch working L El (female) (19) -
mode switch. ND - (9) as shown in
Table 17 I\
Defective pump controller Replace
ON.
- Switch working
. Min. IMKL mode switch.
* Disconnect C2 and * Disconnect El.
El.
* Turn starting Switch
Disconnection in wiring har-
OFF. ness between C2 (female) Repair or
(11). (21) - El (female) (91, WJlace
IO
(19). or contact with ground
Pump controller Engine throttle controller
C2(MIC21) El (MIC
4 4.0 - 0 205F05383-K
i!
: 3.0 -
5
._
:
z 2.0 -
iI
N
p 1.0 -
Engine speed (rpm)

C-16 [_z_z] [Abnormality in throttle signal system] is displayed
* If an abnormality is displayed for the engine throttle controller, go first to troubleshooting E-6.
+I Always connect any disconnected connectors before going on to the next step.
YES
I” same condition
as when measuring
2 YES
t-=-Y=
Defective
controller
pump ReplaCe
- item 1, is [221 -
displayed?
1 NO
Already reset
-\ -\ IS voltage ON.
- between C2 (10) - harness between C2
- (20) normal? (female) (lo), (20) - El
.K .\z 3 YES Repair or
(female) (10). (20). or
wiring harness between replace
. 0.25-4.75V
. Turn starting switch ON. C2 (female) (10) - Ml5
Is voltage
* Fuel control dial (1) - El (female) (10) in
N; between El (10) -
MIN.-MAX. contact with ground
- (20) normal?
205F05385A
20-157
0
c-1 7 [.2.3] [Abnormality in front pump pressure sensor signal
check that the display is [231. (If it is not displayed, the system has been reset.)
i Always connect any disconnected connectors before going on to the next step.
2 YES
In same condition
YI as when measuring
Item 1, is 1231 -
displaYed?
NO
* Turn startina switch
ON.
5 YES
* 0.5 - 4.5 v
. Start engine.
(Highidling) - Start engine.
+ (High idling)
* Repeatarm relief. +
* Repeat
armrelief.
* Min. 1MG?. 1 ;;:

- Turn starting
switch OFF. NO
- Disconnect C3
and C8. z
Pump controller
C3IMIC9) C8(X3)
Front pump
pressure sensor
Rear pump
pressure sensor
205FO5386-1
controller
Already reset
disconnection in Repair or
wiring harness between reDlace
C3 (female) cl)-C8
(female) (1)
Defective front pump ReplaCe

oressure sensor
I disconnection in wirmg
Repair or
harness between C3
replace
(female) (3)-C8 (female)
(2)

harness between C3
Repair or
(female) (6). cl)-C7. C8
reDleG?
(female) (3), (1). or
contact with ground
20-159
C- 18 I.2 _‘4] [Abnormality in rear pump pressure sensor signal
check that the display is 1241.(If it is not displayed, the system has been reset.)
2 YES
In fame conditions
- Item 1, is [241 -
displayed?
NO
ON.
T-t
5 YES
7 \ \ -
Is voltage
betweenc3 (7) -
- (21 normals YES IS voltage
\- -\ - between C7 (3) -
e-0 4 - (1) normal?
* 0.5-4.5v
* Start engine. YES IS VOltage between - 0.5-4.5v NO
(High idling) - c7 (2) - (1) * Start engine.
+ 3 normal? (High idling)
* Repeat arm relief. p
+
Is resistance
* 18-28V * Repeat arm relief.
between c3
- (female) (7) _ . ;;.n starting switch-N0
NO
- (2). (71 -
chassis normal?
- Min. IMQ.
* Turn starting L
switch OFF. NO
* Disconnect C3
and C7.
Pump controller
C3IMIC9) C8(X3)
pressure sensor
205FO5386-1
20-160
0
Replace
disconnectin in Repair or
wring harness ‘eplace
between C3 (female)
(2) - C7 (female) 11)
Defective rear pump

Replace
pressure sensor
disconnection in
qepair or
eplace
C3 (female) (3)- C7
Ifemale) (2)
Short clrcut m wiring qepair or

harness between C3 eplace
(female) (7). (2) -
C7-C8 (female) (3).
(1). or contact with
ground
I
*O-2’
C-19 [_s.‘=,] [Ab normality in pressure sensor power source,
check that the display is 1251.(If it is not displayed, the system has been reset.1
r[
YES
2 I
Is same conditi-
ES ons as when
measuring
Item 1, is I251
displayed?
NO
. 18-28V
ON.
Disconnect C8.
Disconnect C7.
Is voltage YES
. 18-28V between C3 (3)
. Turn startina switch - 12) normal?
AI
H
ON. - I
* Disconnect ~7. L
- 18-28V NO
* Turn starting switch CnaSSlS normal
ON.
_.
a Disconnect C3, C7.
and C8.
Pump controller
C3IMIC9) C8(X3)
Front pump
pressure sensor
Rear pump
205FO5386-1
20-162
0
CatI%?
Defective pump
controller
Already reset
Defective front pump

pressure sensor
Defective rear PumP

pressure sensor
Defective pump
controller
Dwonnecton in wnng
harness between C3 (fe-
male1 (1) and C8 (female)
(1 I, C3 (female1 (31 and
C8X7 (female) (2). C3
(female) (2) and C7 (fe-
male) (1). or contact
with ground
*O-P3
c-20 [.2.‘;J)
[Abnormality in engine speed sensor system] is
displayed
Ir If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
Note: If the decimal point on the pump controller self-diagnostic monitor display does not flash when I
the engine is started, go to troubleshooting F-8.
Call% Remedy

controller
YES When engine is

- started, is [261 -
2 displayed?
Already reset
Is resistance
YES * Start engine. NC, (see Note)
between C3
- (female) (8) - -
Note 1 (4) normal?
Dlsco”“ectlo” Ill wlrlng
harness between C3 (female)
Is resistance
_ between E7
(male) (1) -
(2) normal?
Pump controller
C3(MIC9) M3@16) E2 (St21 E7(X21
Engine
speed
sensor
205FO5389-2
20- 164
0
c-21 [.28][Abnormality in auto-deceleration signal output
* When the auto-deceleration switch is ON.

* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, turn
the auto-deceleration switch ON, then operate the control lever (Neutral - operated), and check
that the display is [281. (If it is not displayed, the system has been reset.)
2 YES Defective pump Replace

controller
Iln same conditions1
Item 1, is [281 -
1 Already reset
Defective engine
throttle controller Replace
Disconnection in
Repair or
C2 (female) (19)-El
* Turn starting switch .epklce
(female) (11). or
OFF. contact with ground
- I&symect C2 and
Table 1
Operation Voltage between C2 (female) (19) - chassis
Auto-deceleration switch ON. lever at neutral I O-l v
1 Auto-deceleration switch OFF, lever at neutrall 8-12V I
Table 2
connector Resistance value
Between C2 (female) (19) - El (female) (11) Max. la
Between C2 (female) (19) -chassis Min. 1 Ma

C2(MIC21) EI(MIC21)
Auto-
deceleration @
P\
12 GND
205F05390A
20-l 6$
0
c-22 [.a.q [Abnormality in overheat signal system] is displayed
Sr If [291 is displayed again when engine is restarted.

jr Always connect any disconnected connectors before going on to the next step.
CaWX Remedy
YES See Engine shop

manual
1
Does monitor
-\ 1-1 _
panel display - YES Defective Pump ReplaCe
overheating? controller
.-.-
\- -\ 2
. Turn starting
Is voltage between
switch ON.
N; C2 (l7), (18) - (8) -
normal? 3 YES Defective monitor
RepleCe
Is resistance bet- panel
p ween P2 (female)
. When normal:
- (12). (13) - (16), -
lo-13v Disconnection in wiring
ND (12) (13) -
* When overheated: harness between C2
chassis normal? Repair or
o--1v (female) (171, (18)-
replaCe
* Start engine - Min. IMQ P2 (female) (12). (131,
- Disconnect C2 end or contact with ground
P2.
PC200-5 Serial No.: 45001 - 58018

PC220-5 Serial No.: 35001 - 36613
Pump controller Monitor panel
C2IMIC 21) P2(040 16)
205FO5391 A
C2(MIC21) P2(040 16)
205FO5391 A
c-23 I%$$$ [Controller abnormal system] is displayed
CEUSS? Remedy
Defective pumP
ReplaCe
controller
20-167
TROUBLESHOOTING OF PUMP CONTROLLER
INPUT SIGNAL SYSTEM
(F MODE)
Failure mode
F- 1 Pump controller monitor does not display [PI 1 . ... ... .. 20-170
F- 2 Pump controller monitor does not display [P21 . ....... 20-171
F- 3 Pump controller monitor does not display [P61 . . . .. . .. 20-173
F- 4 Pump controller monitor does not display Lb51 . . . . . . . .. . 20-174
F- 5 Pump controller monitor does not display [Hi or Lo1 . . . . 20-175
F- 6 Pump controller monitor does not display [AdI . . . . . . . . .. . 20-176
F- 7 Pump controller monitor does not display [UP1 . . .
... . . 20-177
F- 8 Pump controller monitor does not display LC.1 . . .
. . . .. 20-178
F- 9 Pump controller working mode display does not switch . .. . 20-179
F-l 0 Pump controller power mode display does not switch . . . .. 20-180
20-A69
F-l Pump controller monitor does not display
\2 \
.\ . \ J[Work
equipment oil pressure switch]
PC200,200LC-5 Serial No: 45001 - 49706

PC220,22OLC-5 Serial No: 35001 - 35661
* After starting the engine, and operating the work equipment (boom, arm, bucket) levers, it is dis-
played for approx. 1 sec.
* If it is not displayed for any of the boom, arm, or bucket systems when the control lever is operated,
carry out the troubleshooting below.
If it is not displayed for only one or two of the systems, the shuttle valve in that circuit is defective.
A When measuring with the engine started, operate the levers without moving the work equipment.
sr Always connect any disconnected connectors before going on to the next step.
+ When measuring with the engine stopped, charge the accumulator before measuring.
CalATe Remedy
2 YES Already reset

In same conditi-
ons as when
measuring Item 1,
is [PI 1 displayed?
Defective pump
NO Replace
* Start engine. cOntrOller
* Operate lever
(boom, arm,
L-
Isvoltage betweer bucket) Defective contact. dlscon-
Cl (1) - (121, 4 .-_
VFS nectnn I” w,r,nq harness Repair or
(13) normal? between Cl (female1 (1 21, WPlXZ
IS resistance between 1131 - Sl (female) (11.
YES Sl (femaleI 12) - Cl or contact with ground
- Lever at neutral: 3 - (female) (1) normal -
zo-3ov _ and IS circuit insulated Defectwe contact, dlscon-
* Lever (boom, Is resistance from chassis, nect,on I” w,r,ng harness
NO Repair or
arm, bucket) between S1 between C 1 (female) 12) -
operated: _ (male) (1) - (2) _ * Between Sl and Cl: Max. Ifi Sl (fern&l 11). ~rc~ntact
replace
, nOrmal and is - Between wiring harness and
Max. 1 V wth ground
circuit insulated chassis: Min. 1 Ma
* Start engine. from chassis?
* Disconnect Sl and Cl.
. Lever operated:
Defective work Replace
Max. 1 .Q NO
* Lever at neutral : equipment
switch
oil pressure
Min. 1 Ma
. Start engine. * If the condition does
- Disconnect Sl. not become normal
* It is also possible to fit a short connecfor to make judgement. even when the switch
In this case, proceed as follows after checking the voltage between Cl (I) - 112). is replaced, go to H-7.
(13) in Step 1.
. If voltage is 20 - 3OV. answer YES and go to Item 2.
. If voltage is IV or below, answer NO and go to Item 3.
Pump controller
Cl (MICl7)
/ 205FO5392-1
F-2 Pump controller monitor does not display [F _s] [Swing oil
pressure switch (Work equipment*swing oil pressure switch)]
PC200,2OOLC-5 Serial No: 45001 - 49706
PC220,22OLC-5 Serial No: 35001 - 35661
l Swing oil pressure switch
Sr After starting the engine, and operating the swing lever while operating the arm or bucket levers, it
is displayed for approx. 1 sec.
t Always connect any disconnected connectors before going on to the next step.
A Before operating the swing lever, turn the swing lock switch ON.
Remedy
2 YES
I
A read y reset
In same condi-
YE tions as when
measuring Item 1,
is [PZI displayed?
Defective pump
Replace
- Start engine. NO controller
* Operate swing
lever Defectwe contact, dls-
connection in wiring
Isvoltage
between
harness between Cl Repair or
C3 (5) - chassis 4 YES
(female) (12). (I 31 - replace
s2 (female) (1). or
YE contact wtth ground
. Lever at neutral: n /Z%Z&jHT
20-30V Defective contact, dls-
. Swing lever connection in wiring
operated : harness between C3
Max. 1 V (male) (1)- (21 * Between S2 and C3: Max. 1.Q (female) (5) - S2
h normal and is * Between wiring harness and chassis:
* Start engine. (female) (2). or
circuit insulated Min. 1 MQ. contact with ground
from chassis?
* Disconnect S2 and C3.
’ Lever operated : Defective swing oil
Replace
Max. 1a IO
pressure switch
- Lever at neutral: * If the condition
Min. 1Ma does not become
* Start engine. normal even when
. Disconnect 52. the switch is
* It is also possible to fit a short connector to make judgement. I replaced, go to H-7.
In this case. proceed as follows after checking the voltage between C3 (5) and the
chassis in Step 1.
* If voltage is 20 - 3OV. answer YES and go to Item 2.
. If voltage is 1V or below, an?.wer NO and go to Item 3.
Pump controller
Swing oil
pressure switch
205FO5393-1
20-A71
0 Work equipment -swing oil pressure switch
* After starting the engine, and operating the swing lever or work equipment levers, it is displayed
for approx. 1 sec.
A Before operating the swing lever, turn the swing lock switch ON.
Call%? Remedy
2 YES
Already reset
I
I” same condl-
I
YE t,o”saswhen
measunng Item 1,
IS [P21 displayed?
Defective pump controller
Start en&e. NO
1
Operatelever
Is voltage between Defectwe contact. dlscon-

C3 151 - chassis “echo” I” w,nng harness
between S 1 (female1 ill
and Cl (female) (121. 1131,
YES or contact with ground
. Lever at neutral:
20 - 3ov 3 r
Defectwe contact, dlscon-
. Lever operated:
“actlo” I” wnng harness
Max. 1V
Between Sl and C3: Max. IQ between C3 (female1 151 -
. Start engine.
Between wiring harness and chassis: Sl (female) 121. or contact
N
wth ground
Disconnect Sl and C3
. Lever operated: Defective work
Max. 1 R equlpment~ swing oil
NO pressure switch
.
Lever at neutral:
Min. 1 MR * If the condltlon does
not become normal
.
Start engine.
even when the swtch
.
Disconnect Sl.
IS replaced, go to H-7
* It is also possible to fit a short connector to make judgement.
In this case, proceed as follows after checking the voltaae between C3 (5) and the
chassis in Step 1.
* If voltage is 20 - 30V. answer YES and go to rtem 2.
+ If voltage is 1V or below, answer NO and go to Item 3.
Pump controller
Work equipment.
swing oil pressure switch
205FO5728
.
F-3 Pump controller monitor does not display .‘? .‘&I [Travel oil
pressure switch]
* After starting the engine, and operating the travel lever, it is displayed for approx. 1 sec.
*
A Before operating the travel lever, check that the surrounding area is safe.
If it is not displayed when operating the travel lever on one side, the PPC shuttle valve is defective.
2 YES
I I I Already reset
In same conditi-
YE ons es when
measuring Item 1,
is [P61 displayed?
I I
i I Defective pump
Repli3Ce
* Start engine. NO controller
1 * Operate-travel
Defective contact. dis-
lever
connection in w&g
Is voltage between harness between S4
C2 (1) - chassis 4 YES (female1 (11 - Cl
Repair or
E?PlaCe
(female) (12). (13). or
cOntact with ground
. Lever et neutral :
20 - 3ov Defective contact, dis-
. Travel lever Is resistance connection in wiring
I
between s4 harness between C2 Repair or
operated: Max. 1L
(male) (1) - (2) (female) (2) - M3 (13) F3PlZVX
* Start engine.
normal and is * Between wiring harness and chassis: - s4 (female) (2). or
I\
circuit insulated contact with ground
from chassis?
J - Disconnect 54 and C2.
* Lever operated: Defective travel oil
Replace
Max. 1n pressure switch
NO
* Lever et neutral: l If the condition does
Min. 1 Ma not become normal
* Start engine. eve” when the switch
. Disconnect 54. is replaced, go to H-7.
* ‘It is also possible to fit a short connector to make judgemat.
In this case. proceed as follows after checking the voltage between C2 (1) and the
chassis in Step 1.
* If voltage is 20 - 3OV. answer YES and go to Item 2.
* If voltage is IV or below, answer NO and go f~ Item 3.
S4(X2)
Pump controller
Cl (MICl7)
pressure switch
205FO5394-1
20-A73
F-4 Pump controller monitor does not display [:I(L,] [Swing lock
switch]
* After starting the engine, and turning the swing lock switch ON, it is displayed for approx. 1 sec.
Sr If the monitor panel display is normal (if the swing lock lamp on the panel does not light up, go to
P-22).
Ir’ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connectors before going on the next step.
I I
CWXW Remedy
2 YES
Already reset
In same condi-
YES tions as when
measuring Item 1,
is Lb51 displayed?
1 Defective pump Replace
controller
* Swing lock switch NO
Is voltage between ON-OFF
- Defective swing
C2 (4) - (8) lock switch
“lX”Xll?
* Dlsconnectvx I” wrmg
3 YES
harness between C2
Repair or
replace
* Swing lock switch (female) (8) - swng
IS there continuity
ON: Max. 1V lock swtch (1 I. or
L between C2 (female)
contact wth ground
OFF’ l8 - 28v NO (4) -wing lock
* Turn starting Disconnection in wiring
swtch Ll)?
switch ON. harness between C2 Repair or
NO (female) (4) - lock replace
. Turn starting
switch OFF switch (1)
* Disconnect C2.
Swing brake
solenoid valve
M20W4) v
(Q@
Pump controller Fuse
CI(MICl7P) M3E161 I
I
Swing brake
1
Swing lock
switch
C2(MIC21) Swing lock

prolix switch
1
Swing lock @
GND @
205F05730A
20-&74
F-5 Pump controller monitor does not display [.b\. ,] or [!,_.,-,] [Travel
speed switch]
* After starting the engine, and switching the travel speed switch to Hi or Lo, it is displayed for
approx. 1 sec.
Sr If the monitor panel display is normal (if the panel display is not normal, go to P-20).
2 YES
Already reset
In same conditi-
YES ons as when
- measuring Item 1, -
is [Hi] or [Lo1
1 displayed?
Defective pump
Replace
NO controller
Is voltage between
C2 (3) - (8) as -
shown in table 17
3 YES Defective monitor Repair or
* Turn starting Disconnect P2. Is panel reDlace
switch ON. voltage between
* Travel speed switch- ~2 (female) (4) - - Defective contact,
Hi-Lo ND (16)asshown disconnection in
below? NO wiring harness Repair or
between C2 (female) replace
(3) - P2 (female)
ON.
(4). or contact with
* P2 disconnected:
ground
10 - 13v
Table 1
Travel speed switch Lo 10 - 13V
Travel speed switch Hi 1 Max. 1V

C2(MIC21) P2 (04016)
205FO5396
20-&75
F-6 Pump controller monitor does not display [!&J,]
[Auto-deceleration switch]
* After starting the engine, and set auto-deceleration switch to ON, it is displayed for approx. 1 sec.
* If the monitor panel display is normal (if the auto-deceleration display on the panel does not
change, go to P-l 9).
Cause Remedy
2 YES
Al read Y reset
In same conditi-
YES 0”s es when
measuring Item 1,
1 is [Ad] displayed?
controller
YES I3efective monitor

I I>ane1
IIefective contact, or
cjisconnection in wiring
- t harness between C2 Repair or
replace
. P2 disconnected:
I female)
female)
(7) - P2
(7)
10 - 13v
Table 1
Auto-deceleration switch ON Max. 1v

Auto-deceleration switch OFF lo- 13v

C2UvllC2l) P2 (040161
205FO5397
20- 176
0
F-7 Pump controller monitor does not display [_‘,l:‘l] [Power
maximizing switch]
* After starting the engine, and pressing the power maximizing switch, it is displayed for approx. 1
sec.
+ Always connect any disconnected connectors before going on the next step.
I Cause I Remedy I
2 YES
Already reset
Defective pump
ReplaCe
controller
Defective contactT
” or disconnection !n
Repair or
I I I IL4
replSX
. When switch is C2 (female) (12). (8)
not press, ?d: Is resistance
- switch
20 - 3ov between switch _
* When swi tch is NO (1) - (2)
pressed : Max. 1v normal?
Defective power
* When switch is not
..-
ND
. . . ..__ -
Rc?“l.%?e
pressed: Min. 1 MR
* When switch is
pressed: Max. 1.Q
Pump controller
C2(MIC21)
Power maximizing switch
205FO5398
F-8 Pump controller monitor does not display [pQ$JQ]
hJecimal
point of [Engine speed sensor]
+ The display flashes when the engine is started.

C3lJS.e Remedy
YES Defective adjustment of ReplXe

engine speed sensor
Yf
Defective pump
Redace
controller
~:
I I Defective engine speed

- Measure with NO Se”SOr
AC range.
. 0.5 - 3v Defective contact, dis-
* Start engine. connection in wiring
* 500 - 1ooo.Q
harness between C3
* Turn starting switcl 4 YES
(female) (8). (4) - M3
OFF. (1 2). (4) - E2 (I I),
- Disconnect C3.
(I 21 - E7 (female1 (2).
(1). or contact with ground
F
Defective speed sensor Redace

- Between (1) and (2):
500 - 1oooa
- Between (1) and
chassis: Min. 1 Ma
OFF.
- Disconnect E7.
Pump controller
C3(MIC9) M3(Sl6) E2(Sl2) E7(X2)
0 Engine
speed
sensor
@J
205FO5389-1
20-l 78
a
F-9 Pump controller working mode display does not switch
I\ 7 -\ \ \
\ \= 3 7
1
* The working mode is displayed approx. 1 set after the starting switch is turned ON.
* If the monitor panel display is normal and the working mode does not switch, go to
Troubleshooting M-l 7.
CaUSe Remedy
2 YES
under rame con-
di?lO”Las when
Yl meawr,ng Itern
* 7,doeswokring3
mode monifor
dilplayw.Jircll
1 “OUTallV? Defective pump
controller
IS voltagebet- . Switch working NO
L-l
ween c2 (14) mode on
(15) and (8) as monitor panel
shown in Table
l? 3 YES
Defective monitor Panel
. Turn starting
switch ON.
. Switch working Defective contact or
mode on r disconnection in wiring
monitor panel harness between C2
(female) (14) - P2
. Turn starting NO (female) (8). and
switch ON. between C2 (female)
. When P2 is (15) - P2 (female) (9).
disconnected:
10 - 13v
Table 1
Monitor panel
G.0 10 - 13v 10 - 13v C2 (MIC21) P2 (04016)

I \ I
F.0 o-1v 10 - 13v
L.0 o-1v 0 - 1v
205FO5627
2o-i79
F-l 0 Pump controller power set display does not switch
t The power set is displayed approx. 1 set after the starting switch is turned ON.
Ir If the monitor panel display is normal and the power set does not switch, go to Troubleshooting
M-l 8.
However, if the coolant temperature gauge on the monitor panel is showing the red range (over
102”C), the pump controller displays L mode.
Remedy
Already reset
1 Defective pump
RePlaCe
controller
* Switch power
mode on
monitor panel
I
YES
I Defective monitor panel F7epl.Sl2
* Turn starting
switch ON.
. Switch power
I Defective contact, or
mode on disconnection in
monitor panel. wiring harness between
C2 (female) (5) - P2 Repair or
(female) (5). and bet- reDlace
switch ON. - w?en C2 (female) (6)
. When P2 is - P2 (female) (6).
disconnected:
10 - 13v
Table ?

r-\IBa.mBc’l
C2 (MIC21) P2 (04016)
l 10 - 13V when working mode is

L.0 mode
205FO5628
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
Failure mode
Work equipment, travel, swing system
H- 1 Speeds of work equipment, travel, swing are all slow ................... . 20-182
H- 2 There is excessive drop in engine speed, or engine stalls ................ 20-184
H- 3 Work equipment, travel, swing do not move, or speed is extremely slow . 20-186
H- 4 Work equipment, travel, swing lack power ............................. 20-188
H- 5 Power mode selection system does not switch ........................ . 20-188
H- 6 Abnormal noise generated (from around pump) ........................ 20-189
H- 7 Auto-deceleration does not work ..................................... 20-189
Work equipment system
H- 8 Boom, arm speed is extremely slow ................................... 20- 190
H- 9 Work equipment (boom, arm, bucket) speed is slow .................... .. 20- 192
H-l 0 When boom and arm are operated simultaneously, boom is slow ........ . 20- 194
H-l 1 Work equipment (boom, arm, bucket) lacks power ..................... . 20- 194
H-l 2 Excessive hydraul,ic drift ............................................. .. 20- 194
H-13 Excessivetimelag .................................................. . 20-I 96
H-l 4 Does not enter finishing operation mode .............................. 20-I 96
H-l 5 When arm and swing are operated simultaneously, arm is slow .......... 20- 196
Travel system
H-16 When machine is traveling, it deviates naturally to one side
al Deviates in same direction both in forward and reverse . .. 20-I 98
b1 Deviates in different direction in forward and reverse . . 20-200
H-17 Excessive deviation during compound operations .. .... . 20-20 1
H-18 Excessive deviation when starting ...... .... ... .... . 20-202
H-19 Travel lacks power or speed is slow ... .. . ....... . 20-204
H-20 Travel speed does not switch .. . .... . .... ... .... . 20-204
H-21 Machine does not move (one side only) ... ........ .. . 20-205
Swing system
H-22 Doesnotswing ............................................ ....... . . 20-206
H-23 Swing speed is slow or acceleration is poor. .................. ...... 20-208
H-24 Excessive overrun when stopping swing ..................... ...... . 20-209
H-25 Excessive shock when stopping swing ....................... ...... . 20-209
H-26 Excessive abnormal noise when stopping swing .............. ...... . 20-210
H-27 Excessive hydraulic drift of swing ........................... ...... . 20-210
H-28 When operated simultaneously with arm, swing speed is slow . . ...... . 20-210
TABLE OF FAILURE MODES AND CAUSES ............................. ...... . 20-211
20-181
H-l Speeds of work equipment, travel, swing are all slow
* If there are other problems, such as travel deviation or low bucket or swing speed, go to H-l 6.
% 1. If the pressure is not at least 27 kg/cm2, the spool of the acceleration (Hi) end is not fully actuated.
x2. The discharge pressure of the pump has an effect on the TVC valve set pressure, so check it
before adjusting the TVC valve set pressure.
4 YES
v
Is engine speed . When normal relieved:
YES normal when PC200 2150 * 60 rpm
- pump is relieved - PC220 2300 * 60 rpm
with CO canceled?
3
. When CO canceled: NO
PC200 2050 ? 60 rpm PC220 2200 + 60 rpm
YES IS set pressure
* H.0 + H mode
- at Tvcvalve -
normal?
. Arm relief
5 YES
. PC200: 16 ‘; Does condition

2 _ become normal
kg/cm’
+1 ND when TVC Valve
Yl Is relief pressure * pc220: 17_2 is adjusted?
. of F. R Pump - kg/& .,^
normal? NU
. H.0 + H mode
. l-pump relief
- At normal relief: * Engine at high idling
310 - 340 kg/cm’
1 - At 2-stage relief: 6 YES
335 - 365 kg/cm=
- H.0 + H mode DOS condition
Is relief pressure _ become nOrmal _
at charging pump * Engine at high
NO when main relief
normal? idling
valve is adjusted?
%2
* Engine at high NO
idling
. 30 TE kg/cm2
*1
20-182
0
I CalKX Remedy
Leakage inside Replace pump

Pump assembly
21 See Engine shop manual
Adjust
fl/ Defective TVC valve Replace
4djus.t
Defective main relief Replace

valve
(Go to H-3, Item 3)
20-183
H-2 There is excessive drop in engine speed, or engine stalls
YES
I
2
When pump is
I
Y, relieved, is Y,
OUtpUt pressure Of
co valve normal?
3
a At normal relief: Does output f Output pres-
Max. 5.5 kg/cm’ pres$ure become sure becomes
a When CO canceled: _ normal when CO normal
Same pressure at NO valve is * Condition also -
TVC press”re adjusted? becomes
* Engine at high idling normal J
. H.0 + H mode * output pres-
suredoes not -
become
normal I
* PCZOO: 16
+1
-2
. set pressure
becomes
YES
.r
kg/cm’ normal
. PC220: 17
+1
_2
. Problem does
4 I L not cnange
kg/cm2
Does condition . Set pressure
* l-pump relief becomes
become normal
* H.0 + H mode
“orma’
* Engine at high 1v”L when TVCvalve --
. Condition also
.
set pressure is
idling adjusted? becomes
i normal 1
Set pressure
does not
become
normal
20-184
0
Cause Remedy
See Engine shop manual -
Defective adjustment of Adjust

co valve
( Defective CD valve Replace
Defective adjustment of
Adjust
TVC valve
. Defective TVC valve ReplXe

M-3 Work equipment, travel, swing do not move, or speed
is extremely slow
* When there is a big difference from the permissible value.

* Auto-deceleration is normal.
* Mode selection is H.0 and H mode.
YES
3-
Block circuit (1) -
YES (6) in Fig. 1. Is
-charging pump -
relief pressure 4 YES
I
n normal?
_ Is any foreign
material found in
* 30 ‘E kg/cm2 _ oil drained from -
NO charging pump
* Engine at high outlet strainer?
idling
NO
motor.
- Disconnect
gcwernor “lOtOr
Do not move, or connector, and set h
speed is extremely governor lever
to NO INJECTION.
YES
L To I tern 3 above
5
Speed is IS set pressure of

extremely slow - TVCvalve 6 YES
3
normal?
Does condition
become normal ::
. 14 - 17 kg/cm* NO_ when TVC valve
. H.0 + H mode is adjusted? ::
z
NO
Fig. 1 Control circuit
Travel PPC valve
Solenoid valve 4
_Y 9tJ+
R.H. PPC valve

Charging pump
Safety lock valve 5
L.H. PPC valve
205FO5300
20-186
0
Remedy
Defective charging
Wplace relief
ralve
. Defectwe damper
iPT0)
_ - Defective mm pump
(broken shaft, etc 1
Defective set pressure

Idj ust
of TVC valve
20-187
0
H-4 Work equipment, travel, swing lack power
CaUSe Remedy
3 YE
Defective CO valve
correct or
reDlace
YI Outlet Port Of
solenoid valve’
When digging
2 * See conditions for N
Defective
solenoid
CO cancel
valve
ReplaCe
Y ES Item 4 below.
force is
maximized
4 YE Drop in set pressure of Adjust or
* At travel relief: main relief valve ,ep1ace
335 - 365 kg/cm*
1 . Engine at high ,
idling solenoid valve
Does the problem
cxcur when Defective 2.stage
digging force is Replace
- At travel relief and N relief solenoid valve
maximized, or when digging force
during normal is maximized:
25 - 35 kg/cm’
. During normal
operation: 0 kg/cm’
* It is also possible to hold the solenoid

During normal valve outlet hose by hand to judge. 4djust or
Drop in set pressure
operation 3 of main relief valve .ep1ace
NO
H-5 Power set selection system does not switch
Cause Remedy
1
When TVC valve 1 YES
solenoid is remov- Defective TVC valve ReplaCe
ed, and mode

selection switch is
operated with con-
nector still conne-
cted, does spool . Defective TVC solenoid RePlaCe
of solenoid move? NO
I) Turn starting
switch ON.
20-188
0
H-6 Abnormal noise generated (from around pump)
CaUSe Remedy
Clogged strainer Clean

2
Loose piping clamp Tighten

3
Is problem
removed when
piping between
tank and pump is 4 YE
Is oil level in
hydraulic tank oil is drained, are
any metal wear
particles found? Inspect again
Operate for a time
and watch any Depending on
changes in symptoms changes
in symptoms)
Add hydraulic
Lack of oil
oil
H-7 Auto-deceleration does not work
CaUSe Remedy
t-
1 YES Defective travel shuttle Repair or
Valve reDlaCe
Is hydraulic
pressure at inlet
port of travel -
shuttle valve
normal? Defective PPC shuttle Repair or
valve replace
- 25 - 35 kg/cm’ ND
20-189
H-8 Boom, arm speed is extremely slow
l Mode selection is H.0 and H mode.

* When the travel, swing, and bucket speeds are normal.
C.WSl2 Remedy
1 YES Defective operation Repair or

of straight-travel valve replaCe
Does travel shuttle

valve spool move -
smoothly?
Defective operation of Repair or
*Valve on top of NO travel shuttle valve replace
control valve
20- 190
0
H-9 Work equipment (boom, arm, bucket) speed is slow
* When the travel and swing speeds are normal

(However, if there is any travel deviation and the bucket or boom speed is slow when operated indi-
vidually, go first to “H-l 4 When machine is traveling, it deviates naturally to one side”.)
3 YES
Is operation of
- boom holding -
valve normal?
NO
. Check movement of
valve with your hand.
4 YES
Is hydraulic
pressure at Outlet
Arm only ] - port of arm half -
I
flow solenoid
valve normal? NO
. F.0 or L.0 mode: 0 kg/cm2
. Normal operation: 25 - 36 kg/cm2
l It is also possible to hold the solenoid valve outlet
hose by hand to judge.
[ Bucket only
J
1
* ;li~b/c-’ 1
* Engine at high
Is hydraulic drift NO
of slow cylinder _
within standard
ValUe?
5
Does hydraulic
drift become
faster when YES
lever is
operated? NO 6
* See TESTING AND

ADJUSTING.
r[ Arm, bucket ]
* For details of the

* 20 cc/min
type of safety
* When relieved NO
valve, see 7 YES
* Engine at high idling
Table 1. 4
II
L[ BoomonlY 1
Is boom holding
valve normal?
H
* Check movement NO
of valve with your
hand.
Table 1 Table of locations and types of safety valves used for

each cylinder
( ) : Setpressure
Cylinder Bottom end (kg/cm2) Head end (kg/cm 2)
Boom Safen/ -suction valve (355) Safety -suction valve (290)
Arm Safety - suction valve (355) Safety valve (355)

Bucket Safety - suction valve (355) Safetv -suction valve (3551
20-192
0
I Cause Remedy
Repair or
Defective operation of replaCe
control valve spool control valve
(boom) assembly
Defective operation Repair or

of boom holding valve replaCe
Repair or
Defective operation of
replace
control valve spool (arm)
Control valve
assembly
Defective arm half flow

solenoid valve
)I Defective PPC valve
Defective safety (suction)

valve
Defective oil-tightness
of control valve spool
20-193
H-10 When boom and arm are operated simultaneously,
boom is slow.
l When usual operation is normal.
F-i-i
Defective
valve
arm throttle Repair
replaCe
or
H-l 1 Work equipment (boom, arm, bucket) lacks power.
* When the travel and swing speeds are normal.

2 YES
H
i I I
YES Is main relief

pressure normal
at travel relief?
i
1
r
-w I
NO
I-
Does this problem
occur when digging
force is maximized, 4 YES
or during normal I 1 I
operation?
YES
3r
power at both
j_ ( During normal head end and
~0 i operation bottom end, or
One end only ]

NO
Table 1 mm
H-l 2 Excessive hydraulic drift
+I Go to H-9, Item 5.
20-l 94
a
Cause Remedy
1 CO cancel solenoid ReplaCe
valve
Defective OperatiOn Of
*-stage relief solenoid ReplaCe
Valve
- (Go to H-9, Item 2)
(Go to H-9, Item 5)
Defective safety
Replace
(suction) valve
20-195
H-13 Excessive time lag
* If the work equipment speed is normal (if the speed is slow, go first to H-9, Item 2).
CaUSi? Remedy
Defective operation
Replace
of suction valve
Time lag set
H-14 Does not enter F.0 mode (Half flow functiuon)
CaUSe Remedy
Defective operation
of arm half flow ReplaCe
solenoid valve
H-15 When arm and swing are operated simultaneously, arm

is slow
* If the operation of the auto-deceleration is normal (if the auto-deceleration is defective, go first to
H-7).
C.NSe Remedy
Defective OperatiOn of Repair or

swing priority valve repl.3Ce
20-196
0
H-l 6 When machine is traveling, it deviates naturally to one
side
* When the travel speed is normal.

a) Deviates in same direction both in forward and reverse

“I ES
Direction of 41L
YES
deviation . For details, see NO
changes TESTING AND
YES Is OUtpUt preSS”re
ADJUSTING.
- of NC valve
* Fordetails, see normal?
YES
TESTING AND
ADJUSTING. 6-
* When track is rota-
ted freely or during
normal travel, Is differential
-
sensor norma!?
Is main relief the TVC output

pressurenormal? pressure.
* Lever at neutral:
* Lever at neutral:
13 - 19 kg/cm’ No
Max. 5.5 kg/cm’
* Engine at high idling . SeeNore.
1
When pump outle t
hoses are changed
between F and R,
does direction of
deviation change?
10
Are metal particles
YES found in oil
_ drained from final _ YES
drive on side
which deviates? 11 r
p DoesdirectionOf
deviario"
change when
_ leftand
rigil*tmres _
9 NO betwee"
C0"tr.d "he
andIWi".I
joint are
i”tsrchsnged7
YES Does control valve
spool move
smoothly? NO
I I
Direction of
Is output preswre
L deviation does
of PPC valve
NO not change
NO
. 30 ‘g kg/cm2
Note: When the track is rotated freely, if the output pressure of the NC valve is the same as the
output pressure of the TVC valve, both the jet sensor and NC valve are normal.
20-:98
CCV_lSC? Remedy
Defective adjustment See TESTING

of pump AND
ADJUSTING
Leakage of inside
ReplaCe
pump
Defective operation
Replace
of servo valve
Defective operation Adjust or

of NC valve replace
7 YES Drop in set pressure

Adjust
Does condition of jet sensor relief valve
becc~me normal
when relief valve
of jet sensor is
interchanged or
adjusted? Defective jet sensor Clean or
orifice replaCe
. never operated: NO
Max. 2 kg/cm’
Drop in set pressure Of Adjust or

main relief valve replace
- ’ Defective final Repair or

drive replace
Defective control
Replace
valve body
Defective swivel
Replace
joint
Defective travel Replace motor

rncltor assembly
Defective Operation Of
Replace
COntrOl valve spool
Defective PPC valve Replace
20- 199
b) Deviates in different direction in forward and reverse (See Fig. 1 I
2 YES Defective swivel

joint packing replace
YES lS OUfpUt pWss”W
, - of PPC valve
__ normal?
Repair or
Is relief pressure - - Defective PPC valve
replace
normal at travel - . 30 ‘E kg/,-+ NO
relief?
a Engine at high idling
. 335 - 365 kg/cm2 ND Drop in set pressure Replace safetv

. Engine at high idlint of travel motor Safety
valve assembly
valve
Location of defective swivel

Fig. 1 joint packing and direction
of deviation in travel
20-200
0
H-l 7 Excessive deviation during compound operations
* If individual travel is normal.
CS_lSC? Remedy
2 YES Defective operation Repair or

of straight-travel valve replaCe
Does spool of
YES travel shuttle
1 - valve mclve
smoothly?
Is oil pressure at
- travel shuttle valve repIS
inlet port of travel NO
shuttle valve
normal?
.25 - 36 kg/cm* Defective operation of

NO PPC shuttle valve
* If the pressure in Item 1 is lost, the auto-deceleration also will not work.
*O-$O’
H-l 8 Excessive deviation when starting
* When the travel speed is normal

* If there is also deviation during normal travel, go to “H-l 6 When machine is traveling, it deviates
naturally to one side.”
For deviation during simultaneous operations with the work equipment, go first to “H-l 7 Excessive
deviation during compound operations.”
* Bleed all air completely from the circuit.
\IES 4 YES
Deviates at
full stroke
NO
El
Does machine
deviate at lever
full stroke, or
during fine
control?
. 220mm/20m 6 YES
7
is OUtpUt
YES_ pressure at NC
valve at fast end
normal?
5
Machine deviates Is differential - Control lever at NO
when starting, pressure of jet neutral: Max.5.5 kg/cm=
I regardless of N - - sensor at fast - * Traqk rotating freely: Min. 18 kg/cm*
NO fine control, or side (outside of a Engine at high idling
_ N - Full stroke turn) normal? 7 YES
- ,s”,::99’ lever at
13 - 19 kg/cm2
- Control lever at
full stroke problem reversed?
Max. 2 kg/cm= NO
a Engine at high idling
20-202
0
Remedy
Defective OperatiOn
of servo valve
Defective control
valve
Defective swivel joint
Defective travel motor
servo valve
Defective adjustment of
NC valve
Defective jet sensor

relief valve
Defective jet SenSOr

orifice
20-203
H-19 Travel lacks power (or speed is slow)
Ir The mode selection is H.0 and H mode.

* When there is no travel deviation.
* If the main relief pressure has dropped, the work equipment lacks power even for normal work. If
the CO cancel and 2-stage relief valve systems are defective, the work equipment lacks power for
work using the power maximizing function.
Cause Remedy
2 YES Repair or
Defective CO valve
Is hydraulic replace
YES preSS”re at Outlet
- port of co cancel -
solenoid valve
1 Il0rlllal? Defective CO cancel Replace
* See conditions for NO solenoid valve
Is main relief Item 3 below.
pressure at travel -
relief normal?
3 YES Drop in set pressure of 4djust or
At travel relief: Is hydraulic main relief valve replace
335 - 365 kg/cm* pressure at Outlet
Engine at high N& port of 2.stage -
idling relief solenoid
valve normal?
I I I Defective 2.stage relief
1:
replace
. At travel relief and NO solenoid valve
with power
maximized:
25 - 35 kg/cm’
. During normal
operation: 0 kg/cm’
H-20 Travel speed does not switch
* When the travel speed is normal at Hi or Lo.
Remedy
Defective travel motor

1 YES
.Speed change servo Replace motor
Is hydraulic valve ass’v
pressure at
outlet port of -
travel weed
solenoih normal? Defective travel speed
solenoid valve Replace
* At Hi: NO
25 - 35 kg/cm’
At Lo: 0 kg/cm’
20-204
0
H-21 Machine does not move (one side only)
CaUSe
I Remedy
2 YES Repair 0,
Defective final drive
replace
Is any foreign
YES material found in _
I
oil drained from
final drive?
I Travel motcar brake Replace motor
dragging assern b I y
NO
Is main relief
pressure at motor -’
relief normal? .
3 YES Defective travel I Replace safety
. At travel relief: mtxclr safety valve valve
Is hydraulic pressure
325 - 365 kg/cm’ normal at motor
* Engine at high - relief when safety -
idling NO va,ves are
interchanged?
Defective travel Replace motor
. For standard value, NO motor assembly
see Item 1.
H-22 Does not swing
l When other work equipment and travel speeds are normal

* Turn swing lock switch OFF.
YES
4
Is any foreign
YES material found in
oil drained from
swing machinery? 5 YES
3-
Does control
Is hydraulic L valve spool move
NO
YES_ pressure et left smoothly?
and right relief
normal?
2 _ NO
-1Is hydraulic
* .285 - 300 kg/cm2
r H
Does not swing pressure et swing Engine at high
YES
in either brake solenoid NO
idling
direction valve Outlet port
normal?
I
. Lever operated:
25 - 36 kg/cm2 NO
Does not swing in
- Lever at neutral:
either direction, or 0 ka/cm’
in one direction l It is a?so possible to hold the solenoid valve outlet hose by hand to judge.
6 YES
When left and
o”
Does not swing right safety valves
~0 are interchanged, -
I in one direction l- 0”
is problem
reVet?Xd? z
NO
l IS possible to measure
also
the hydraulic pressure to

judge.
* 285 - 300 kg/cm2
- Engine at high idling
20-206
0
CaLI% Remedy
Repair or
Defective swing machinery rep,ace
Replace motor
Defective motor brake assembly
control valve spool
Defective swing motor Replace motor

assembly
Defective operation Of
swing brake solenoid Replace
valve
- Defective safety valve Replace
. ‘Defective PPC valve Replace
20-207
H-23 Swing speed is slow or acceleration is poor
+ When other work equipment and travel speeds are normal. (If there is also deviation (to right)
during normal travel, go first to “H-l 6 When machine is traveling, it deviates naturally to one side”.)
CaUSe Remedy
Excessive leakage inside

3 YES swing motor, or brake
7ep1ace motor
assembly
dragging
YE Does spool move
smoothly when
2 Defective operation of
NC control Valve spool
YI Both left and

right
4 YES Drop in set pressure of

Adjust
* Must be the same a! co valve
TVC valve outp”f
pressure become normal
I\ when CO valve is
* At relief:
Max. 5.5 kg/cm’
Defective operation Of
. Measure at NC valw
co valve
ReplaCe
For standard value, NC
both left and
see Item 2.
right, or in one
direction only?
6 YES Drop in set pressure of
- Time taken to start Adjust
F[
safety Valve
swing (set) (90’) :
PCZOO: Max. 3.4
sec.
PC220: Max. 3.8
* Time taken for
Defective safety valve qeplace
swing (secK5 turns)
One direction . For standard value, NC
Both PC200 and
only see Item 5.
220: Max. 30 NO
* Is also possible to NO
Defective PPC valve GDlaCe
measure the hydraL c
pressure to judge.
.285- 300 kg/cm2
-Engine at high idling
20-208
0
H-24 Excessive overrun when stopping swing
* If the speed is slow or the acceleration is poor, go first to H-23.
Cause Remedy
VES [ Both left and Replace motor

L right . Leakage inside motor
assemblv
excessive to both
left and right, or
in onidirection
r One direction Replace or
C Defective safety valve
* Overrun when NO I only adjust
sropp,ngswl~g:
* PC200: 120
* PC220:
-.
160’
- tnguneat nagllldllng
0”
t3 H-25 Excessive shock when stopping swing
S+
* When the swing speed is normal.
C&US= Remedy
Defective Swing
Repair
machinery
Defective swing motor Replace

brake
Is shock excessive . Lever operated: 25 - 36 kg/cm’ NO Defective swing brake Replace

on both left and a Lever et neutral: 0 kg/cm’ solenoid valve
right, or in one *When the swing is operated and the lever
direction only? is returned to neutral, the hydraulic
pressure becomes 0 after approx. 6 sec.
i One direction
OlllY
1 Defective safety valve ReDlaCe
NO J
20-209
0
H-26 Excessive abnormal noise when stopping swing
* When the swing speed is normal.
CaUSe Remedy
2 YES 3efective swing

3epair
nachinery
Is any foreign I
H
YES Both left and material found in
right
1
oil drained from
swing machinery?
1
NO
Defective
Valve
lift check 3ePlXe
on both left and

right, or in one
direction only?
3 YES
Defective safety valve 3ep1ace
L
One direction become normal 1
I
O”lV when safetv
NO
interchanged?
3efective suction valve 3eplace
NO
H-27 Excessive hydraulic drift of swing
CaUSe Remedy
1 YES Defective swing motor Replace motor

brake assem b I v
Is hydraulic
pressure et swing
brake solenoid -
valve Outlet port
normal? Defective swing brake Replace
solenoid valve
. never at neutral: NO
0 kg/cm’
* Lever operated:
25 - 36 kg/cm2
H-28 When operated simultaneously with arm, swing speed

is slow
l When the usual swing speed is normal.
CCdUSe Remedy

swing priority valve ,ep1ace
20-210
0
TROUBLESHOOTING OF MONITOR SYSTEM
(P MODE)
Failure mode
P- 1 Monitor panel lamps do not light up for 3 seconds when starting
SwitchisturnedON _..........................._....................___... 20-2 14
a) No monitor panel lamps light up.. . .... . ..... . .... ... ..._ . 20-214
b) Some monitor panel lamps do not light up .... . .... . ... .. . .. 20-2 14
P- 2 Monitor panel lamps all light up when starting switch is turned ON,
butdonotgoout ......................................................... 20-2 15
P- 3 When starting switch is turned ON (engine stopped), CHECK items flash . . 20-216
a) Coolant level flashes . . . . .... . . . .. . . . . . ... . .. .... 20-2 16
b) Engineoillevelflashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._ 20-217
c) .... .. . .... . .... . .... . _ .... ... . ..
Hydraulic oil level flashes 20-218
P- 4 Preheating display lights up . . . . . . . . . . . .
is not being used, but preheating 20-219
P- 5 When starting switch is turned ON and engine is started, CHECK items flash . 20-220
a) Alternatorsystem ..................................................... 20-220
b) Engineoilpressuresystem ............................................. 20-220
P- 6 When starting switch is turned ON (engine stopped), CAUTION items flash 20-22 1
P- 7 When starting switch is turned ON and engine is started, CAUTION items flash . 20-222
a) Engine oil pressure flashes ......... y ............................ 20-222
b) Coolant level flashes ............................................ 20-222
cl Coolant temperature flashes ..................................... . 20-223
d1 Chargeflashes.. ............................................... 20-223
e) Fuellevelflashes ............................................... 20-224
:: P- 8
:: a) When starting switch is turned ON (engine stopped),
2 buzzer does not sound for 1 second ...... . ...... ... . . 20-225
CAUTION item is flashing but buzzer does not sound.. .. .. . . . 20-225
b) There is no abnormality display on the monitor, but the buzzer sounds 20-225
P- 9 Panel lighting of monitor panel does not light up ................................. : 20-226
P-IO Coolant temperature shows abnormally ...........................
low temperature 20-227
P-l 1 Coolant temperature gauge gives no display ...................................... 20-227
P-12 Fuel gauge always displays FULL ................................................ 20-228
P-13 Fuel gauge gives no display ..................................................... 20-228
P-14
a) Lamps do not light up ....................................................... 20-229
b) Lamps light up even when lamp switch is not operated ......................... 20-229
P-15
a) Wipers do not work. ........................................................ 20-231
b) Wipers work even when wiper switch is not operated .......................... 20-23 1
P-16
a) Fandoesnotwork .......................................................... 20-233
b) Fan works even when fan switch is not operated ............................... 20-233
P-17 Working .................................................
mode does not switch 20-235
P-18 Power mode selection system does not switch .................................... 20-236
P-19 Auto-deceleration does not switch
(Does not enter auto-deceleration; auto-deceleration is not canceled) ............ 20-237
P-20 Travel speed does not switch between Hi and Lo .................................. 20-238
P-21 Warming-up operation is not carried out below 3O”C, or warming-up
operation is not canceled even when temperature goes above 30°C ............. 20-239
P-22 Even when swing lock switch is turned ON (LOCK),
swing lock lamp on monitor panel does not light up ............................ 20-240
20-213
P-l Monitor panel lamps do not light up for 3 seconds
when starting switch is turned ON
a) No monitor panel lamps light up
Cause Remedy
2 YES
Defective monitor panel Replace
YES Is voltage between

- Pl (female) (1) - -
1 (3) “ormal7
Defective contact. Or
Clea”
harness between fuse 3 - (defective
Is voltage between contact) or
terminals of fuse * Voltage 20 - 30V NO Pl (female) (1) or Pl
replace
- . Turn starting switch (female) (3) - M6 (9) -
3 - chassis ground
ON. chassis ground
“OWllal?
* Voltage 20 - 30v NO
Disconnection in fuse
&place after
* Turn starting switch Ispecting caus<
ON. If disconnectio
Monitor panel
PI (04020)
205FO5300
b) Some monitor panel lamps do not light up
Defective monitor panel replace
20-214
P-2 Monitor panel lamps all light up when starting switch is
turned ON, but do not go out
*
CFlUSe Remedy
Defective monitor panel ReplaCe
20-215
P-3 When starting switch is turned ON (engine stopped). CHECK
items flash (Levels for CHECK items are as specified)
jr Check that the coolant is at the specified level before carrying out the troubleshooting.
Defective coolant level

sensor system -
(See P-26)
Does display go off 3 YES

Defective monitor panel Repl.WX
when short connec-
tor is connected to
P8 (fern&l?
1SHT
Defective contact, or dis- Clean (defectiv
Is there continuity connection in wiring harnes contact) or
_ between P8 * Connect and disconnect between P8 (female) (1) - rE+NX
(female) (2) - - short connector to P8 M6 (1) - Pl (female) (17)
chassis ground? (female).
- ?urn &ting switch Defective contact, or
* Turn starting switch OFF. disconnection in wiring Clean (defectiv
. Disconnect Pl harness between P8 :ontact) or
- Dieconnect W (female) (2) - chassis replaCe
ground
Table
Pl (04020) P8 (X2)
Coolant level sensor
205FO5894
20-2 16
0
bl $ (Engine oil level) flashes
cl
* Use the dipstick to check that the engine oil is at the specified level before carrying out the
troubleshooting.
CZilSe Remedy
Defective engine oil !evel

YES -
*ensx system
1 1 (See P-25)
2 YES
, Defective monitor panel ReplaCe
Clean (defective
contact) or
reDlace
P5 (female:
1 6~14 (5) - Pl (female) 1 I
I I
ground.
. Disconnect Pl, P5
Table . Turn starting switch OFF
Pl (04020) Ml4 68) E8GWP8) P5CXl) Engine oil

level sensor
205FO5896
20-217
0
cl
L!?-d
L (Hydraulic oil level) flashes
PC200,2OOLC-5 Serial No: 45001 - -

C.%JSC? Remedy
PC220,22OLC-5 Serial No: 35001 - *
Check that P9
?ot defective
Icontact, inser-
tion), check
weration of
‘ES Defective hydraulic oil iensor accordir
level sensor to Standard
~aluesTable fo
(See P-27) electrical
:ompo”e”ts,
then replace
3 YES
when short connec- I II Defective monitor panel Replace
tor is connected to
* Turn starting Clean (defecti\
switch ON. contact) or
harness between P9
~ (female) (1) - M3 (1) - reDlace
. Connect and disconnect shoR connector Pl (female) (10)
Defective contact, or discon-

- Turn starting switch nection in wiring harness Clean (defectiv
OFF between P9 (female) (21 - contact) or
NO rep I ace
1 Disconnect P9 M3 (11) - Ml4 (8) -chassis
ground
Table
v PI (04020) M3 (S16) P9 (X2)

Hydraulic oi
level sensor
Monitor
205FO5898
PC200,2OOLC-5 Serial No: - and up

PC200,2OOLC-5 MIGHTY Cause
PC220,22OLC-5 Serial No: * and up
‘ES
DefectEve hydraulic oil level
1 sensor system (See M-27)
Does display go out

when P9 (female)
(1) is grounded to 2 YES
I Defective monitor panel ReplXE
Is continuity
* Turn starting
between Pl (famale)
switch ON.
* Disconnect P9.
r (10) and (3) es
DefectEve contact. or
shown in Table? ClFXVl
disconnection in wirinq
1 (defective
* Turn starting harness between P9 -
NO contact) or
switch ON. (female) (1) - M3 (7) - PI
r&%X
* Disconnect Pl. (female) (101
Table
Between P9 (female)
continuity
and (3)
Connected I
Yes
Not connected No Pl(O4020) M3CS16) P9CXl) Hydraulic oil

level sensor
205FO5899
*O-i’
*
P-4 Preheating is not being used, but preheating display
lights up
c
H
” j IS Voltage between Wiring harness between
Pl (9) - chassis heater relay - E8 (3) - After inspec-
ground normal?
NO 3 YES
Ml4 (4) - Pl (female) tion, repair or
i (9) in contact with +24V. replace
1 Is voltage between
or defective heater relay
voltage between
- ov _ Ml4 (3). (4) - _
El
Is a Turn starting switch chassis ground
starting switch Wiring harness between
ON. normal? After inspec-
terminal Rl wiring Ml4 (male) (3) - Ml (3)
_ chassis is ground tion, repair or
- starting switch in
* ov NO replace
“O”lXJ? . Turn startinq switch contact with +24V
. ov
* Turn starting switc
ON.
After inspec-
tion, repair or
replace
PI (04020)
Ml4tS8)
+24V
Heater relay Electrical

intake air
heater
205FO5304
20-219
a
P-5 When starting switch is turned ON and engine is started,
CHECK items flash
* Check both the alternator system and engine oil pressure system.
Call*= Remedy
a) Alternator system
2 YES
. Defective monitor panel ReplaCe
Is voltage between
YES PI (female) (7) -
1- chassis ground
Defective cony! or dis-
p normal?
Is voltage be- connection in wlrlng Clean (defective
tween alternator .26-30V tNO harness between alternator Contact) or
terminal R - - . Start engine, and terminal R - E8 (2)- Ml4 replace
chassis ground run et half (2) - Pl (female) (7)
normal? , thcottle or above.
* 26-30V
_ Defective alternator Replace
. Start engine, and NO
run et half
throttle or above.
Check that
terminal is not
b) Engine oil pressure system defective
tact,
(con-
insertion),
* When the engine oil pressure is normal. check operation
of sensor ac-
cording to
Standard Values
YES Defective engine oil Table for elect-
1 pressure sensor rical
‘Doer display go off compo”ents,
when wiring then replace
harness terminal Contact of wiring harness
of engine oil
.NO 2 YES between engine oil
After inspection,
PreSSWe senror is ti pressure sensor - E8 (8)
removed? repair or replace
- Is there conti- - Ml4 (7) - Pl (female)
* Turn starting switch nuity between (16) with chassis ground
ON. - Pl (female) (16) -
- chassis ground?
NO
* Remove wiring harness
terminal of engine oil
pressure sensor.
* Disconnect Pl
Pl (04020) Ml4 68)
o Alternator terminal R
Engine oil
pressure sensor
205FO5950
20-220
a
P-6 When starting switch is turned ON (engine stopped),
CAUTION items flash
* When the engine oil pressure is normal.
CatIS? Remedy
YES
Defective alternator Replace
3
Is voltage between ,Nirina harness be-
YES_ alternator terminal _ tween alternator
R - chassis ground NO 4 YE! j terminal R - ES (2) - \fter inspectic
20 - 3OV? ~14 (2) - Pl (female) epair or replal
2- yd4i; contact with
_ * Do not start
Is there continuity engine.
YI ; between PI - Remove alternator
(female) (16) - - terminal R wiring. Defective monitor panel SeplXX
(3)? 3
- Remove alternator
1 . Turn starting switch terminal R wiring.
Defective contact, Or :lean (defecti\
OFF.
disconnection in Wiring :ontact),repai!
L-t
Is there continuity * Disconnect P1
I harness between E8 3r replace
between M 14 NO
(female) (7) - (male) (8) - Ml4 (7) -
chassis ground? Pl (female) (16)
f Turn starang switch

Defective engine Oil
OFF.
* Disconnect Ml4 pressure sensor
harness between Ml4
(female) (7) - ES (8) - Repair or
engine oil pressure Sensor repke
* Disconnect Ml4
Pl (04020) M1468)
o Alternator terminal R
Engine oil
pressure sensor
205FO5950
P-7 When starting switch is turned ON and engine is started,
CAUTION items flash
(When there is no abnormality in CHECK items or engine)
a) &
r-l (Engine oil pressure) flashes
Defective engine oil

1 pressure sensor
Does display go
off when wiring
Contact of chassis
harness of engine -
2 YES ground with wiring
oil pressure
harness between E8
sensor is removed?
(male) (6) - Ml4 (7)
* Start engine. Is there continuity - PI (female) (16)
- between Pl
NO (female) (16) - W?
NO
Defective monitor panel
* Disconnect Pl
PI (04020) MI4681
Monitor Engine oil
panel pressure
sensor
rfi F205C5 I29
(Coolant level) flashes
*O-i**
cl B--l (Coolant temperature) flashes
2 YES Defective cool.ant tempe-

_
rature Sensor system
Does displav go (See P-24)
YES off when short
, - connector is
connected to P7
- (female)? NO
IS cOOla”t Defective monitor panel FkpbX
tWTlpW.3t”W! * Start engine.
gauge within red
range?
. Start engine, and

yy;;;;,lf throttle NO . Defective monitor Panel ReplaCe
PI (04020) M I4(S8) E8ISWP8) P 7(X2)

Coolant temperature sensor
Monitor panel @
205F05307A
d) m (Charge) flashes
I
2 YES
Defective monitor oanel Replace
Is voltage be-
YEz K%A7) - -
1 Defective contact, or
chassis ground
disconnection in
Is voltage be- normal? Clean (defec
tween alternator
20 -30V NO alternator terminal R contact) or
terminal R - - - EB (2) - Ml4 (2) - P1 replaCe
chassis ground * Start engine.
(female) (7)
normal?
*20-30V
. Start engine, and Defective alternator Replace
run at half throttle No
Pl(O4020) Ml4(S8)
I
Monitor panel 3 0 Alternator terminal R
205FO5308-1
20-223
0
e) @ (Fuel level) flashes
L-l
* Check that there is fuel before carrying out troubleshooting.
Catls.2 Remedy
Defective fuel level

sensor system -
(See P-23)
Defective monitor panel i3.3piWG.5
* The surface of the fuel varies, so there is a

delay built info the display for the fuel level.
* Defective monitor panel ReplaCe
PI (040201 M6(SIO) P6(XI)

Fuel level sensor
Monitor panel
205F05309A
2Q-:24
P-8 (a) When starting switch is turned ON (engine stopped),
buzzer does not sound for 1 second
CAUTION item is flashing but buzzer does not sound.
t Of the CAUTION item, the buzzer does not sound if there is any abnormality in the charge or fuel
level.
Remedy
1 YES Defective monitor panel

Does buzzer sound
when Pl (female)
(I 1) and chassis Disconnection in wiring
harness between Pl
(female) (I 1) - P4 (2) ReplaCe
_ buzzer C-J, or between
- turn starting switch
+24V - P4 (7) - buzzer
ON.
(+), or defective buzzer
P-8 (b) There is no abnormality display on the monitor, but

the buzzer sounds
Cause Remedy
Contact of chassis ground 4fter inspection

1 YES with wiring harness .epai r or
between Pl (female) .epiace
(11) - buzzer (-1
Does buzzer
sound when Pl is -
removed?

* Remove PI. NO
- turn starting switch
ON.
r- +24V
Monitor
205FO531 OA
20-225
a
P-9 Panel lighting of monitor panel does not light up (liquid
crystal display is normal)
CalKGe Remedy
Replace bulb, 0
1 YES Bulb broken or defective :lean (defective
contact :ontact)
Is bulb broken or
is there defective -
contact?

- Remove bulb. NO
* Check condition of
bulb visually.
20-226
P-IO Coolant temperature shows abnormally low
temperature
* If the coolant temperature actually remains low, check the engine system.
YES Defective coolant

temperature sensor system
1 I
(See P-24)
Does display of all .I I
Defective monitor panel ZeplaCf2
Defective contact, or dis-

1 is connected f~ P7? 1 1~0 harness between Pl lean (defectiv
(female) (6) - Ml4 (6) - 3ntact) or
- Turn starting switch OFF. E8 (6) - P7 (female) (I) ?place
or P7 (female) (2) - ES
(7) - chassis ground
P-l 1 Coolant temperature gauge gives no display (during

operation, no level of gauge is displayed)
Defective coolant tempe-

‘ES
rat”re sensor system
-
(See P-24)
Does display of
l-t
coolant tem-
perature gauge
I
appear when P7 After inspectior
is removed? repair,or replace

ON.
OFF. -
P-l 0, 11 Related electrical circuit diagram
PI (04020) M 14(S8) ES(SWP8) P 7(X2)

Coolant temperature Sensor
Monitor panel 6
205FO5311A
20-227
0
P-12 Fuel gauge always displays FULL
* Check first if the fuel tank is actually full before carrying out troubleshooting.
CaUSe Remedy
YES Defective fuel level

sensor system -
(See P-23)
Does display of
fuel gauge go off d
“ontact of chassis ground
when P6 is NO 2 YES ,vith wiring harness be- ifter inspection
re”lClWd? zpair, or
tween P6 (female) (1) -
M6 (4) - Pl (female) (5) ?oleCe
* Turn starting switc IS there continuity
ON. between Pl 15) - -
. Wait for approx. 2 chassis ground?
minutes. NO
Defective monitor panel IepiaCe
. Disconnect Pl, P6
. The surface of the fuel varies, so there is a delay built into

the display for the fuel level.
P-l 3 Fuel gauge gives no display
* Check if there is any fuel before carrying out troubleshooting.
Defective fuel level

sensor system
(See P-23)
‘ES
Defective monitor Panel ReplaCe
disconnection in wiring clean (defective
1harness between P6 contact) or
* Turn StaRing switch
OFF.
1(female) (1) - M6 (4) - replace
P1 (female) (5)
- Disconnect P1. P6
P-l 2, 13 Related electrical circuit diagram
PI (04020) M6C30) P6(XI)

Fuel level sensor
Monitor panel @- -3 I
1
205FO5312A
20-228
0
P-14 (a) Lamps do not light up
YES
n I Defective monitor panel ;eplaCe
Does lamp light UP

YES when PI (female) lean (defective
- (14) and chassis - Disconnection, defective ontact) or
ground are con- NO 3 YES
contact in lamp ,place
nected?
l- Is there any dis- Defective contact, or dis-
- . Turn starting switch connection or connection in wiring
ON. defective contact harness between Pl
Do LEDs on . Disconnect P, (female) (14) - lamp
in lamp? :lean (defective
monitor panel - relay R4 (2). between
light up? lamp relay R4 (1) - fuse ontact) or
- Check visually. NO Dplace
(5). between !amp relay
- Turn startinq switch R4 (5) - M6 (3) - MS
(1). or between M6 (3)
ON. -
- Ml0 (1) - M9 (1)
* Turn lamp switch
ON. Defective monitor panel leplace
NO
P-14 (b) Lamps light up even when lamp switch is not

operated
Is there
continuity
3 YES
s
Contact of chassis ground
with wiring harness bet-
ween Pl (female)
lamp relay R4 (2). or
defective lamp relay
(14) -
After
tion,
rl?plXZ
inspec-
repair or
YES
2 - between PI
_ (female) (14) - \Ei ,r,ng harness between M6
lfemalel 131 - M8 ifemale) After inspec-
chassis ground? NO
Does lamp light (1) or M6 (female1 (3) - tion, repair or
YES * Turn starting switch MlO(ll -MS(femalel(l) replace
- up when PI is -
OFF. I” contact with +24V
removed?
1 * Disconnect Pl.

Are LEDs on Defective monitor panel Replace
ON.
monitor panel - NO
out?

ON. Defective monitor panel Replace
* Turn lamp switch NO
OFF
20-229
a
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
+24V
M6c3IO) M 8tMI)
I
Lamp relay (R4)
MI0
TmT Boom head lamp
205FO5313-1

M8tMI)
Monitor lamp
Boom head lamp
7+r
M4l(MIl
Head lamp (L.H.)

on cab
l
M40tM I)
Head lamp (R.H.)

on cab
205FO5772
20-$30
P-15 (a) Wipers do not work
CalAX Remedy
2
goes wiper work
when Pl (female) 4 YE
Defective wiper motor Replace
ES
(15) and chassis
1
Defective contactl or dis-
connection in wnng Clean (defective
ON.
~ harness between PA4 contact) or
* Disconnect Pl
(female) (2) - M5 (2) replace
DO LEDS on - chassis ground
monitor panel Defective wiper relav,
or defective contact,
TgYNm”arringswirchI or disconnection in Clean (defectivr
NO wiring harness between contact) repair
* Turn starting switcl h * Turn wiper switch wiper relay Rl (3) - or replace
ON. ON.
. Turn wiper switch
M5 (1) - M4 (female)
* 20 - 3ov (1)
ON. * Disconnect M4
Defective monitor panel REQISX
P-15 (b) Wipers work even when wiper switch is not

operated
CaUSe RemedV

with wiring harness A fter inspection
3 YES
between Pl (female) (15) re ipair or
Is there --).viper relay Rl (female) TE !place
YES continuity
2 - between Pl
(female) (15) - Wiring harness between
wiper relay Rl (3) - A fter inspection
M5 (1) - M4 (1) in re#pair or
Does wiper work _ - Disconnect Pl. NO contact with +24V, or re,pIace
when Pl is removed’ - Turn starting switch defective wiper relay
OFF.
. Turn starting switch NO

Are LEDs on Defective monitor panel R ep1ace
ON.
monitor panel
* Turn.starting switcl
ON. R eDlaCe
* Turn wiper switch
OFF
+24V M SM4) M4tKES4) (KES4)
(CN-Rl)
205FO5314
20-232
P-l 6 (a) Fan does not work
CalSe Remedy
4
Does fan work Is there con- Replace
Defective heater
v ES when PI (female) tinuity between
(12) (or (13)) - R2 (female) (3) 3efective contaFt! or dis-
chassis ground YES - Ml 2 (female) :onnection in wrang
are connected? (2), or between >er”ess between PI
Ii Ifemale) (12) - heater
R3 (female) (3) Clean (defectivm
I x4aY R2 (2). between PI
Gjy12 (female) .female) (13) - heater contact) or
* Turn starting switch ‘clay R3 (2). between Ml i replace
ON. R2 (female) (3)
(Lo side) or R3 .female) (2) - heater
* Disconnect Pl xlay R2 (3). or between
(female) (3) (Hi
side) - chassis Ml2 (female) (3) heater
,elay R3 (3)
Defective heater relay Replace
* Turn starting
switch ON. Jisconnection in wirina
- Turn starting switc, h ,arness between R2 -
:female) (2) -PI (12) Repair or
ON.
* Turn fan switch :female), or between R3 replace
* Turn startinq switch
ifemale) (2) -PI (13)
ON. ON. -
,female)
* Turn heater switch

N(
P-16 (b) Fan works even when fan switch is not operated
Cause Remedy

with wiring harness
between Pl (female) (12) After inspec-
heater relay R2 (2). oi tion, repair or
3 YES
. between PI (female) (13) replace
Is there continuity - heater relay R3 (2)
YES between P1
2 - (female) (12) (or - Contact of chassis
_ (13)) -chassis ground with wiring
ground? harness between heater After inspec-
NO
. - Ml2 (2) (or (3)) - tion, repair or
YES Does fan work when - Turn starting switch heater relay R2 (3) or R3 replace
Pl is removed? - OFF. (3). or defective heater
1 relay R2 or R3

Are LED% on
monitor paner -
ON. . Defective monitor panel Replace
NO
out?

ON.
- Turn fan switch ND
. Defective monitor panel Replace
OFF.
20-233
a
+ 24V M 12
205FO5315
20-234
P-17 Working mode does not switch
I CaLlW! I Remedy
a) Even when monitor panel switch is pressed, mode

display (LED) above switch does not change.
b) When monitor panel switch is pressed, mode

display (LED) above switch changes.
See troubleshooting of
pump controller system
harness between C2
(14) - P2 (8) or correct or
between C2 (15) - P2 replaCe
(9). or short circuit
with GND
Table 27 NO
Replace
* Turn starting switch I
ON.
Table 1
Working mode 1 Between (14) - (8) 1Between (15) - (8)
H.0 1 12V (Note) Max. IV
G.0 12V (Note) 12V (Note)
F.0 Max. 1v 12V (Note)

L-0 Max. 1v Max. 1V
Table 2
Working mode Between (8) - (16) Between (9) - (16)
H.0 12V (Note) Max. 1V
G.0 12V (Note) 12V (Note)
F.0 Max. 1V 12V (Note)

L.0 Max. 1V 1 Max. 1V
Note: If the voltage is not 12V and is unstable, take the answer
as YES.
C2 (MIC21) P2 (04016)
205FO5627
20-232
0
P-18 Power set does not switch
Remedy
a) Even when monitor panel switch is pressed, mode

display (LED) above switch does not change.
b) When monitor panel switch is pressed, mode display (LED)

above switch changes.
YES See troubleshooting of

1 I pump controller system
Is voltagebetween
C2 (5) - (8) and Disconnection in wiring
between (6) - (8) - harness between C2 (5)
as shown in Table 2 YES - P2 (5) or between C2
3epair or
xplace
I? Is voltage between (6) - P2 (6). or short
- Turn starting Switc P2 (5) - (16) and circuit with GND
ON. 9 between (6) - -
ND (16) as shown in
Tadle 27 NO
Defective monitor panel 3eplace
ON.
Table 1 Table 2
Between (5) - (8) Between (6) - (8)
Note: If the voltage is not 12V and is unstable,

take the answer as YES.
C2 (M IC21) P2 (04016)
205FO5628
20-236
0
P-19 Auto-deceleration does not switch (Does not enter
auto-deceleration; auto-deceleration is not canceled)
Cause Remedy
a) Even when monitor panel switch is pressed, ON-OFF display

(LED) above switch does not change.
_ Defective monitor panel ReplaCe
bl When monitor panel switch is pressed, ON-OFF display

(LED) above switch changes.
See troubleshooting of
YES
pump controller
1 system
Is voltage between Disconnection in wiring

C2 (7) - (8) es - harness between C2
shown in Table l? ~
2 YES
s (7) _ P2 (7). or
correct or
replaCe
contacf with chassis
- Turn starting switch Is “‘Itage betwee” ground
L P2 (7) - (16) as -
ON.
ND shown in Table I?
NO Defective monitor panel ReplaCe

ON.
Table 1
. Voltage
Auto-deceleration
Max. 1V
switch ON
Auto-deceleration
12V (Note)
switch OFF
Note: If the voltage is not 12V and

is unstable, take the answer as
YES.
205F05397A
20-237
o-
P-20 Travel speed does not switch between Hi and Lo
CiXlSe Remedy
a) Even when monitor panel switch is pressed, Lo -Hi display

(LED) above switch does not change.
)efective monitor panel ReplaCe
b) When monitor panel switch is pressed, Lo - Hi display

(LED) above switch changes.
ice troubleshooting of
lump controller systenl
>isconnection in wiring
harness between C2 (3)
- P2 (4). or contact
vith chassis ground
L
a Turn starting switch
b lefective monitor panel %PlaCe
ON.
Table 1
r-1
Note: If the voltage is not 12V

and is unstable, take the
answer as YES.
C2uvlIC21) f’2 (04016)
~_fj$jzj
205F05396A
20-238
0
P-21 Warming-up operation is not carried out below 3O”C,
or warming-up operation is not canceled even when
temperature goes above 30°C
* Carry out troubleshooting first for E-l 2 Automatic warming-up is defective
Remedy
See E-12
YES Defective coolant tern-

71 perature sensor
Isvoltage betweer Warming-up
.I
P2 (11) - (16j.a~ 5 operation is Wiring harness between
shown in Table l? not carries Pl (female) (6) - M6
O”t (6) - P7 (1) in contact Repair or
with chassis ground or replace
- Turn starting switcl
other GND wiring
ON.

OFF.
. Disconnect Pl, P7
YES
Defective coolant tem-
21
perature sensor
I -1 I
l-
Can warming-up
LI
Warming-up
operation is be canceled when Defective contact, or dis-
NO not canceled short connector is
3 YES
connected to P7 harness between Pl Repair or
Is there continuity (female) (6) - M6 (6) replace
. Start engine. between Pl (female) - P7 (I)
Ng (6) -chassis ground -
when short connector
is connected 10 P7.
IL
Defective monitor panel RePlaCe
OFF.
f Disconnect Pl, P7
Note: If the voltage is not 12V and

is unstable, take the answer
as YES.
PI (040201 M14K381 E86WP8) P7(X2)

Coolant temperature sensor
Monitor panel @
205FO5307-1
20-;39
P-22 Even when swing lock switch is turned ON (LOCK),
swing lock lamp on monitor panel does not light up
Sr Only carry out this troubleshooting if the swing lock is actually applied.
CWSe Remedy
1 YES
Is voltage between
PZ (3) - (16) as -
shown in Table I?
NO harness between swing
correct or
replace
* Turn starting switch lock switch (1) - P2 (3)
ON.
Swing lock switch
P2(04016)
Monitor panel
205FO5741
20-240
0
P-23 Fuel level sensor system defective
Note 1: Difference between fuel level and gauge display
If the gauge display position is “lo”, the fuel level display is 78% or 100%; if it is "1 “,
the fuel level display is less than 14.5%. If the machine is on a slope, the display and
actual fuel level will be different. Therefore, when checking, always stop the machine on
level ground and wait for at least two minutes before reading the gauge. (The fluid level
changes when the machine is moving, so a time delay is provided to give a stable display.)
+ Remove the fuel level sensor when carrying out this troubleshooting.
CaLIS Remedy
3 YES
Interference with sensor %?PlKZ
I1 inside tank :Note
2)
Defective contact of connector Clean COnnectOr

or replace
Defective sensor (Note 2) Replace

NO
resistance between
Connector 11) and
flange as shown in
4 YES Disconnection in wiring

harness (Note 3) Repalce sensor
(Defective clamp)
Check wiring
(Outside force applied)
. harness visually. Is -
it broken?
Defective sensor Reolace

NO
F20205053
Note 2: There is probably interference with the sensor inside the tank, or defective installation.
Install carefully when replacing.
Note 3: Check for any vibration at the connector mount, and take the necessary action if the vibration
is excessive.
20-241
0
P -24 Coolant temperature sensor system defective
bs,~siS~t~nce
temperat”reSenSOr
(male) (1) -
03nneCtor
and (2) as shown I”
1
YES
P
2 YES
,-
c
I Defectwe contact of
(Note 1)
COnneCtOr
harness INore 2)
Clean COnneCtOr
orreplacesen*cJr
Replace sen*cJr
Table ? 1 (Defective clamp)
P Check wiring (Outside force applied)
- harness VISUBIIY. Is -
NO it broken?
Defective sewor ReplaCe

NO
Table 1
Normal tem-
Approx. 37 - 50ki2
perature (25°C
100°C Approx. 3.5--4.Okfl
Sensor
F20205054
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so replace the connector (harness) at the chassis end.
is excesive.
20-242
0
P-25 Defective engine oil level sensor system
Note 1: Variations in oil level
The oil level changes according to the angle of the machine, the engine speed, and the oil
temperature, so if any abnormal display is given, stop the machine on flat ground and check the
oil level again.
+ Remove the oil level sensor when carrying out this troubleshooting.
Remedy
Defective movement of
Clean
L ’ float caused by dirt
Is any dirt or dust

YES
- stuck to movable - Replace
part of float? 3 YES
sensor (Note
41
Is float badly
1 - cracked, chipped. or -
NO damaged?
Move the float up Clean or
and down. Is the repl.Xe
NO connector (Note 2) connedor
resistance between -
connector (1) and
flange as shown in
Table l? Disconnection in wiring
4 YES harness (Note 3)
(Defective clamp)
(Outside force applied)
Check wiring
L harness visually. Is -
NO
,t broken?
Defective sensor Replace

NO
Table 1
Aiizfzs
F20205055
Note 2: If the problem occurs again, the connector (female side) at the chassis end is probably
defective, so check the connector and wiring harness at the chassis end.
is excessive.
Note 4: The installation is probably defective, so be careful when installing. If the problem occurs
again, check for any vibration at the connector mount, and take the necessary action if the
vibration is excessive.
P-26 Coolant level sensor system defective
Note 1: Variations in coolant level
The coolant level changes according to the angle and swaying of the machine, so if any
abnormal display is given, stop the machine on flat ground and check the coolant level
before carrying out the check again.
* Remove the coolant level sensor when carrying out this troubleshooting.
Cause Remedy
YES Defective movement Of float Clean

2 because of dirt
stuck in float? Replace sensor

3 YES Resonance of nlO”Df (Note 41
- Is float badly
_ cracked, chipped, or -
NO damaged?
Move the float up Defective contact
and down. Is the Clean connector
of connector
resistance between NO or replace
(Note 2)
connector 11) and
flange as shown in
Tahlr 1,
4 DisconneCfion in wiring
YES harness (Note 3) Repalce sensor
Is wiring of wiring
I
(Defective clamp)
harness broken? is (Outside force applied)
. resistance between
I connector (1). (2)
and sensor below
IsI? Defective tensor RePlaCe
NO
Table 1
Float UP Max. lC2
1 Float DOWN 1 Min. lMS2 1
F20205056
is excessive.
20-244
a
P-27 Hydraulic oil level sensor system defective
PC200,2OOLC-5 Serial No: 45001 - -
PC220,220LC-5 Serial No: 35001 - -
Note 1 : Variations in hydraulic oil level
The hydraulic oil level changes according to the angle and swaying of the machine, so if any
abnormal display is given, stop the machine on flat ground and check the hydraulic oil level
before carrying out the check again.
* Remove the hydraulic oil level sensor when carrying out this troubleshooting.
C.3U.W Remedy
Defective movement of float Clean

because of dtrt
YES Is any dirt or dust

- stuck in float? Replace Sensor
3 YES
Resonance of mount
(Note 41
- Is float badly
1 - cracked, chipped. or _
NO damaged,
Move the float up Defective contact
and down. Is the Clean Connector
of connector
resistance between NO or replace
(Note 21
tonnector (1) and
(21 as shown in
Table?
4
YES harness (Note 3)
1 l?epalce se”sor
Is wring of wiring (Defective clamp)
harness broken? Is (Outside force applied)
_ resrstance between _
NO connector (1). (2)
a$ensor below
Defective sensor ReplXe
NO
Table 1
F20505366
is excessive.
20-i45
PC200,2OOLC-5 Serial No: * and up
PC220,22OLC-5 Serial No: - and up
Note 1: Variations in hydraulic oil level
The hydraulic oil level changes according to the angle and swaying of the machine, so if any
abnormal display is given, stop the machine on flat ground and check the hydraulic oil level
again.
+ Remove the hydraulic oil level sensor when carrying out this troubleshooting.
I==
Cause Remedy
YES Defective movement 01

2 float caused by dirt
Clean
Y ES Is any dirt or dust

stuck to movable -
3 YES Replace
part of float?
Resonance at mount sensor (Note
1 4)
- Is float badly
1 - cracked, chipped, or _
NO damaged?
Clean or
and down. Is the replace
NO connector (Note 2)
resistance between connector
connector (1) and
flange as shown in
4 YES harness (Note 3) ReplaCe
(Defective clamp) sensor
Check wiring (Outside force applied)

i harness visually. Is -
10 it broken?
Defect,ve sensor Replace

NO
Table 1
z%zJz%G
F20205055
is excessive.
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL.. . 30- 4 ENGINE, HYDRAULIC PUMP

PRECAUTIONS WHEN Removal and Installation .......... 30-30
CARRYING OUT OPERATION . 30- 5 DAMPER
SPECIAL TOOL LIST . . . . . . . . . . . 30- 7 Removal and Installation .......... 30-32
WEIGHT TABLE . . . . . . _. . . . . 30- 7-2 CENTER SWIVEL JOINT
TIGHTENING TORQUES AND Removal and Installation .......... 30-32
STANDARD VALUES TABLE .. 30- 9 Disassembly and Assembly ........ 30-34
LUBRICANT AND COOLANT TABLE 30- 11 FINAL DRIVE
STARTING MOTOR Removal and Installation .......... 30-34
Removal and Installation ........ . . 30- 12 Disassembly ..................... 30-36
ALTERNATOR Assembly ........................ 30-38
z Removal and Installation . 30-12 SPROCKET
:: ENGINE OIL COOLER Removal and Installation .......... 30-42-I
: Removal and Installation . 30-14 TRAVEL MOTOR
FUEL INJECTION PUMP Disassembly .................. 30-43-I
Removal and Installation . 30-14 Assembly ..................... 30-43-5
WATER PUMP SWING MOTOR
Removal and Installation . 30-16 Removal and Installation .......... 30-44
NOZZLE HOLDER Disassembly .................... 30-45
Removal and Installation . 30-16 Assembly ..................... 30-45-3
TURBOCHARGER SWING MACHINERY
Removal and Installation 30-18 Removal and Installation ........ 30-45-8
THERMOSTAT Disassembly .................... 30-46
Removal and Installation 30-18 Assembly ....................... 30-48
ENGINE FRONT SEAL REVOLVING FRAME
ENGINE REAR SEAL SWING CIRCLE
Removal and Installation 30-20 Removal and Installation .......... 30-56
GOVERNOR MOTOR IDLER, RECOIL SPRING
CYLINDER HEAD Disassembly and Assembly. ....... 30-58
Removal and Installation 30-24 TRACK ROLLER
AFTER-COOLER Removal and Installation .......... 30-60
Removal and Installation 30-26 CARRIER ROLLER
HYDRAULIC COOLER Removal and Installation .......... 30-60
Removal and Installation ... . . 30-26 TRACK SHOE
REDIATOR, HYDRAULIC COOLER Removal and Installation .......... 30-62
Removal and Installation ........ 30-28 CHARGING PUMP
Removal and Installation .......... 30-64
HYDRAULIC PUMP BOOM CYLINDER
Removal and Installation .......... 30-64 Removal and Installation . . . . . . . . 30-83-I
Disassembly .................. 30-65-I ARM CYLINDER
Assembly ..................... 30-65-6 Removal and Installation ... . . . . 30-84
MAIN PUMP INPUT SHAFT OIL SEAL BUCKET CYLINDER
Removal and Installation .......... 30-66 Removal and Installation . . . . . . 30-85-I
CONTROL VALVE HYDRAULIC CYLINDER
Removal and Installation .......... 30-66 Disassembly . . . . . . . . . 30-86
Disassembly ..................... 30-68 Assembly.. . . . . . . 30-88
Assembly ........................ 30-70 WORK EQUIPMENT
MAIN RELIEF VALVE Removal and Installation . .... . 30-90
Removal and Installation .......... 30-72 BUCKET
Disassembly and Assembly ........ 30-72 Removal and Installation .. . . 30-92
TVC VALVE ARM
Removal and Installation .......... 30-74 Removal and Installation . . . . 30-92
CO l NC VALVE ARM, BUCKET
Removal and Installation .......... 30-74 Removal and Installation . . . . . _ . . 30-94
SERVO VALVE BOOM
Removal and Installation .......... 30-74 Removal and Installation .. . ... 30-95-I
WORK EQUIPMENT PPC VALVE CAB
Disassembly and Assembly ........ 30-77-I COUNTERWEIGHT
TRAVEL PPC VALVE Removal and Installation . . . . . . . . 30-96
Removal and Installation .......... 30-78 ENGINE THROTTLE CONTROLLER
Disassembly and Assembly ........ 30-78 Removal and Installation .. .. ... 30-98
BOOti HOLDING VALVE PUMP CONTROLLER
Disassembly and Assembly ........ 30-80 MONITOR PANEL
PPC SHUTTLE VALVE Removal and Installation .. ... . 30-98
Removal and Installation .......... 30-82
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
(I) When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are markedm, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 00 0 ASSEMBLY ...... Tilte of operation
a ................................ Precautions related to safety when carrying out the
operation
1. XXXX(1) ........................ Step in operation
* ............................... Technique or important point to remember when
removing XXXX !I ).
2. AAA(2): ...................... m Indicates that a technique is listed for use
during installation
3. 0 0 0 0 assembly (31
:
_ ............................. See Lubricant and Coolant Table
INSTALLATION OF 0 0 OASSEMBLY . Title of operation

. Carry out installation in the reverse order to removal.
I.. . . . . . . . . . . . . . . . . Technique used during installation
* . . . . . . . . . . . . . . . . . . Technique or important point to remember when in-
stalling A A A (2).
. Adding water, oil _ ... ... Step in operation
sr . . . . . . .. . .... .... Point to remember when adding water or oil
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools
(1) For details of the description, part number, and quantity of any tools (A,, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
4. Listing of tightening torque, weight, refill amount for oil and water
(I) If symbolssuch as m , &,or%@ appear in the operation procedure, See TIGHTENING

TORQUES AND STANDARD VALUES TABLE, MAINTENANCE STANDARD TABLE, WEIGHT
TABLE, and LUBRICANT AND COOLANT TABLE for details of the values.
PRECAUTIONS WHEN CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
. If the coolant contains antifreeze, dispose of it correctly.

. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws 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 handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
I) Hoses and tubes using sleeve nuts
Nominal Sleeve nut (elbow end)
Plug (nut end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 107376-50315 107221-20315 (Nut), 07222-00312 (Plug)
04 / 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)

05 107376-50522 107221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)

10 07376-51034 07221-21034 (Nut), 07222.01018 (Plug)
12 07376-51234 07221-21234 (Nut).07222-01219 (Plus)
2) Split flange type hoses and tubes
Nominal Sleeve head

Flange (hose end) Split flange
number (tube end)
04 07379-00400 07378-I 0400 0737 I-30400
05 07379-00500 07378-l 0500 0737l-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
A
A
Taper 1 I8
202F2001
24 /07049-024301 24 1 20 / 30
27 /07049-027341 27 122.5 1 34
Precautions for installation operations
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that
there is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with antifriction compound (LM-PI.
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then con-
nect securely.
When using eyebolts, check that there is no deformation or deterioration, screw them fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
Precautions when completing the operations
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run g
the engine to circulate the water through the system. Then check the water level again. g
If the hydraulic equipment has been removed and installed again, add engine oil to the specified “0
level. Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been re-
moved for repair, always bleed the air from the system after reassembling the parts.
t For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equpment related
parts.
SPECIAL TOOL LIST
Nature of work Symbol Part No. Part Name o’ty Remarks
1 791-545-l 510 Installer 1 Installation of floating seal

Disassembly,
assembly of final A 2 796-540-I 110
drive assembly
3 790-331-I 110
t
791-600-2001
791-6:;-8003
Disassembly,
assembly of recoil B 791-635-3160 Extension II I
spring assembly
790-I 01-l 600 rZJll:er (70 t) 1 :
790-I 01-l 102
791-630-3000 Remover & installer 1

Disassembly,
Removal, press fitting
assembly of track C 790-I 01-l 300 Cylinder (100 t) 1
of master pin
shoe assembly
790-I 01-I 102 Pump 1
. Removal,
installation of
charging pump
assembly D 796-750-1410 Oil stopper
* Removal, instal-
lation of main
pump assembly
790-502-I 002
Arm cylinder
Socket (PC200, 220)
790-302-I 450 (width across flats: Boom, bucket
95 mm) cylinder Removal,
installation
1 (PC220)
of nylon
nut
Socket Boom, bucket
790-302-I 350 (width across flats: cylinder
85 mm) (PC200)
Disassembly, 790-I 01-l 102 Pump I 1 I II

assembly of Expansion of
E 2 790-720-I 000 Expander 1
hydraulic piston ring
cylinder assembly
Arm cylinder
796-720-I 680 Ring 1
(PC220)
3 796-720-I 670 Ring
Bucket cylin-
796-720-I 660 Ring 1
der (PC220)
07281-01279 Clamp 1 All cylinders
. Removal, instal- 796-900-I 200

lation of boom
assembly
. Removal, instal- F 790-I 01-3800
lation of work
equipment
assembly 790-I 01-l 102 Pump
Nature of work Symbol Part No. Part Name O’ty Remarks
I I I I
790-501-5000 Repair stand 1
1 790-901-21 IO Bracket 1
790-901-I 350 Plate 1

Disassembly,
assembly of travel G 2 1 799-301-1600 1 Oil leak tester
I
1
I
Removal of brake piston
motor assembly
3 790-445-3810 Push tool 1
Press fitting of bearing
4 790-445-3870 Push tool 1 inner race
5 790-445-3820 Plate 1 Transporting
790-501-5000 Repair stand 1
1 790-901-2110 Bracket 1
790-901-2290 Plate r1 1
2 1 799-301-1600 1 Oil leak tester kit 1 Removal of brake piston

I I
c
Disassembly,
assembly of swing H
motor assembly 3 11 Re;z,vJ, installation of
795-630-I 803 Torque wrench set 1
4 790-445-3910 Holder 1 Installation of center shaft
796-730-2000 Wrench 1
F Measurement of rotating
d
torque
795-630-I 803 Torque wrench set 1
-
790-501-5000 Rapair stand 1
1 790-901-2110 Bracket 1
790-901-2150 Plate 1
2 790-345-I 020 Plate 1
796-730-2120 Screwdriver 1
Removal, installation of
bearing retainer
Disassembly,
assembly of
K
hydraulic pump
assembly
I, installation of
790-445-6100
Measurement of rotating
orque wrenc
30-g-l
WEIGHT TABLE
Unit: kg
Machine model PC200,2OOLC-5 PC200, 2OOLC5 MIGHTY
Serial No. 45001 and up 58019 and up
Cylinder head assembly 40 40
Hydraulic cooler assembly 55 55
.:p Radiator, hydraulic cooler assembly 80 94
L” Air cleaner assembly (with bracket) 35 35
Engine, main pump assembly 750 750
Center swivel joint assembly 45 45
.& Final drive assembly 460 460
r! Sprocket 40 40
&
3 Swing motor assembly 55 55
l?
Swing machinery assembly 280 280
Revolving frame assembly I 4,400 I 4,770
% Idler, recoil spring assembly 270 270

-;
2 Recoil spring assembly 140 140
u
3 Idler assembly 130 130
E Hydraulic pump assembly 210 210

aI
F Control valve assembly 180 180
cn
.u Boom cylinder assembly 190 190
?I
s Arm cylinder assembly 250 250
>
I Bucket cylinder assembly 160 190
; Work equipment assembly 3,400 3,750
E Bucket assembly 650 715
g Arm assembly 1,000 1,250

;i
“, Arm, bucket assembly 1,650 2,000
z
E Boom assembly 1,750 1,750
‘g Operator’s cab assembly 240 240

w”
+ Operator’s seat assembly 30 30
0
3 Counterweight 3,400 4,400
Unit: kc
Machine model I PC2205 I

Serial No. I 35001 and up I
1 Cylinder head assembly I 40 I
Hydraulic cooler assembly 55
?
‘F Radiator, hydraulic cooler assembly 80
w
Air cleaner assembly (with bracket) 35
Engine, main pump assembly I 750 I

Center swivel joint assembly I 45 I
Final drive assembly 460
.G
r!! Sprocket 40
&
3 Swing motor assembly 55
0
a Swing machinery assembly 280
Revolving frame assembly I 4,400 I

% Idler, recoil spring assembly 270
.;
g Recoil spring assembly 140
m
3 Idler assembly 130
TIGHTENING TORQUES AND STANDARD VALUES TABLE
I Machine model
Item Unit
PC200,2OOLC-5
PC220,22OLC-5
L
PC200,2OOLC-5
MIGHTY
1 Head cover mounting bolt 0.9 f 0.1 0.9 + 0.1

-
2 Rocker arm assembly mounting bolt, nut 2.5 k 0.5 2.5 f 0.5
3 Rocker arm locknut km 4.5 * 0.5 4.5 f 0.5

I
4 Cylinder head mounting bolt 1 st step
2nd step :
3rd step
0
90 +30
0 I 90 ‘30
0
5 Rear seal assembly
1) Flywheel mounting bolt 1 st step 9+3 9*3
km
2nd step I 18i 2 I 181 2
2) Face runout, radial runout of

flywheel
-
6 Engine mounting bolt
1 Damper assembly mounting bolt I 7.25 +0.75

I 7.25 f 0.75
2 Final drive assembly

1) Retainer mounting bolt 11.25 k 1.25 11.25 k 1.25
2) Retainer mounting bolt
3) Starting torque kgmk
4) Carrier mounting bolt 11.25 i 1.25 13.25 i 1.25
5) Carrier mounting bolt

I 6.75 i- 0.75 6.75 + 0.75
6) Cover mounting bolt

Initial tightening torque
I 8.0
I
8.0
Additional tightening
angle
7) Final drive assembly mounting bolt *
Travel motor assembly

3 kgm 28 k 3 28 k3
1) Cradle mounting bolt I
2) End cover mounting bolt
I 56 f 6
I 56 + 6
Machine model
PC200,2OOLC-5
PC220,22OLC-5
PC200,2OOLC-5MIGHTY
28 f 3 28 i 3
0 Safety valve 13 f1.5 13 i 1.5
Swing machinery assembly

11.25 & 1.25 11.25 f 1.25
1) Carrier gear pin mounting bolt
2) Carrier assembly plate mounting b,olt 39.25 + 4.25 39.25 f 4.25
3) Bearing cage mounting bolt
* When adjusting preload (only 4 bolts) 2.0 2.0
* After adjusting 6.75 + 0.75 6.75 f 0.75

Swing motor assembly
1) Plug of check valve 38 & 5 38 f 5
knm
2) Safety valve 18+ 1
3) Retainer mounting screw 1st step Max. 0.1
2nd step 0.5 & 0.1
3rd step 1.35 f 0.15
4) Brake case assembly mounting bolt 18, 2
6 Revolving frame assembly mounting bolt 111 f 11

1 Recoil spring assembly
1) Installed load of spring kg 11,100 12,900
2) Free length of spring 603.5
3) Installed length of spring 466

Machine model
Item Unit PC200,2OOLC-5
PC200,2OOLC-5MIGHTY pc220r 220LC-5
Hydraulic pump assemblv
1 i) Mounting bolt of main pump input shaft
housing assembly
2) Plate bolt of cradle
3) Bearing retainer screw
4) Housing mounting bolt
5) Pump sub-assembly mounting bolt
6) End cap mounting bolt (Front)
(Rear)
7) Impeller mounting bolt
8) Servo piston mounting bolt
9) Servo valve assembly mounting bolt
10) Rear pump assembly mounting nut
11) CO * NC valve mounting bolt (Front pump)

12) TVC and CO * NC valve mounting bolt
(Rear pump)
13) Tube joint bolt
14) Sleeve nut of hose

Control valve assembly -k :gm
2
1) Check valve mount plug
2) Safety-suction valve
3) Set sensor relief valve
4) Main relief valve

3 Work equipment PPC valve assembly
1) Joint
2) Nut
4 Boom lock valve assembly
1) Safetv valve 19f 1 19f 1
2) Spool mount plug 4 t 0.5 4 * 0.5
3) Check valve body mounting bolt 6.75 i 0.75 6.75 f 0.75

5 Hydraulic cylinder assembly
1) Bucket cylinder Head mounting bolt 27.5 + 4 27.5 + 4
Piston nut 720 f 72 720 + 72
2) Arm cylinder Head mounting bolt 38 f 5.5 38 -c 5.5
Piston nut 1,040 + 104 1,040 * 104
3) Boom cylinder Head mounting bolt 27.5 k 4 27.5 + 4
Piston nut 720 f 72 1,040 f 104

REMOVAL OF STARTING REMOVAL OF ALTERNATOR
MOTOR ASSEMBLY ASSEMBLY
A Disconnect the cable from the negative (-1 A Disconnect the cable from the negative (-1
terminal of the battery. terminal of the battery.
1. Governor motor assembly 1. Wiring (I) (See F3)

l Remove governor motor assembly. 2. Adjustment bolt (2) (See F3)
For details, see REMOVAL OF GOVER- t Loosen mounting bolts and nuts (3).
NOR MOTOR ASSEMBLY. 3. Fan belt (4) (See F3) m
2. Heater switch (I 1 (See Fl) 4. Mounting bolts and nuts (3) (See F3)
3. Governor motor bracket (2) (See Fl 1 5. Alternator assembly (5) (See F3)
4. Wiring (3) (See F2)
5. Wiring connector (4) (See F2)
6. Starting motor assembly (5) (See F2)
INSTALLATION OF
ALTERNATOR ASSEMBLY
INSTALLATIN OF
l Carry out installation in the reverse order to
STARTING MOTOR removal.
ASSEMBLY
B
l Carry out installation in the reverse order to . Adjust the fan belt tension.
removal. For details, see Standard Value Table
for Engine. ::
:
0
30-12
0
Fl
F2050530 1
F2
F20505302
3023
REMOVAL OF ENGINE OIL REMOVAL OF FUEL
COOLER ASSEMBLY INJECTION PUMP ASSEMBLY
1. Fuel injection pipe (I 1 (See F3) m
1. .Draining cooling water 2. Control rod (2) (See F31
2. Dust indicator hose (I), intake pipe (2) (See + Mark the mounting hole of the clevis pin.
Fl) 3. Heater switch (3) (See F3)
3. Turbocharger heat insulator plate (3) (See Ir Remove the heater switch mounting
Fl) bolts, and move the heater switch to-
4. Lubrication tube (4) (See F21 wards the rear.
5. Oil level gauge guide (5) (See F2) 4. Spill hose (4) (See F3)
6. Oil cooler assembly (6) (See F21 m 5. Fuel hose (5) (See F3)
6. Lubrication tube (6) (See F3)
7. Bracket (7) (See F31
8. Fuel injection pump assembly (8) (See F3)
m
INSTALLATION OF ENGINE * Remove 5 front end mounting bolts and
OIL COOLER ASSEMBLY 1 pump end mounting bolt.
l Carry out installation in the reverse order to INSTALLATION OF FUEL

removal.
INJECTION PUMP ASSEMBLY
removal.
& Oil cooler assembly: m
Gasket sealant (LG-7)
QZI Sleeve nut:
l Refilling with water
See Tightening Torques and
t Add water to the specified level, and run
Standard Values Table
the engine to circulate the water
m
through the system. Then check the
l Install the injection pump as follows.
water level again.
1) Set No. 1 cylinder at compression
top dead center.
Sr Rotate the crankshaft in the
normal direction and align the
pointer with the 1.6 TOP line on
the crankshaft pulley. (See F4)
If no match mark can be seen on
the idler gear, rotate the crank-
shaft one more turn.
2) Replace the normal bolt with bolt
0, and lock drive gear (9) in posi-
tion. (See F5) .
3) Injection pump assembly
* Insert pin @ (+4.0 - 4.5 mm,
length = approx. 100 mm)
through cover mounting bolt
hole a, and check that the pin
enters the casting hole in the
drive gear smoothly. (See F6)
4) Remove bolt @ and tighten the
normal bolt again. (See F5)
l Adjust the fuel timing and bleed the air
from the fuel circuit.
For details, see TESTING AND ADJUST-
ING.
30-14
0
Fl
I-:3
F205053Of 205FO5400
F2 F'4
I
mark C
(View from flywheel)

F20505305 014OF107
F5
1
9.
F6
‘I -- 20UF01206.KC
REMOVAL OF WATER REMOVAL OF NOZZLE
PUMP ASSEMBLY HOLDER AS$EMBLY
1. Draining cooling water 1. Fuel injection pipe (I) (See F2) m

2. Wiring connector (I 1 (See Fl) 2. Spill hose (2) (See F2)
3. Hose (2) (See Fl I 3. Holder (3) (See F2) m
4. Fan belt (3) (See Fl) m 4. Nozzle holder assembly (4) (See F2) m
+ Loosen the mounting bolts and nuts of + When removing the nozzle holder as-
the alternator assembly, then remove sembly, be careful not to let any dirt or
the adjustment bolt, and move the alter- dust get in.
nator assembly towards the block.
5. Plate (4) (See Fl 1
6. Water pump assembly (51 (See Fl)
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
INSTALLATION OF WATER
PUMP ASSEMBLY removal.

removal.
m Sleeve nut:
For details, see Tightening
m
Torques and Standard Values
l Adjust the fan belt tension.
Table
For details, see Standard Value Table
/
for Engine. g
l Refilling with water w Mounting bolt: Z
* Add water to the specified level, For details, see Tightening Z
and run the engine to circulate the Torques and Standard Values
water through the system. Then Table
check the water level again. m
* When installing the nozzle holder as-
sembly, check and clean the nozzle
mount, then install.
30-16
0
F20505307
30617
REMOVAL OF REMOVAL OF
TURBOCHARGER ASSEMBLY THERMOSTAT AhSEMBLY
1. Dust indicator hose (I), intake pipe (2) (See 1. Draining cooling water
FII 2. Connector (1 I (See F3)
2. Turbocharger heat insulator plate (3) (See 3. Thermostat assembly (2) (See F3I
FII
3. Lubrication drain tube (4) (See Fl)
4. Hose (51 (See F2)
* Disconnect the hose, and move it to-
INSTALLATION OF
wards the intake connector.
6. Lubrication inlet tube (61 (See F2) THERMOSTAT ASSEMBLY
6. Muffler heat insulator plate (7) (See F2)
7. U-bolt (8) (See F2) Carry out installation in the reverse order to
8. Bracket (9) (See F2) removal.
9. Turbocharger assembly (I 0) (See F2) Refilling with water
* Remove the turbocharger mounting -f Add water to the specified level, and run
nuts, pull out the muffler drain hose, the engine to circulate the water
move the muffler assembly towards the through the system. Then check the
counterweight, then remove the tur- water level again.
bocharger assembly.
INSTALLATION OF
TURBOCHARGER ASSEMBLY

removal.
3028
’ / F20505310
F2
F20505309
::
s
m
0
3029
REMOVAL OF ENGINE REMOVAL OF ENGINE
FRONT SEAL REAR SEAL
1. After-cooler assembly (PC220-5 only) 1. Damper assembly

l Remove after-cooler assembly. l Remove damper assembly.
2. Radiator, hydraulic cooler assembly For details, see REMOVAL OF DAMPER
l Remove radiator and hydraulic cooler ASSEMBLY.
assembly. 2. Flywheel (I 1 (See F4) /nl
For details,
TOR, HYDRAULIC
see REMOVAL OF RADIA-
COOLER ASSEMBLY.
A may The pilot of the flywheel
suddenly come
is shallow,
out, so be careful
and
3. Fan (I) (See Fl) not to get your fingers caught.

4. Vibration damper (2) (See Fl) 3. Rear seal (2) (See F5) m
5. Fan belt (3) (See Fll a
* Loosen the mounting bolts and nuts of
the alternator assembly, then remove
the adjustment bolts, and move the al-
INSTALLATION OF ENGINE
ternator assembly towards the block.
6. Pulley (4) (See F2) REAR SEAL
* Using puller 0, remove the pulley, then
remove the collar. l Carry out installation in the reverse order to
7. Front seal (5) (See F3) a removal.
111/
* Tightening order of mounting bolts (See
F5)
INSTALLATION OF ENGINE m Mounting bolt:
FRONT SEAL For details, see Tightening
Torques and Standard Values
l Carry out installation in the reverse order to Table.
. Use dial gauge @ to measure the face
removal.
runout and radial runout of the flywheel.
(See F6)
l Adjust the fan belt tension. For details, see Tightening Torques and
For details, see Standard Value Table Standard Values Table.
for Engine. m
jn21
* When assembling, check the wear
groove of the seal lip contact portion of
a Lip of oil seal: Grease (G2-LI)
the crankshaft, and if necessary, move
-k Press fit the front seal so that it is level
the seal approx. 2 mm (change a from
with the surface of the front cover.
20 mm to 22 mm) towards the flywheel
before assembling. (See F7)
&I& Lip of oil seal: Grease (G2-LI)
30-20
a
1 F
I -1
705FWi401
---. -_ ._. 205FO5404
F2 F5
r
205FO5402 6143F105
F3 F6
205FO5403 6140F287A
a
I
202FO5415
REMOVAL OF GOVERNOR
MOTOR ASSEMBLY
A Disconnect the cable from the negative (- 1

terminal of the battery.
1. Control rod (I) (See Fl)

Sr Remove the clevis pins at the governor
motor end.
2. Wiring connector (21 (See Fl I
3. Governor motor assembly (3) (See Fl 1
INSTALLATION OF
GOVERNOR MOTOR
ASSEMBLY

removal.
30;22
Fl
r
REMOVAL OF CYLINDER INSTALLATION OF
HEAD ASSEMBLY CYLINDER HFAD ASSEMBLY
1. Water pump assembly removal.
l Remove water pump assembly. m
2. Turbocharger assembly m Sleeve nut:
l Remove turbocharger assembly. See Tightening Torques and
3. Wiring (‘I 1 (See Fl) Standard Values Table
4. Intake connector (2) (See Fl I m
5. Breather hose (3) (See Fl 1 w Mounting bolt:
6. Fuel filter assembly (41 (See Fl I See Tightening Torques and
* Disconnect the fuel filter assembly, and Standard Values Table
move it towards the fan. m
7. Fuel injection pipe (5) (See Fl) m m Mounting bolt:
8. Spill hose (6) (See Fl) See Tightening Torques and
9. Nozzle holder assembly (7) (See Fl) m Standard Values Table
* Remove 6 nozzle holder assemblies m
together with the spill hoses. Jr Tighten the mounting bolts and nuts
10. Head cover (8) (See F I) / starting from the center and working
11. Rocker arm assembly (9) (See F21 @!%! out in order to the outside. (See F41
J, Loosen the locknut, then loosen the ad- + Check that the ball of the adjustment
justment screw 2 - 3 turns. screw is fitted securely in the socket of
12. Push rod (I 0) (See F2) the push rod.
13. Cylinder head assembly (I I) (See F3) m l Adjust the valve clearance.
& kg See Weight Table ING, Adjusting valve clearance.
w Mounting bolt, nut: 0”
See Tightening Torques and 0”
Standard Values Table Z
w Locknut:
m
jl Be careful to check that there is no dirt
or dust on the mounting surface of the
cylinder head or inside the cylinder.
Jc When installing the gasket, check that
the grommets have not come out.
Ir Tighten the cylinder head mounting
bolts 2 - 3 turns by hand, then tighten
in the order given in the diagram.
a Mounting bolt:
Anti-friction compound (LM-
PI
m Mounting bolt:
Sr After tightening, make one punch mark
on the bolt head to indicate the number
of times it has been tightened. (See F5)
l If any bolt already has five punch
marks, do not reuse it. Replace it
with a new bolt.
4
Exhaust side
Front tii Rear
Order for tightening head bolts
nn
205FO5405 6206F401 A
F2 F5
1
Make marks on bolt and cylinder hand
I- @$jY I) @+To
205FO5406
-I F621201067A
205FO5407
REMOVAL OF REMOVAL OF HYDRAULIC
AFTER-COOLER ASSEMBLY COOLER ASSEMBLY
(PC220 only)
1. After-cooler assembly (PC220 only)
1. Hose (I) (See Fl) l Remove after-cooler assembly.
2. After-cooler assembly (2) (See Fl I For details, see REMOVAL OF
t Sling the after-cooler assembly, and AFTER-COOLER ASSEMBLY.
remove the mounting bolts, then lower 2. Hose (11 (See F2)
the after-cooler assembly and pull it out. 3. Net (2) (See F2)
4. Hydraulic cooler assembly (3) (See F3)
* Sling the hydraulic cooler assembly, and
remove mounting bolts, then lower the
hydraulic cooler assembly and pull it out.
INSTALLATION OF
AFTER-COOLER ASSEMBLY & kg See Weight Table
(PC220 only)
Carry out installation in the reverse order to

INSTALLATION OF
l
removal.
HYDRAULIC COOLER
ASSEMBLY

removal.
l Refilling with oil
* Add oil to the specified level, and run
::
the engine to circulate the oil through
g
the system. Then check the oil level
:
again.
30-26
0
F”
2
:
i
L
I I
F205053 12 ~ F20505313
F3
1
F20505314
REMOVAL OF RADIATOR,
HYDRAULIC COOLER
ASSEMBLY
1. After-cooler assembly (PC220-5 only)

l Remove after-cooler assembly.
For details, see REMOVAL OF AFTER-
COOLER ASSEMBLY
2. Draining water
3. Hose (I) (See Fl 1
4. Hose (2) (See F2)
6. Shroud (4) (See F2I
Ir Remove the shroud and move it
towards the engine.
7. Radiator and hydraulic cooler assembly (5)
(See F3)
+ Sling the radiator and hydraulic cooler
assembly, then remove the mounting
bolts, and lift off the radiator and
hydraulic cooler assembly.
&I kg See Weight Table
INSTALLATION OF
RADIATOR, HYDRAULIC
COOLER ASSEMBLY

removal.
. Refilling with oil
Ir Run the engine to circulate the oil
through the system.
Then check the oil level again.
l Refilling with water
Sr Run the engine to circulate the water
through the system.
Then check the water level again.
30-28
0
Fl
I I
205FO5408
F2
205FO5409
F3
205FO5410 1
30-29
a
REMOVAL OF ENGINE,
HYDRAULIC PUMP
ASSEMBLY 15. Wiring connector (15) (See F5)
16. Ground connection (16) (See F5)
A Disconnect the cable from the negative (-1

terminal of the battery.
*yLower the work equipment to the ground
and stop the engine. Then loosen the oil
filler cap slowly to release the pressure
inside the hydraulic tank.
l Remove hydraulic tank strainer, and use
tool D to stop the oil. (See Fl)
l When not using tool D, remove drain
plug and drain the oil from hydraulic
tank and piping.
17. Engine and hydraulic pump assembly (I 7)
:
_ See Lubricant and Coolant Table (See F6) m
* After removing the piping, mark with tags * When removing the engine and hydrau-
to prevent mistakes when installing. lic pump assembly, do not forget to dis-
connect the piping and wiring, and
1. Draining water check that there is no interference at
2. Air cleaner cover (I 1 (See F21 any point when removing.
3. Air cleaner assembly (2) (See F2)
Ir Remove
remove
the
the
air
air
cleaner
cleaner
cover,
assembly
then b kg See Weight Table
together with the bracket.
& kg See Weight Table

4. Muffler heat insulator plate (3) (See F2) INSTALLATION OF ENGINE,
5. Dust indicator hose (4) (See F2)
HYDRAULIC PUMP
7. Tube (6) (See F2) ASSEMBLY
9. Wiring connectors (81, (9) (See F3, F4) l Carry out installation in the reverse order to
removal.
m Mounting bolt:
Refilling with oil
* Run the engine to circulate the oil
through the system.
10. Wiring (I 0) (See F4)
11. Fuel hose (I I) (See F4)
12. Hose (I 2) (See F4) Q See Lubricant and Coolant Table
13. Fan and vibration damper assembly (I 3) Refilling with water
(See F4) + Run the engine to circulate the water
Ir Remove vibration damper mounting through the system.
bolts, and move fan assembly towards Then check the water level again.
radiator.
14. Intake pipe (I 4) (See F4)
30630
Fl
I
F9879 205FO541
F2 F6
I I
205FO5411 205FO5415
205FO541
F4
I
11
30$31
REMOVAL OF DAMPER REMOVAL OF CENTER
ASSEMBLY SWIVEL JOINT ASSEMBLY
1. Hydraulic pump assembly *A& Lower the work equipment to the ground
4
l Remove hydraulic pump assembly. and release the remaining pressure in the
For details, see REMOVAL OF HYDRAU- circuit. For details, see TESTING AND
LIC PUMP ASSEMBLY. ADJUSTING, Releasing pressure in
2. Damper assembly (I 1 (see Fl 1m hydraulic circuit for machines with PPC
valve.
1. Hoses (1). (2). (3) (See F2)

2. Elbow (4) (See F21
INSTALLATION OF DAMPER 3. Hose (5) (See F3)
ASSEMBLY 4. Link (6) (See F31
5. Center swivel assembly (7) (See F4)

fi kg See Weight Table
removal.
m
a) Damper spline:
Anti-friction compound (LM-G)
w Mounting bolt: INSTALLATION OF CENTER

See Tightening Torques and SWIVEL JOINT ASSEMBLY

removal.
;3
m
0
* Run the engine to circulate the oil N
0
through the system.
Then check the oil level agian.
F2
205FO5416 205FO.50
F3
I 5
F4
30-33
0
DISASSEMBLY OF CENTER REMOVAL OF FINAL DRIVE
SWIVEL JOINT ASSEMBLY ASSEMBLY
1. Remove cover (I 1. (See Fl) I. Sprocket

2. Remove snap ring (2). (See Fl) l Remove sprocket.
3. Using push-puller 0, pull out swivel rotor *A, Loosen the oil filler cap slowly to
(4) and ring (3) from swivel shaft (5). (See * release the pressure inside the hy-
Fl, F2) draulic tank.
4. Remove snap ring (61, then remove oil seal 2. Hose (11 (See F4)
(7) and slipper seal (8). (See Fl) 3. Final drive assembly (2) (See F5) m
* Sling the final drive assembly, then
remove the mounting bolts, and lift off
the final drive assembly.
ASSEMBLY OF CENTER See Weight Table

SWIVEL JOINT ASSEMBLY
1. Assemble slipper seal (8) to swivel rotor (4).

(See Fl I INSTALLATION OF FINAL
2. Using push tool 0, press fit oil seal (7) to
swivel rotor (4), and install snap ring (6).
DRIVE ASSEMBLY
(See Fl , F3)
&I& Lip of oil seal: Grease (G2-LI)
removal.
3. Set swivel shaft (5) on block, then using
push tool, tap swivel rotor (4) with a plastic
hammer and install. (See Fl)
* When installing the rotor, be extremely &I& Mounting bolt:
careful not to damage the lips of the Thread tightener (LT-2)
slipper seal and the oil seal. w Mounting bolt:
4. Install ring (31, and secure with snap ring See Tightening Torques and
(2). (See Fl 1 Standard Values Table
5. Fit O-ring and install cover (I 1. (See Fl) l Bleeding air
Bleed the air from the motor.
For details, see TESTING AND
ADJUSTING, Bleeding air from travel
motor.
After bleeding the air from the motor,
check the level of the hydraulic tank.
30-34
0
Fl
P
‘-6s
205FO5423
t1
205FO5420 205FO5424
F2
205FO542 1
F3
30635
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
6. Ring gear
Remove ring gear (I 2). (See F6)
1. Draining oil
7. No. 2 sun gear
Remove drain plug and drain oil from final
Remove sun gear (I 3). (See F6)
drive case.
8. Thrust washer
: Remove thrust washer (I 4). (See F7)
- Final drive case:
9. No. 2 carrier assembly
See Lubricant and Coolant Table
2. 1) Remove carrier assembly (I 5). (See F7)
Cover
Using forcing screws and eyebolts 0,
remove cover (I 1. (See F I)
3. Thrust washer 2) Disassembly of carrier assembly

Remove thrust washer (2). (See F2) i1 Remove mounting bolts (I 61, then
4. No. 1 sun gear shaft remove holder. (See F8I
Remove sun gear shaft (3). (See F2) ii) Set carrier assembly (I 5) in press,
5. No. 1 carrier assembly then using push tool 0, pull out pin
I) Remove carrier assembly (4). (See F2) (171, and remove gear assembly
(I 8). (See F9)
2) Disassembly of carrier assembly iii1 Remove bearing (20) and spacer

i) Remove mounting bolts (5). then (21) from gear (19). (See FIO)
remove holder. (See F3) iv) Remove outer race (221. (See FIO)
ii) Set carrier assembly (4) in press,
then using push tool 0, pull out pin
(61, and remove gear assembly (7).
(See F41
iii) Remove bearing (9) and spacer (IO) 10. Retainer

from gear (8). (See F5) Remove mounting bolts (23) and (241, then
iv) Remove outer race (I I). (See F5) remove retainer (25). (See Fl I)
11. Spacer
Remove spacer (26). (See F12)
30;36
Fl F6 F7
12
13
205FO5425 205FO5430 205FO5431
F2 F8 F9
m I 205F0542E i
F4 FIO
205FO5427 205FO5428
F! Fll F12
r
205FO5429 205FO5435 205FO5436

ASSEMBLY OF FINAL
DRIVE ASSEMBLY
12. Hub assembly
I) Using eyebolts @I, remove hub
1. Hub assesmbly
assembly (27) from travel motor. (See
1) Using push tool, press fit bearings (3 I)
Fl) and (30). (See F4)
2) Using tool A,, install floating seal (29).
(See F41
3) Using tool A,, install floating seal (28).
(See F5, F6)
Sr When installing the floating seals,
remove all oil and grease from the
O-ring and O-ring contact surface,
and dry completely before installing.
* After installing the floating seals,
coat the sliding surfaces thinly with
2) Remove floating seal (28). (See F2)
engine oil.
3) Remove floating seal (291. (See F3)
4) Remove bearings (30) and (31). (See F3)
4) Using eyebolts 0, set hub assembly

(27) on travel motor, then using push
tool, tap to press fit bearing. (See F7)
30G38
I F5
27
0 8
I
205FO5437 205FO5439 205FO5438
F2 F3 F6
205FO5438 205FO5439 205FO5509

i
F7
\
I 205FO5437
30639
2. Adjusting bearing clearance 4. No. 2 carrier assembly
I) Using tool A,, hold bearing, and I) Assembly of carrier assembly
temporarily tighten 2 bolts. (See Fl) i1 Using push tool, press fit outer race
2) Rotate hub 2 - 3 turns to settle bearing. (22) to gear (191. (See F6)
3) Loosen bolts of tool A,, and then ii) Assemble spacer (21) and bearing
tighten again to a torque of 2.0 kgm. (20). (See F6)
(See Fl)
4) Using a depth micrometer, measure
stepped difference a between end face
of shaft and inner race, and dimension b
of gear coupling. (See F2)
* Measure two places and take the
average value.
5) Calculate difference (cl between
iii) Set carrier assembly (I 5) in press,
dimension b and stepped difference a
then assemble gear assembly (I 8).
(b - a = c).
and using push tool 0, press fit pin
(I 7). (See F7)
6) Select a spacer to give a value of
+ Be careful to keep the pin
-0.05
C straight, and rotate the gear
-0.15 mm
when press fitting the pin.
* Select the suitable thickness of iv) Fit holder and tighten with mounting
spacer from the 8 types of spacer. bolts (I 6). (See F8)
J+I& Mounting bolt:
Thread tightener (LT-2)
m Mounting bolt:
See Tightening Torques
3. Retainer and Standard Values
II Fit retainer (25). and tighten with mount- Table
ing bolts (24) and (25). (See F4) 21 Install carrier assembly (I 5). (See F9)
5. Thrust washer
a Mounting bolt:
Assemble thrust washer (I 4). (See F9)
6. No. 2 sun gear
B Mounting bolt (24): Assemble sun gear (I 3). (See FIO)
See Tightening Torques and 7. Ring gear
Standard Values Table Align with teeth surface of carrier, and in-
B Mounting bolt (23): stall ring gear (I 2). (See FIO)
See Tightening Torques and a Ring gear mounting surface:
Standard Values Table Thread tightener (LG-6)
2) Check adjustment of bearing clearance
again.
Hook spring balance @ in the tap hole 8. No. 1 carrier assembly
for the sprocket mounting bolt, pull to I) Assembly of carrier assembly
rotate the hub on the shaft and measure i) Using push tool, press fit outer race
the starting force. (See F5) (I I) to gear (8). (See Fl I)
* Starting force: ii) Assemble spacer (IO) and bearing
See Tightening Torques and Stan- (9). (See Fl I)
dard Values Table
Ir If the starting force is higher than
the standard value, there is a preload
on the bearing, so adjust again.
30-40
0
Fl F6
F2
F20505367
1
F7
22
F8
20
205FO5434
Gear coupling
k
I
F20505368 205FO5441 205FO5432
F3 F4 F9 FIO
24
205FO5436 205FO5435 205FO5431 1 205FO5430
Fl 1
1
205F2469A / 205FO5429
30-41
0
iii) Set carrier assembly (4) in press, 2) Tightening method when not using
then assemble gear assembly (7), angle tightening wrench
and using push tool 0, press fit 0 Tighten bolts to specified initial
pin (6). (See Fl) torque.
jr Be careful to keep the pin m Mounting bolt:
straight, and rotate the gear See Tightening Torques
when press fitting the pin. and Standard Values
iv) Fit holder and tighten with mount- Table
ing bolts (5). (See F2) ii) Make start mark on cover and
socket in accordance with angle of
& Mounting bolt:
hexagon of bolt. (See F6)
iii) Make end mark at specified tight-
m Mounting bolt:
ening angle from start mark. (See
and Standard Values F6)
* Make the end mark on the
Table
cover only.
2) Align with teeth surface of ring gear,
B Mounting bolt:
and install carrier assembly (4). (See
F3)
and Standard Values
9. No. 1 sun gear shaft
Table
Assemble sun gear shaft (3). (See F3)
iv) Tighten until start mark on socket
10. Thrust washer
is aligned with end mark on
Assemble thrust washer (2). (See F3)
cover. (See F6)
11. Cover
+ When carrying out disassembly and
Using eyebolts 0, install cover (1). (See
assembly of the final drive on the fol-
F4).
lowing serial numbers, replace mount-
& Cover mounting surface: ing bolt 0 with bolt @I, and tighten
Gasket sealant (LG-6) according to procedures 1) or 2)
. Procedure for tightening cover mount- above. (See F7)
ing bolts - PC200,2OOLC-5
1) Tightening method when using angle Serial No: 45001 - 61725
tightening wrench - PC220,22OLC-5
i) Tighten bolts to specified initial Serial No: 35001 - 36986
torque.
m Mounting bolt: 12. Refilling with oil
See Tightening Torques Tighten drain plug and add engine oil
and Standard Values through oil filler.
Table
ii) Using tool A3, tighten bolts to % Final drive case:
specified tightening angle. (See See Lubricant and Coolant
Table
F5)
w Mounting bolt: * After installing the final drive assem-
See Tightening Torques bly to the body, check the oil level
and Standard Values again at the specifid position.
Table
30642
Fl F2 F
Start mark
on cover
0
4 6 II--
/ Mounting bolt Start mark

on socket
205FO5442 205FO5427 205FO59 I2
F3 F7
r
Bolt @I Bolt @
1 205FO5426 2rJ5FO59 I3
F4
1.
205FO5425
F5
lousing
_.
205FO59 I I
30-i2-1
REMOVAL OF SPROCKET
1. Track shoe assembly

* Remove track shoe assembly.
For details, see REMOVAL OF TRACK
SHOE ASSEMBLY.
2. Jacking up machine
+ Swing the work equipment 90” to jack
up the machine, then set block 0 be-
tween the track frame and the track
shoe. (See Fl)
3. Sprocket (1). (See Fl) m
* Sling the sprocket, then remove the
mounting bolts, and lift off the
sprocket.
INSTALLATION OF
SPROCKET
. Carry out installation in the reverse order

to removal.
m
& Mounting bolt:
w Mounting bolt:
3042-2
Fl
I 1
30643
DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY (HMVIGO)
1. Motor assembly
Remove motor assembly from final drive as-
sembly.
* For details, see DISASSEMBLY OF FINAL
DRIVE ASSEMBLY.
2. Spring, pistons
Remove spring (1) and pistons (2) and (3).
* Mark match marks on the case and the
piston.
3 F20505412
3. Set motor assembly (4) in tool Gl.

Gl
4. End cover assembly, valve plate

P \
1) Remove end cover assembly (5)
/
F20505413
2) Remove valve plate (6).

* If the valve plate is to be used again,
keep it in a safe place and be careful
not to damage the cylinder block
mounting surface.
3) Using gear puller 0, remove outer race

(7) and spacer (8). F20505"','
+ Check the thickness of the spacer.
F2050541E ,
r F2050541E
4) Disassemble end cover as follows
0 Remove safety valve assembly (10).
* The set pressure is higher than the
set pressure of the main relier
valve, so do not disassemble it.
ii) Remove plug (II), then remove spring
(12) and valve (13).
iii) Remove plug (14), then remove spool
(15), spring (16), and plate (17).
iv) Remove plug (18), then remove ball
(19). 11
F20505417
v) Remove plug (20), then remove spring
(21), retainer (22), and spool (23).
A A force of approx. 40 kg is brought to

bear on the plug, so push the installa-
tion tool perpendicularly against the
plug when loosening it.
F20505418
5. Spring 24 25
Remove spring (24).
F20505419
6. Piston assembly
Using tool G2, blow in air, and remove
brake piston (25).
+ If the air pressure is high, the brake pis-
ton will fly out, so be careful.
7. Disc, plate
Remove disc (26), Plates (27) and (28).
8. Bearing
Using bearing race puller 0 and gear puller
0 remove bearing (29).
+ Be careful not to contact the bearing rol-
ler portion with the puller.
+ If the cylinder block is to be used again,
put a gasket or paper on the valve plate
contact surface to protect the surface.
* The puller must not be allowed to scratch
or damage the cylinder block sliding sur-
face.
F20505421
9. Cylinder block, piston assembly

1) Remove cylinder block (30) and piston as-
sembly (31) as one unit.
F20205262
2) Disassemble into cylinder block (30), re-

tainer guide (33), shoe retainer (34), and
piston (35), and remove spring (44) and I 33 44 30
shim (45) from retainer guide.
* Check the number and thickness of
the shims, and keep in a safe place.
34 35 45
F20205263
10. Rocker cam

Remove rocker cam (36).
F20505422
30-&3-3
11. Cradle
Remove 4 bolts from final drive end, then
remove cradle (37).
12. Shaft assembly

Remove shaft assembly (38).
F2050542:
30-&3-4
ASSEMBLY OF TRAVEL MOTOR ASSEMBLE (HMV 160)
Precautions when assembling

1) Clean all parts, check for dirt or damage,
and repair any burrs.
2) Coat the rotating and sliding surfaces of
all parts with engine oil (EOIO-CD) before
installing.
* Always use the following parts as a set.
i) Cradle and rocker cam
ii) Cylinder block and valve plate
1. Set motor case (39) to tool Gl.
2. Bearing outer race

Using push tool 0, press fit bearing outer
race (40) in case.
3. Oil seal
Using push tool, press fit oil seal (41) in
case.
41 F20505424
4. Shaft assembly
1) Using tool 63, press fit bearing (42) to
shaft (43).
F20205272
2) Install shaft assembly (38).
5. Cradle
Align with dowel pin, and set cradle (37) in
position.
m Mounting bolt:
See Tightening Torques and Stan-
dard Values Table
J, It is not permitted to use the seal washer
again, so always replace it with a new
part. F20505423
6. Rocker cam
Align with cradle groove, and install rocker
cam (36).
t Install the rocker cam with the thick stop-

per facing the case mating surface which
has two drill holes.
I F20505425
7. Cylinder block, piston assembly

1) Assemble cylinder block and piston as-
sembly as follows.
i) Assemble piston (35) to shoe retainer
(34).
* The variation between the thick-
ness of the shoe lips must be
within 0.005 mm.
(Spare parts are supplied in a kit
within these dimensions.)
F20205274
ii) Assemble spring (44) and shim (45) to

retainer guide (33).
F20205275
t Assemble the springs as shown in
the diagram, then select shims and
assemble so that the dimension in
the diagram is 141.90 rfr 0.10 mm.
Spring
* Assemble the thick shim at the
spring end.
iii) Set retainer guide (33) to cylinder
block (30).
Shim
Spring
F20205276
iv) Assemble piston assembly (31) in cy-

linder block (30).
31
F20205277
2) Align cylinder block (30) and piston as-

sembly (31) wit.h spline of shaft, then in-
stall.
I \ F20205262 1
30-4$3-7
8. Shim adjustment of retainer guide
1) Install valve plate (6) with cylinder block
end facing straight up.
2) Put a steel scale in contact with case
(39), and measure dimension 0 between
case and valve plate.
* The shaft is an outboard type and is
at an angle, so make it as perpendicu-
lar as possible, measure at several
places, and take the average.
* Do not push down on the valve plate.
F2020527a
3) Select shim (45) for retainer guide so that

dimension 0 is 2.30 + 0.41 mm.
* When changing the thickness of shim
(45), disassemble to the condition in
7-I)-ii). A clearan
4) After adjusting dimension 0, check that 1.7 i 0.1
mm is
dimension of clearance 0 from end cover
formed
(5) is 1.7 f 0.1.
* The dimension for portion @ is 4 mm.
z 5) After completing selection of shim,
z remove end cover and valve plate.
:
9. Plate, disc, piston

1) Assemble plate (28), then assemble plate
(27) and disc (26) in order.
* There are 6 plates and 5 discs.
* Align the discs at three places with
the notched tooth on the spline.
2) Fit O-ring and backup ring, then install
brake piston (25).
* Assemble so that the piston groove is
aligned with the dowel pin in the end
cover. ,
F20205297
* Assemble the backup ring in the di-

rection shown in the diagram.
Backup ring
O-ring
Backup ring
F20205298
10. Adjustment of shaft end play
1) Using tool G4 and puller, press fit bear- n Puller
ing (29) to shaft (38).
F20205281
2) Assemble spacer (8) in end cover, and in-

stall bearing (7).
Sr Assemble the same spacer as was
removed.
F20505415
3) Install end cover (5) to motor case.

* This is temporarily stopped, so do not
install the spring and O-ring of the
parking brake.
J
m Mounting bolt:
4) Fit dial gauge @ to motor case, then

move shaft in axial direction, and
measure movement of shaft in axial di-
rection (end play).
+ End play: 0.05 - 0.25 mm
30-&3-9
5) If dimension is not within standard range,
adjust again as follows.
i) Remove end cover. Outer race
ii) Remove outer race.
For details, see disassembly step 4-3).
iii) Set outer race to bearing measure
dimension 0 from case and end face
of outer race, then decide spacer @
from following formula.
@=14.35-@
iv) Select spacer from Table.
F20205284
b mm ~ 1.60
1.69
1.70
- 1.79
1.80
- 1.89
1.90
~ 1.99
2.00
- 209
2.10
- 2.19
2.20
- 2.29
2.30
- 2.39
2.40
-2.49
Selected 708.SH 708.SH 708.8H 708.8H 70%8H 708.8H 70%8H 708-W 708.8H
spacer -12290 -12280 -12220 -12230 -12240 --1216O -12250 -72270 --12210
VI Assemble selected spacer, assemble

again according to assembly proce-
dure 10-2) - 4), and measure end
play.
vi) After completion of adjustment,
remove end cover.
11. End cover assembly

1) Assemble end cover assembly as follows.
+ Precautions when installing the plug.
Remove all the grease from the plug,
then coat the thread with two drops
of adhesive. (Adhesive: Loctite #638)
i) Assemble spool (23), retainer (22), and
spring (21) in turn, then fit O-ring and
install plug (20).
I 1’2
A A force of approx 40 kg is brought 11
F70!i05417
to bear on the plug, so push the
installation tool perpendicularly
against the plug when tightening
it.
m Plug: See Tightening Torques

and Standard Values Table
F20505418
ii) Assemble ball (19), then fit O-ring
and install plug (18).
W Plug: See Tightening Torques
and Standard Values
Table
iii) Assemble plate (17), spring .(16), and

spool (15) in order, then fit O-ring
and install plug (14).
Qa Plug: See Tightening Torques
and Standard Values
Table
iv) Assemble valve (13) and spring (12),

then fit O-ring and install plug (11).
m Plug: See Tightening Torques
and Standard Values
Table
v) Fit O-ring and install safey valve as-

sembly (10).
m Safety valve assembly:
2) Install end cover assembly as follows.

i) Install spring (24) for parking brake.
6
* Assemble the spring so that the
outside circumference is in the
“open” direction.
ii) Align with dowel pin, and install valve
plate (6) to end cover. 24
F20505426 F20205286
iii) Fit O-ring, and align dowel pin with
piston groove, then install end cover
assembly (5).
w Mounting bolt:
12. Pistons, spring

Align match mark, and install pistons (3) and
(2), and spring (1).
* Assemble the piston with no spring at
the discharge port end.
F20505412
. When storing or transporting the motor

assembly, install tool G5 to the oil seal
end.
Ir When doing this, coat the lip surface of
the oil seal with engine oil using your
finger tip.
\
F20205287
1
30-g-12
CHECKING CONTACT BETWEEN CYLINDER
BLOCK AND VALVE PLATE, AND ROCKER CAM
AND CRADLE
1. Checking contact between cylinder block
Cylinder block Centering tool
and valve plate
1) Make a centering tool for the cylinder
block and valve plate.
* The tool can be made of a soft ma-
terial such as plastic or bakelite.
2) Remove grease from the parts to be
checked.
* Do not wipe with a cloth.
3) Set the tool in position, and coat the cy-
linder block side with inspection paint.
t Apply the paint thinly.
4) Put the valve plate on top, push with a
force of 4 - 5 kg and rotate 2 - 3
times.
5) Remove the valve plate, transfer the con-
tact surface to tape, and check the con-
tact surface.
* The standards for the contact surface are
as follows. z
F20703037
0”
Valve plate a. Seal Min. 80% :
Cylinder block a. Seal Min. 80%
Valve plate Cylinder block
FL’0703038
2. Inspection of contact of rocker cam and
Contact less
cradle than 50%
1) Remove grease from parts to be in- /Contact 50% - 90%
spected.
? ;;;tna;; yore
+ Do not wipe off with waste cloth. I OrJ
55 ’ 77
2) Coat cradle with inspection paint.
Contact 50% - 90%
t Coat with paint thinly. 4F-
‘I Cmm&ss
3) Put rocker cam on top, push down with a / 0
force of 4 - 5 kg, and move 2 - 3 times
between
angle.
min. tilt angle and max. tilt
4) Remove rocker cam, then transfer contact

surface to tape and inspect contact pat-
~ ’
k-
Crad’e F20205290
tern.
* The standard for the contact pattern
is as shown in below.
* The part fails the inspection if there is
no contact at the center but only con-
tact at the outside.
[Reference]
If the contact is not within the standard
range and lapping is carried out, always
lap the mating parts together.
* Any part that is scratched must not
be reused.
30-4d?-14
REMOVAL OF SWING
MOTOR ASSEMBLY
* A+AC and
Lower the work
release the
equipment
remaining
to the ground
pressure in the
circuit. For details, see TESTING AND AD-
JUSTING, Releasing pressure in hydraulic
circuit for machines with PPC valve.
1. Hoses (1).
-k Disconnct 7 hoses.
2. Swing motor assembly (2).

* Sling the swing motor assembly, and
remove the mounting bolts.
&I kg See Weight Table
8;
F20505317
I,NSTALLATION OF SWING
MOTOR ASSEMBLY
0 Carry out installation in the reverse order to

removal.
0 Refilling with oil
* Add oil to the specified level, and run
again.
DISASSEMBLY OF SWING MOTOR ASSEMBLY (KMF90-2 (AB))
1. Brake case assembly

1) Using a block, set the swing motor as-
sembly (1) at an angle of approx 25”.
2) Lift off brake case assembly (2).
F20205291
2. Brake piston
Set brake case assembly (2) in tool HI, then
use tool H2 to remove brake piston (3).
* If the air pressure is high, the brake pis-
ton will fly out, so be careful.
F20205292
3. Piston assembly
1) Using tool H3, remove screw, then
remove retainer (4).
2) Remove piston assembly (5) and center
ball (6).
J, The screw is not permitted to be, re-
used, so scrap it.
F20205293
4. Disc, plates
Remove disc (7) and plates (8) and (9).
I F2020.5294
5. Cover
Remove snap ring (12), then remove cover
(13).
* Lever the groove with a screwdriver.
F20205295
i
6. Drive shaft
1) Remove snap ring (17), then remove
spacer (16).
F20205296
2) Push down drive shaft (15) with press

and remove.
F20205297
3) Remove bearing (18), then remove outer

race (19), and remove seat (20) and
spring (21).
* The outer race can be pulled out by
hand.
F20205298
7. Spring
Remove spring (26).
8. Cylinder block assembly

1) Remove cylinder block (28) together with
center shaft from housing (27).
_w-m_
\ /
J
F20505427
2) Remove center shaft (30), center ring

(31), and spring (29) from cylinder block
(28).
F20205300
9. Valve plate
Remove valve plate (32).
10. Safety valve

Remove safety valve (33).
11. Check valve

Remove plug (34), then remove spring (35)
and valve (36).
F20505428
3044-2
ASSEMBLY OF SWING MOTOR ASSEMBLY (KMF90-2 (AB))
Precautions when assembling

1) Clean all parts, check for dirt or damage,
and repair any burrs.
2) Coat the rotating and sliding surfaces of
all parts with engine oil (EOIO-CD) before
installing.
1. Bearing
Press fit bearing (37) in housing (27). h I.
* Check that the bearing is completely

press fitted up to the end face.
F20205303
2. Check valve
Assemble valve (36) and spring (35), then fit
O-ring and install plug (34).
@\
G= Plug: See Tightening Torques and ,34
Standard Values Table 35
Plug: Thread tightener (LT-2)
3. Safety valve
Fit O-ring and install safety valve (33).
w Safety valve:
See Tightening Torques and Stan- I F20505428
dard Values Table
4. Valve plate
Turn over housing, then align valve plate
(32) with dowel pin, and install.
* Check that there is no clearance (play) at
the mounting surface with the housing.
30-65-3
5. Cylinder block assembly
1) Install cylinder block (28). ~ 28
2) Assemble spring (29) and center ring (31)
in cylinder block, then install center shaft
(30).
3) Using tool H4 secure center shaft (30).
* Pulling force: 150 - 200 kg
* When doing this, check that the cylin-
der block cannot be rotated by hand.
F20205305
6. Bearing
Press fit bearing (25) to drive shaft (15).
7. Outer race
Press fit outer race (24) in brake case (23).
F202053061j II&==?v/Fi
8. Assembly of drive shaft assembly

15 28
II Assemble shaft (15) in brake case (28),
and put piston mounting side on block /
0.
2) Install spring (21).
* Align the spring so that the outside
circumference opens.
3) Align with spring, and install seat (20).
4) Install outer race (19).
I=20205308
5) Press fit bearing (18).

* Press fit carefully and make sure that
spring (21) does not come away from
the seat.
* From the point where the bearing rol-
ler contacts the outer race, rotate the
shaft while press fitting it.
t Press-fitting load: 748 - 1606 kg
F20205309
6) Assemble spacer (16) of thickness of 5.4
mm, and install snap ring (17).
* Check that the snap ring is fitted se-
curely in the ring groove.
(If it does not fit, replace it with a 5.0
mm spacer.)
F20205296
9. Measuring procedure for clearance (portion 1

@I) between seat (20) and brake case
Push out drive shaft (15) from piston
mount until bearing inner race (22),
spacer (16), and snap ring (17) are in
close contact.
* Pushing force: 288 - 1144 kg
(Force can be applied up to 2000 kg)
After the above parts come into close
contact, apply a load of 2000 kg.
f Check that the spacer cannot be ro- 0205311
tated by hand.
Fit dial gauge 0 to brake case, push
drive shaft (15) with 500 - 2000 kg, and
measure amount of movement of shaft.
* Movement: 0.1 - 0.4 mm
t If the amount of movement is not
within the standard range:
* If it is more than 0.4 mm, replace
with a 0.58 mm spacer (706-7E-
11320)
- If it is smaller than 0.1 mm, re-
place with a 0.5 mm spacer (706-
86-40030) F20205312
* After replacing the spacer, measure
the amount of movement again.
10. Measuring rotating torque of drive shaft

1) Apply ample oil to bearing.
2) Using tool H5, rotate at approx. 1 turn/5
set, and measure rotating torque of drive
shaft.
* Rotating torque: 0.1 - 0.16 kgm
* if it is not within the standard value,
F20205313
replace the bearing with a new part.
30-i5-5
11. Cover
1) Install oil seal (14) to cover (13).
a Lip surface of oil seal:
Grease (G2-LI)
F20205314 L’
2) Fit O-ring and install cover (13).

3) Install snap ring (12).
F20205295
12. Discs, plates

Assemble plate (9), then assemble plates (8)
and discs (7) in turn.
sr Align the discs at three places with the
notched tooth on the spline.
F20205294
13. Piston assembly

1) Set ball (6) of cener shaft to shaft.
2) Assemble piston (5) to retainer (4), and in-
stall as one unit to shaft.
\k----q F2020529:I 1
30-$5-6
3) Using tool H3, tighten screws (7) in order
shown in diagram.
PCE& Screw: Thread tightener (LT-2)
w Screw: See Tightening Torques
and Standard Values Table
* Remove all grease from the thread, then

dry it and coat with thread tightener.
Wipe off any thread tightener that is
squeezed out.
-f After tightening, check that the big end @ F-20205317
of the piston and the center ball move
smoothly.
”
Ir After tightening, check that the play in

the axial direction of the piston assembly
is within 0.35 mm.
14. Brake piston

Fit O-ring and install brake piston (3).
* Assemble so that the piston pin groove is
aligned with the dowel pin of the end
cover.
15. Brake case assembly F20505429
1) Set housing (27) so that cylinder block is

perpendicular.
-rt Before assembling spring (26), it is
better to assemble brake case assem-
bly (2) in the housing, and align the
brake piston and dowel pin.
2) Install spring (26) to housing.
3) Face hole of center ball in direction of
center shaft, then fit O-ring to brake case.
4) Align pin groove of brake piston with
dowel pin, and install brake case assem-
bly (2).
- F20505427
+ Tighten the mounting bolts uniformly.
If the mounting bolts become heavy,
do not forcibly tighten; remove the
brake case assembly and start again.
w Mounting bolt:
* When finally tightening the mounting

bolts, set in tool HI.
& Mating surface of case:
Gasket sealant (LG-1)
F20205291
3045-7
REMOVAL OF SWING
MACHINERY ASSEMBLY
1. Swing motor assembly

(For details, see REMOVAL OF SWING
MOTOR ASSEMBLY)
1) Disconnect 7 hoses (1).
2) Remove swing motor assembly (2).
F20505317
2. Swing machinery assembly (1).

* Sling the swing machinery assembly, then
using forcing screws, and remove the
swing machinery assembly.
63kg See Weight Table
INSTALLATION OF SWING
MACHINERY ASSEMBLY
0 Carry out installation in the reverse order to

removal.
0 Refilling with oil
* Run the engine to circulate the oil
through the system.
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
vi) Remove inner races (I 2) and (13)
from case (I I). (See F9)
1. Draining oil
Remove drain plug and drain oil from swing
machinery case.
_ : Swing machinery case:

2. Cover assembly
I) Remove mounting bolts, then using
eyebolts 0, remove cover assembly
(I). (See Fl)
Sr There are 9 mounting bolts at the
top and 3 mounting bolts at the
bottom. 3. Shaft
2) Disassembly of cover assembly Remove shaft (I 4). (See FIO)
Remove cages (2) and (3). (See F2) 4. Ring gear
* Check the number and Remove ring gear (I 5). (See FIO)
thickness of the shims, and
keep in a safe place.
Remove outer races (4) and (5) from
cage. (See F3, F4)
ti
iii) Remove mounting bolts, then 5. Carrier assembly
remove cover (6). (See F5) I) Remove mounting bolts, then remove
iv) Remove gear assemblies (7) and (8). carrier assembly (I 61. (See Fl I)
(See F61 2) Disassembly of carrier assembly
i) Remove mounting bolts (I 7). then
remove holder. (See F12)
v) Remove bearings (9) and (IO) from ii1 Set carrier assembly (I 6) in press,
gear. (See F7, F8) and using push tool 0, remove pin
(181, then remove gear assembly
(I 9). (See F12, F13)
iii) Remove holder (20). (See F13)
Fl F2 9
205FO5444 L 205FO5445
H u 205FO5452
F3 4
! 4
205FO5446 205FO5447 205FO5453
F5
- F6 :I1 F12
/ 205FO5448 205FO5449 205FO5454 205FO5455
F7 8 F 13
1 10
I 205FO545C 205FO5451 20 205FO5456

ASSEMBLY OF SWING
MACHINERY ASSEMBLY
iv) Remove bearing (22) and spacer
(23) from gear (21). (See Fl)
I. Case assembly
v) Remove inner race (24). (See Fl 1
I) Using push tool, press fit bearing (33).
(See F8)
2) Assemble spacer (29). (See F9)
31 Using push tool, press fit bearing (30).
(See F9)
6. Shaft assembly 2. Shaft assembly

I) Loosen mounting botls (251. (See F2) I) Assembly of shaft assembly
2) Set shaft and case assembly (26) in i) Using push tool 0, press fit oil seal
press, and using push tool 0, remove (32). (See FIO, Fl I)
shaft assembly (27). (See F3) a Outer circumference of oil
seal: Adhesive (LG-6)
3) Disassembly of shaft assembly ii1 Assemble cover (31) to shaft (28).

i) Remove spacer (29) from shaft (See F12)
(28). (See F4) ET& Lip of oil seal: Grease (LG-6)
ii) Remove bearing (30). (See F4) iii) Set case assembly in press, and
iii) Remove cover (31). (See F5) press fit shaft assembly (27). (See
F13)
iv) Tighten mounting bolts (25). (See
F13)
&?k Cover mountig surface:

Adhesive (LG-6)
iv) Remove oil seal (32) from cover. 3. Carrier assembly

(See F6) I) Disassembly of carrier assembly
7. Case assembly i) Using push tool, press fit inner race
Remove bearing (33). (See F7) (24). (See F14)
ii) Assemble spacer (23) and bearing
(221 to gear (21). (See F14)
30-48
0
Fl
205FO5457 205FO5463 205FO5464
F2 :3 F'10 F:I1
32
205FO5458 205FO5459 205FO5465 205FO546;
FE F12 13
28 28
31 31
205FO5460 205FO5461 205FO5461 205FO5466
F6 7 F14
32
205FO5462 205FO5463 205FO5457

iii) Assemble holder (20). (See Fl) ii) Using push tool 8, press fit bearing
iv) Set carrier assembly (I 61 in press, (I 0) in gear. (See F7)
then assemble gear assembly (191, iii) Using push tool 0, press fit bearing
and using push tool 0, press fit pin (9) in gear. (See F8)
(18). (See F2)
+ Be careful to keep the pin
straight, and rotate the gear
when press fitting the pin.
* After press fitting the pin, check
that the gear rotates smoothly.
v) Fit holder and tighten with mounting iv) Install gear assemblies (8) and (7).
bolts (I 7). (See F3) (See F9)
VI Fit cover (6) and tighten with
KY& Mounting bolt:
mounting bolts. (See FIO)
a Cover mounting surface:
m Mounting bolt:
See Tightening Torques Adhesive (LG-6)
and Standard Values

Table
2) Fit carrier assembly (I 61, and tighten
with mounting bolts. (See F4)
&& Mounting bolt:

W Mounting bolt:
vi) Using push tool, press, fit outer
races (5) and (4) in cage. (See Fl 1,
F12)
4. Ring gear
Install ring gear (I 5). (See F51
&III& Ring gear mounting surface:

Thread tightener (LG-6)
5. Shaft
Assemble shaft (I 4). (See F5)
7. Adjusting preload of bearing

6. Cover assembly 1) Remove O-ring, and install cages (3)
I) Assembly of cover assembly and (2). (See F13)
i) Using push tool, press fit inner races Ir Install 2 bolts each at a and b.
(I 3) and (I 2) in case (I I). (See F6) Sr Rotate the spline shaft for the
motor mount 5 - 6 turns, then
tighten the bolts to the specified
torque.
m Bolt:
and Standard Values
Table
30-50
a
Fl F2 F7 F8
205FO5467 205F0546E 205FO5469
4 9 10
.6
205FO5455 205FO5454 205FO5448
Fll F 12
_F
205FO5453 205FO5447 205FO5446
F13
I’ -
205FO5452
30-51
a
2) Selecting shims
Measure points “c” and “d” with a
feeler gauge, then select shims from the
table below.
* Types of shims:
t = 0.4, t = 0.5, t = 0.6
t = 0.7, t = 0.8
3) Remove cages (3) and (2). (See Fl 1
4) Fit O-rings and install cages (3) and (2).
(See Fl)
m Mounting bolt:
* Check that the spline shaft for the
motor mount rotates smoothly by
hand.
5) Using eyebolts 0, install cover assem-
bly (I). (See Fl)
a Cover assembly mounting

surface: Adhesive (LG-6)
8. Refilling with oil
Tighten drain plug and add engine oil
through oil filler.
Q Swing machinery case:

Fl
il
I 205FO5472
F2
I
205FO5444
30-53
0
REMOVAL OF REVOLVING INSTALLATION OF
FRAME ASSEMBLY REVOLVING FRAME
ASSEMBLY
1. Boom cylinder assembly
l Remove boom cylinder assembly. l Carry out installation in the reverse order to
2. Work equipment assembly removal.
l Remove work equipment assembly.
For details, see REMOVAL OF WORK (
EQUIPMENT ASSEMBLY. * The dimensions of the mounting bolts,
3. Counterweight assembly diameter of the washers, and thickness
l Remove counterweight assembly. of the washers differs according to the
4. Cab assembly mounting position, so refer to the table
l Remove cab assembly. and diagram below when installing. (See
For details see REMOVAL OF OPERA- F4)
TOR’S CAB ASSEMBLY.
Diameter Thickness
5. Hoses (I). (See Fl) Bolt Bolt size
of washer of washer
O’ty
6. Link (2). (See Fl) a 24 - 105 48 6 4

7. Revolving frame assembly (3). (See F2) m b 24 - 105 48 9 2
* For the mounting bolts marked % c 24 - 60 48 6 2
move the control box assembly, remove Others 24 - 60 48 6 18
the grommets, then remove the bolts. % 24 - 70 48 6 4
J, When removing the mounting bolts, x :This indicates the size of bolts used only on the
leave 2 bolts each at the front and rear. PC220.
* Using lever block, adjust the balance of
the revolving frame assembly to the &I?+ Mating surface of swing circle:
front and rear, and left and right, Gasket sealant (LG- I)
remove the remaining bolts, then lift off. AFL Mounting bolt: ::
* When removing the revolving frame as- Thread tightener (LT-2) z
sembly, be careful not to hit the center 2
m Mounting bolt:
swivel joint assembly.
&?Ikg See Weight Table
30-54
0
Fl F4
I I 205FO5473 1 205FO5476
F2
205FO5474 /
z
::
g F3
F
I
205FO5475
30-55
0
REMOVAL OF SWING REMOVAL OF IDLER,
CIRCLE ASSEMBLY RECOIL SPRING ASSEMBLY
1. Revolving frame assembly I, Track shoe assembly

l Remove revolving frame assembly. l Remove track shoe assembly.
For details, see REMOVAL OF 2. Idler and recoil spring assembly (I 1. (See F31
REVOLVING FRAME ASSEMBLY. * Sling the idler and recoil spring
2. Swing circle assembly (I 1. (See Fl 1m assembly, and pull out to the front to
Ir Remove 36 mounting bolts. remove.
& kg See Weight Table & kg See Weight Table

3. Disconnection of idler and recoil spring
assembly
Secure recoil spring with block 0, then
sling idler assembly, remove mounting
INSTALLATION OF SWING bolts, and disconnect idler assembly (2) and
CIRCLE ASSEMBLY recoil spring assembly (3). (See F4)
J, Make match marks on the matching sur-
l Carry out installation in the reverse order to face of the idler and the recoil spring.
removal.
6 kg See Weight Table
Ir Install swing circle assembly (I) with

the inside soft zone (S) mark facing 90”
to the left. (See F2)
INSTALLATION OF IDLER,
& Mounting bolt:
RECOIL SPRING ASSEMBLY 0”
0”
m Mounting bolt: g
removal.
&I& Circle teeth surface:

Grease (G2-LI)
Volume: 21 Q
30-56
a
Fl F3
I I
\L/
F20505318 205FO5477
F20505319 205FO5478
z
::
$
30657
DISASSEMBLY OF RECOIL ASSEMBLY OF RECOIL
SPRING ASSEMBLY SPRING ASSEMBLY
1. Remove piston assembly (2) from recoil 1. Assembly of piston assembly

spring assembly (I 1. (See Fl) I) Assemble ring (14) and U-packing (I 3)
2. Disassembly of recoil spring assembly to piston (91, and secure with snap ring
I) Set recoil spring assembly (I) to tool B. (12). (SeeFl)
(See F2) 2) Fit valve (1 I) and secure with lock plate
*yThe spring is under large installed (IO). (See Fl)
load, so be sure to set the tool prop- 2. Assembly of recoil spring assembly
erly. Failure to do this is dangerous. I) Assemble dust seal (8) to cylinder (7).
* Spring installed load: (See Fl)
See Tightening Torques and Stan- a Lip of dust seal: Grease (G2-LI)
dard Values Table 2) Assemble cylinder (7) and yoke (6) to
2) Apply hydraulic pressure slowly to spring (51, and set in tool C. (See Fl)
compress spring, then remove lock 3) Apply hydraulic pressure slowly to
plate (31, and remove nut (4). (See Fl) compress spring, tighten nut (4) so that
* Compress the spring to a point installed length of spring is dimension
where the nut becomes loose. “ “, then secure with lock plate (3).
+ Release the hydraulic pressure (lee F3)
slowly and release the tension of * Installed length of spring:
the spring. See Tightening Torques and
* Free length of spring: Standard Values Table
See Tightening Torques and Stan- 4) Remove recoil spring assembly (I) from
dard Values Table tool B. (See F2)
3) Remove yoke (61, cylinder (71, and dust 3. Assemble piston assembly (2) to recoil
seal (8) from spring (5). (See Fl) spring assembly (I 1. (See Fl)
3. Disassembly of piston assembly
ALI& Piston: Grease (G2-LI)
I) Remove lock plate (I 0) from piston (91,
* Assemble the cylinder assembly so that
then remove valve (I I). (See Fl 1
the mounting position of the valve is
2) Remove snap ring (I 21, then remove U-
exactly at side.
packing (I 31 and ring (I 4). (See Fl)
30;58
1
205FO547!
F3
481
30659
REMOVAL OF TRACK REMOVAL OF CARRIER
ROLLER ASSEMBLY ROLLER ASSEMBLY
1. Lubricator (I I. (See Fl) 1. Track shoe assembly

* Loosen the lubricator, and loosen the Ir Using hydraulic jack 0, push up the
track shoe tension. track to a position where the carrier
*‘,The adjustment cylinder is under ex- roller assembly can be removed. (See
tremely high pressure. Fl)
Never loosen the lubricator more than 2. Carrier roller assembly (I 1. (See F3) 1
one turn.
If the track tension is not relieved, move
the machine backwards and forwards.
2. Track roller assembly (21. (See F2) m
Ir Remove the mounting bolts of the track INSTALLATION OF CARRIER
roller, then swing the work equipment ROLLER ASSEMBLY
90”. jack up the machine, and remove
the track roller assembly.
removal.
6 kg See Weight Table
1
& Mounting bolt:
INSTALLATION OF TRACK
ROLLER ASSEMBLY
l Carry out istallation in the reverse order to

removal.
+ Set the track roller assembly to the

mounting position, then operate the
control levers to lower the machine
slowly, and tighten the mounting bolts
temporarily.
A?+ Mounting bolt:

Thread tightener (LT-21
* Operate the control levers to lower the
machine completely to the ground, then
tighten the mounting bolts fully.
30660
Fl 3
F20505320 F20505322
F2
30;6 1
REMOVAL OF TRACK SHOE
ASSEMBLY
1. Positioning track
Sr Stop the machine in a position where
the track can be laid out to the rear
when the master pin is pulled, then
loosen lubricator (I) to relieve the track
tension.
*F The adjustment cylinder is under ex-
tremely high pressure.
Never loosen the lubricator more than
one turn.
If the track tension is not relieved, move
the machine backwards and forwards.
2. Master pin (2) m
+I Using tool C, pull out the master pin.
(See F2, F3)
3. Track shoe assembly (3) m
* Move the machine forward so that the
position of the temporary pin is at the
front of the idler, then put block @ in
contact with the grouser, pull out
temporary pin 0, and remove the dust
seal. (See F3)
Sr Drive the machine in reverse to lay out
the track.
INSTALLATION OF TRACK
SHOE ASSEMBLY

removal.
m
* Using tool C, press fit the master pin.
(
Ir Deflection of track:
See Tightening Torques and Stan-
dard Values Table
F20505320
F2
F2050532:
0”
0”
2 F3
I
F20505324
REMOVAL OF CHARGING REMOVAL OF HYDRAULIC
PUMP ASSEMBLY PUMP ASSEMBLY
%&Lower the work equipment to the ground *&Lower the work equipment to the ground
4
and stop the engine. Operate the control and stop the engine. Operate the control
levers several times to release the remaining levers several times to release the remaining
pressure in the hydraulic piping. Then pressure in the hydraulic piping. Then
loosen the oil filler cap slowly to release the loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. pressure inside the hydraulic tank.
Remove hydraulic tank strainer, and use . Remove hydraulic tank strainer, and use
tool D to stop the oil. (See Fl) tool D to stop the oil. (See F3)
* When not using tool D, remove drain + When not using tool D, remove drain
plug and drain the oil from hydraulic plug and drain the oil from hydraulic
tank and piping. tank and piping.
: :
w See Lubricant and Coolant Table _ See Lubricant and Coolant Table
1. Hoses (I 1. (See F2) . Draining oil from damper chamber
2. Tube (2). (See F2)
:
3. Charging pump assembly (3). (See F2) U See Lubricant and Coolant Table
1. Muffler heat insulator plate (I). (See F4)
2. Muffler assembly (2). (See F4)
3. Muffler bracket (3). (See F4)
4. Tubes (4). (See F4)
5. Hoses (51, (6). (See F4)
INSTALLATION OF * Disconnect 2 hoses (6).
CHARGING PUMP 6. Wiring connector (7). (See F5)
ASSEMBLY 7. Hoses (8). (See F51
8. Hydraulic pump assembly (9). (See F6)

removal. kg
E!?l See Weight Table
* Refill to the specified level, and run the
engine to circulate the oil through the
system. Then check the oil level again. INSTALLATION OF
Q See Lubricant and Coolant Table HYDRAULIC PUMP
ASSEMBLY
. Carry out installation in the reverse order to

removal.
Refilling with oil
* Refill to the specified level, and run the
engine to circulate the oil through the
system. Then check the oil level agian.
Ir Add oil to the damper chamber to the
specified level.
Q See Lubricant and Coolant Table

Fl F3
I
L/
F9879
L/
F9879
F2 F4
I
I /
205FO5483
F5
r
1
205FO5484
205F05485
30-65
0
DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY
(HPV090 + 090)
Note) The procedure for disassembly is basi-

cally the same for both front and rear
pumps, so this section describes the dis-
assembly of the front pump only. When
there are differences, however, they will
be noted at the appropriate place in the
description.
1. WC and CO, NC valve assembly

1) Set pump assembly (1) in tool Kl.
i
F20505430
a Remove hose (2).

3) Remove tube (3).
4) Disconnect wiring, then remove TVC and
CO, NC valve assembly (5). (Rear pump)
5) Remove CO, NC valve assembly (6).
(Front pump)
I F20505431
2. Rear pump assembly

1) Sling rear pump assembly (7). ? I 8
2) Remove 4 nuts at front pump assembly
end, then remove rear pump assembly
(7).
* Disconnect at the middle of the end
caps.
3. Servo valve assembly

Remove servo valve assembly (8).
5432
4. Impeller
Using tool K5, remove bolt (9), then remove
plate (IO), washer (IOA) and impeller (11).
t Check the number and thickness of the
shims, and keep in a safe place.
t Be careful not to lose plate (10).
F2050543311 F20505434
5. End cap
Remove end cap (13).
* The force of the spring is bearing on the
valve plate, so loosen the mounting bolts
uniformly.
6. Valve plate
Remove valve plate (15).
* For a pump which has been operated,
the valve plate will have become stuck to
the cylinder block, so twist it carefully
without causing scratches.
Note) If the cylinder block and valve plate
will be reused, store them as a set.
1‘5
F30.505436
7. Pump sub-assembly
Support cylinder block and shaft, then
remove pump sub-assembly (17).
30-$5-2
8. Servo piston
1) Using forcing screws 0 (Dia. = 10 mm,
Pitch = 1.5 mm) and nut 0, remove cap
(18) and shim (20).
2) Remove spring (22).
3) Repeat Step 1) and remove cap (19) and

shim (21).
4) Remove servo piston (23).
* The servo pistons used for the front
and rear are not the same part, so
mark them to distinguish them.
\
23
DISASSEMBLY OF PUMP F20505439 11 F20505440
SUB-ASSEMBLY
9. Slider
Remove slider (24).
IO. Cylinder block

1) Remove cylinder block (25).
F20205329
2) Disassemble cylinder block as follows.

29A 29 29e 27
U Using bolt -0 (10 mm or 12 mm) and
washers 0, compress spring (26).
* Installed load: Approx. 130 kg
ii) Remove snap ring (27).
iii) Loosen nut 0 slowly, and allow
spring to expand until tension is
removed.
iv) Remove washers (28A) and (28B),
and spring (26).
A
1 w F2020533j
3o-k5-3
11. Drive shaft assembly
1) Screw in forcing screws, and remove
housing (29) and shim.
* Check the number and thickness of
the shims, and keep in a safe place.
* The charging pump is removed for
the rear pump, but there is no shim.
2) Remove snap ring (30).
I F2020533’
3) Knock out drive shaft (31) from piston

end to remove.
12. Piston
Use tool K3 to remove 4 screws (43), then
remove bearing retainer (44), shoe retainer
(45), spacer (46), and piston (47).
‘43
F20505441
1
-46
F20703017
WHEN REUSING PUMP DRIVE SHAFT AND
END CAP
- Removal of inner race from pump drive

shaft
1) Remove snap ring (38), then remove
washer (37), inner race (40), and bearing
(41).
F20205335
2) Using bearing race puller 0, remove

inner race (42).
F20205336
30-g-5
ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY
(HPV090 + 090)
Precautions at time of assembly

1) Clean each part thoroughly and remove
all sharp edge and rough edges.
2) Apply engine oil (EOIO-CD) to the rotat-
ing and sliding parts before assemblying
them.
* Be sure to use the following parts as a
set.
i) Cradle and rocker cam
ii) Cylinder block and valve plate
Note) The procedure for assembly is basi-
cally the same for both front and rear
pumps, so this section describes the
assembly of the front pump only.
When there are differences, however,
they will be noted at the appropriate
place in the description.
ASSEMBLY OF PUMP
SUB-ASSEMBLY
1. Piston assembly
1) Fit dowel pin (50) to cradle, set rocker
cam (49) in position, then install plate
(46).
* The side of the rocker cam with the 48
groove faces the oil hole side of the
cradle.
xI1, Plate bolt: Thread tightener
(LT-2)
(Loctite #262)
50
m Plate bolt: F20205338

+r After tightening’ the bolts, check that
the rocker cam moves smoothly.
2) Select the spacer thickness as follows.
i) Assemble shoe retainer (45) to piston
(47), put on the level block, then
measure distance 0 to top surface of
shoe retainer.
ii) Select spacer thickness as follows.
Spacer thickness = distance 0 +
(0.03 to 0.07 mm)
+ There are three types of spacer.
3) Install spacer (46) selected in Step 2)-i)

and ii), then install piston (47), shoe re-
tainer (45) and bearing retainer (44).
Using tool K3, install screws(43).
& Bearing retainer screw:
m Bearing retainer screw:
Rocker cam
F20703022-1
4) Hold rocker cam in position, then using Rocker cam

tool K4 pull piston (47) with a force of 2
- 3 kg, and measure clearance 0 be-
tween piston shoe and rocker cam.
* Measure the clearance with the rocker Retainer bearing
cam at position a or b, and measure
for all nine piston.
* Clearance: 0.03 - 0.07 mm
* If clearance 0 is not within the stan-
dard range, adjust the spacer again.
F20703021
Pull
K4’
‘Rocker cam
F20505442
3o-F-7
2. Drive shaft assembly
1) Press fit inner race (42) to drive shaft
(31).
31
r------------ --------\
/
I--..
‘-_
__-- 3
F20205342
2) Install bearing (41), inner race (40) and

washer (37).
37 F2050544:
Select washer as follows.

i) Install inner race (40), then install
snap ring (38).
+ Check that the snap ring is not de-
formed or damaged, and correct any
burrs before installing. Install with the
cut inside part facing the opposite di-
rection from the inner race.
ii) Using a thickness gauge, measure
clearance 0 between snap ring (38)
and inner race (40).
I
40
F20505444 F20205344
Push the snap ring securely into the
groove on the opposite side from the
inner race.
iii) Install selected washer (37).
Washer thickness = clearance 0 + (0
to 0.1 mm)
* Check that there is no play beteen the
snap ring and the washer. There are
three types of washer.
30-$5-8
5) Press fit drive shaft (31) to cradle (36).
7) Install oil seal (35) to housing (29).

6 Lip of oil seal: Grease (G2-LI)
F20205348
8) Fit O-ring and shim (34) selected in step

9), and install housing (29) to cradle.
w Mounting bolt:
* Wind the shaft with tape to prevent
damage to the oil seal lip surface.
* Install cover to rear pump.
9) Select shim for housing as follows.
i) Push drive shaft -(31) in completely,
and measure dimension 0 of end face
of bearing outer race (33) and cradle.
ii) Measure dimension @ of housing (32).
F20205351
iii) Select shim to give following thick-

ness.
* Shim thickness: @ - 0 = 0 +
0.05 - 0.15 mm.
* Therefore, there is a clearance of
0.05 - 0.15 mm at portion @I.
+ Threre is no shim at the rear
pump.
F70505446
3. Cylinder block
28A 26 288 27
1) Assemble cylinder block as follows.
i) Assemble washer (28A), spring (26)
and washer (28B).
+ Assemble the washer facing in the
direction shown in the diagram.
ii) Using bolts 0 (IO mm or 12 mm),
washers @I and nut 0, compress
spring (26).
iii) Install snap ring (27).
F20205330
2) Align with drive shaft and piston, and in-

stall cylinder block (25).
* Always install the valve plate (which
forms a set with the cylinder) together
with the cylinder, or makr a mark and be
careful not to make any mistake.
F2020535: 3
4. Servo piston
1) Set pump case (32) in tool Kl.
2) Install servo piston (23).
* The servo pistons used for the front
and rear are not the same part, so be
careful not to make any mistake when
assembling them.
* The length from the center is different for

the end with the spring and the end
without the spring.
Rear pump
F20505448
3) Adjust servo piston as follows.

- Max. swash plate angle side
i) Align tool K6 with dowel pin and
groove g for servo valve arm of servo
piston, and set tool K6 in position.
* As seen from the rear of the front
pump, the right side (the top when
mounted on the machine; the side
with the spring) is the maximum
swash plate angle side. (maximum
flow side)
Note: For the rear pump,
same tool turned over.
use the
1 1 F20505449
ii) Measure distance 0 between servo

piston and case.
F2050545C1
3o-F’
iii) Measure distance @ of cap (18).
iv) Select shim thickness as follows.
@ - 0 = 0 + 0.05 mm
* After adjusting the shim, put it in
a set with the cap.
F2020535E
. Min. swash plate angle side

* To adjust the minimum swash plate
angle, replace tool K7 with the tool
for the minimum angle, and repeat
the same procedure as in Steps i) -
iv).
Note that the case faces in the oppo-
site direction from the maximum
swash plate angle side.
\
Servo piston Clearance C
Clearance C
F20703026
Servo valve
mounting
surface
Pump case
Clearanc
(a
5. Pump sub-assembly
1) Install slider and O-ring.
* Fit the O-ring in the pilot portion and
F20703027
the joint portion.
2) Install 2 joints on case.
t Install with the small hole facing the
cradle side.
3) Align ‘the slider with the servo piston,
and install pump sub-assembly (17).
J, Be careful that the O-ring is not
caught. Also, be careful not to drop
the cylinder.
m Mounting bolt:
See tightening Torques and
* Assemble rear pump using tool K2.
6. End cap
1) Press fit bearing (14) to end cap (13).
2) Install joint and O-ring.

-f Install the joint with the large hole
facing the end cap.
3) Coat with engine oil, align with pin and
bearing, and install valve plate (75).
or Check that it is aligned with the end
cap port, and that there is no inter-
ference with the pin and bearing.
F20505452
4) Install end cap (13).

m Mounting bolt:
m Mounting nut:
* There is the force of the spring inside
the cylinder block, so tighten the
mounting bolts uniformly.
7. Impeller
1) Adjust clearance between impeller and
end cap portion 0 as follows.
i) Measure thickness @ of plate (IO).
ii) Assemble plate (10) to coupling, and
install impeller.
* Check that impeller (11) and end
cap portion 0 are in contact.
iii) Measure dimension 0 from end face
of coupling (IIA) to plate (IO).
iv) Measure dimension @ from end face
of coupling to shaft (31).
v) Use measured values @I, 0, and @ as
follows to select shim.
* k3 - (0 + 63) + (0.5 * 0.1) mm =
shim thickness
2) Assemble plate (10) to coupling (IIA),

then fit shim (12) selected in Step 1) and
washer (IOA), then using tool K5, install
impeller (11).
& Mounting bolt: Thread tightener
(LT-2)
(Loctite #262)
m Mounting bolt: See Tightening Tor-
ques and Standard
Values Table
F20505454 11
10A
F20505434 F20505433
3) Check interference or impeller (11) and

rear end cap as follows.
i) Measure dimension of end face of
Front end c
rear end cap to end face of front end
cap portion 0.
ii) Measure protrusion dimension 0 of
impeller vane from front end cap.
iii) Check that measured dimension is
0 > 0.
* If the above dimension is
0 > 0, there is no clearance at 12
F20505455
portion @I, so the impeller vane
will contact the rear end cap at
the time of assembly. To prevent
this, repeat the procedure at step
7 -1) and adjust the shim (12)
again.
30-6&l 4
8. Servo piston cap
1) Install spring (22) on the right as seen
from the rear of the pump.
2) Fit O-ring, and shims (20) and (21) se-
lected in step 4, then install caps (18)
and (19).
Ir When installing cap (18) at spring end,
use 2 forcing screws 0 (Thread dia.
= 10 mm, Pitch = 1.25 mm) and 2
nuts 0.
D Mounting bolt: 22 F20505438 " F205054371
* After installing the cap, measure the
rotating torque of pump using tool
KS.
i) There must be no variation in the ro-
tating torque (Range of variation:
Max. 0.3 kgm) and the rotating torque
must be less than 1.4 kgm.
ii) If the rotating torque or range of vari-
ation are not within the standard
value, disassemble the pump assem- /
bly and assemble it again. 21 F.20505456
9. Servo valve assembly

Fit O-ring, align arm with servo piston, then
install servo valve assembly (8).
* Be careful not to let the O-ring drop out.
Tighten the bolts gradually on opposite
sides in turn.
w Mounting bolt:
F20505457
10. Rear pump assembly

1) Install O-rings to front and rear end caps.
2) Raise rear pump assembly (7), align
spline, and install.
D Mounting nut:
See tightening Torques and
F20505432
30-62- 15
11. TVC and CO, NC valve assembly
1) Fit O-ring and install CO, _NC valve as-
sembly (6). (Front pump)
m Mounting bolti
2) Fit O-ring, install TVC and CO, NC valve
assembly (5), then clamp wiring. (Rear
pump)
B Mounting bolt:
See Tightening Torques and I F20505431

3) Fit O-ring and install tube (3).
m Joint bolt:
4) Install strainer, then install hose (2).
m Sleeve nut:
J, After completion of assembly, check
the quality of the parts.
After completing the assembly of the
pump assembly, use a test stand (A
type or C type) to check the quality.
* For details of the procedure for check-
ing quality, see TESTING METHODS.
30-g- 16
CHECKING CONTACT BETWEEN CYLINDER
BLOCK AND VALVE PLATE, AND ROCKER
CAM AND CRADLE
1. Checking contact between cylinder block
and valve plate.
Cylinder block Centering tool
1) Make a centering tool for the cylinder
block and valve plate.
* The tool can be made of a soft ma- \
terial such as plastic or bakelite. ........ ..............
................
...............................
...................
. ... . . .....
j::::::::::::::::::::~::::::::::

. . . . . . . ... . . ... ... ... . ..........
................
...... ...........................
.....................
..................
:.:.:.: ..........................
. . ..I.. ... . . ... .................
checked. :::::::::::::::::::~::::::~:::::

3) Set the tool in position, and coat the cy-
linder block side with inspection paint.
* Apply the paint thinly.
41 Put the valve plate on top, push with a
force of 4 - 5 kg, and rotate 2 - 3
times.
51 Remove the valve plate, transfer the con-
tact surface.
* The standards for the contact surface are
as follows. ::
::
Valve plate a. Seal Min. 80% F20703037 g
Cylinder block a. Seal Min. 80%
Valve plate Cylinder block
F20703038
2. Checking contact between rocker cam and
cradle
checked.
2) Set the tool in position, and coat the
cradle side with inspection paint.
* Apply the the paint thinly.
3) Put the rocker cam on top, push with a
force of 4 - 5 kg, and move 2 - 3 time
from the stopper contact position to the
maximum angle.
4) Remove the rocker cam, transfer the con-
tact surface.
* The standard for the contact surface are
as follows.
Pump Dimension a Contact Contact b from

Model (mm) surface a to outside
HPV 090 72 Min. 80% Min. 50%
* If there is no contact at the center but

only at the outside, the contact is no
good.
F20703039
Reference:
If the contact is not within the contact
standard value, when carrying, always lap
both parts together.
* Parts with scratches cannot be reused.
30-62- 18
REMOVAL OF MAIN PUMP REMOVAL OF CONTROL
INPUT SHAFT OIL SEAL VALVE ASSEMBLY
1. Hydraulic pump assembly *FLower the work equipment to the ground

l Remove hydraulic pump assembly. and release the remaining pressure in the
For details, see REMOVAL OF HYDRAU- circuit. For details, see TESTING AND AD-
LIC PUMP ASSEMBLY. JUSTING, Releasing pressure in hydraulic
2. Housing assembly (I 1. (See Fl) m circuit for machines with PPC valve.
Jr Using forcing screws, remove the hous- * Mark the piping with tags to prevent mis-
ing assembly and the shims. takes in position when assembling.
3. Oil seal (2). (See F2) B 1. Wiring connector (I 1. (See F4)
l Remove oil seal from housing. 2. Hoses (21, (3). (See F4)
* For hose (31, remove 8 PPC hoses.
3. Hose (4). (See F5)
4. Hose (5). (See F51
5. Tube (6). (See F5)
INSTALLATION OF MAIN * Remove the tube together with the
PUMP INPUT SHAFT OIL bracket.
SEAL 6. Hose (7). (See F5)
7. Hoses (81, (9). (See F5)
.+ For hose (81, remove 3 PPC hoses.
removal. For hose (9). remove 4 PPC hoses.
8. Tubes (I 0). (See F5)
+ Disconnect 4 tubes together with the
bracket, and remove the 2 remaining
m Mounting bolt:
tubes.
9. Hose (I I). (See F61
IO. Solenoid valve (I 2). (See F6)
m
11. Wiring connector (I 3). (See F6)
* Using tool 0, press fit oil seal (2) in
12. Clamp (I 4). (See F6)
housing (I 1. (See F3)
13. Control valve assembly (I 5). (See F7)
a Lip of oil seal: Grease (G2-LII * Remove the control valve assembly
together with the frame.
INSTALLATION OF
CONTROL VALVE
ASSEMBLY

removal.
Ir Add oil to the specified level, and run
again.
Fl F4
205FO5486
F2 F5
20UF01210-K \ T F2050532E
i
F‘3 6
/a
’ ” 20UF01211-K
F7
/ F20505328
i
30-67
a
DISASSEMBLY OF
CONTROL VALVE
6. Bucket valve
ASSEMBLY I) Remove case (281, then remove spring
(29) and retainer (30). (See Fl)
* The set pressure of the safety valve cannot 2) Remove case (31). then remove spring
be adjusted when the safety valve is in- (32) and retainer (331, and pull out
stalled on the machine, so do not disassem- spool (34). (See Fl)
ble it. * This is applicable for the arm-Lo, ser-
. The following explanation uses the left con- vice, and arm-Hi spools.
trol valve as the example. * Shim (35) is installed in the spring of
1. Main relief valve, jet sensor relief valve the arm-Hi valve, so be careful when
Remove main relief valve (I) and jet sensor removing.
relief valve (2). (See Fl ) 7. Straight-travel valve
2. Safety-suction valve I) Remove plate (36). then remove spring
Remove safety-suction valve (31, (41, and (371. (See Fl)
(5). (See Fl 1 21 Remove plug (38). pull out spool (39).
3. Check valve (See Fl)
Remove plug (61, then remove spring (7)
and check valve (8). (See Fl)
4. L.H. travel valve
I) Remove case (9). then remove retainer
(IO), spring (I I), retainer (I 2). spring
(I 3). and retainer (141, and pull out
spool (I 5). (See Fl)
2) Remove case (I 61, then remove retainer
(171, spring (18). retainer (I 9), spring
(201, and retainer (21). (See Fl 1
* This is applicable for the swing, M-l.
travel, boom-Lo, and boom-Hi spools.
* Retainer (19) is not assembled in the
boom-Lo spool.
* Boom-Hi spool
i) There is a shim inserted in the
spring, so be careful when removing.
ii) In place of parts (I 61 - (21) in Step
21, a plate is installed.
5. Arm throttle valve
I) Remove plug (221, the remove washer
(231, spring (241, and washer (251. (See
Fl)
2) Remove plate (261, then pull out spool
(271. (See Fl)
* The swing priority valve is installed as-
sembled in the opposite direction to the
arm throttle valve.
Fl
2---
205FO5487
205FO5488
30-69
a
ASSEMBLY OF CONTROL
VALVE ASSEMBLY
5. Check valve
1. Straight-travel valve Install check valve (8) and spring (71, then
I) Assemble spool (391, then fit O-ring fit O-ring and install plug (61. (See Fl)
and install plug (38). (See Fl)
633 Plug:
2) Fit spring (37) and install plate (36).
(See Fl)
2. Bucket valve
I) Assemble spool (34). fit retainer (33)
Install safety-suction valve (5). (41, and (3).
and spring (321, then fit O-ring and in-
(See Fl)
stall case (3 I). (See F I)
Fit retainer (30) and spring (29). then fit
W Safety-suction valve:
2)
O-ring and install case (28). (See Fl) See Tightening Torques and
* This is applicable for the arm-Lo, ser- Standard Values Table
7. Jet sensor relief valve, main relief valve
vice, and arm-Hi spools.
* Install jet sensor relief valve (2) and main
Shim (35) is installed in the spring of
the arm-Hi valve spool, so be careful of relief valve (I I. (See Fl)
the position when installing. m Jet sensor relief valve:

3. Arm throttle valve See Tightening Torques and
I) Assemble spool (271, then fit O-ring Standard Values Table
and install plate (26). (See Fl) m Main relief valve:
2) Fit washer (251, spring (241, and washer See Tightening Torques and
(231, then fit O-ring and install plug Standard Values Table
(22). (See Fl)
* The swing priority valve is installed as-
sembled in the opposite direction to the
arm throttle valve.
4. L.H. travel valve
1) Install retainer (211, spring (201, retainer
(I 9). spring (I 81, and retainer (I 71, then
fit O-ring and install case (I 6). (See Fl)
2) Assemble spool (I 51, install retainer
(141, spring (I 3). retainer (I 2). spring
(I I), and retainer (IO), then fit O-ring
and install case (9). (See Fl)
Sr This is applicable for the swing, R.H.
travel, boom-Lo, and boom-Hi spools.
* Retainer (19) is not assembled in the
boom-Lo spool.
* Boom-Hi spool
i) Shim is installed in the spring of the
boom-Hi valve spool, so be careful
of the position when installing.
ii) In place of parts (21) - (I6) in Step
1 I, a plate is installed.
30-70
a
Fl
205FO5487
38
3: -‘d
205FO5488
30671
REMOVAL OF MAIN RELIEF DISASSEMBLY OF MAIN
VALVE ASSEMBLY RELIEF VALVE ASSEMBLY
*y Lower the work equipment to the ground 1. Loosen nut (21, and remove plug (I). (See
and stop the engine. Operate the control F3)
levers several times to release the remaining t Before loosening the nut, measure prot-
pressure in the hydraulic piping. rusion dimension a of the plug from the
Then loosen the oil filler cap slowly to end face of the nut. (See F2)
release the pressure inside the hydraulic 2. Remove retainer (3). (See F3)
tank. 3. Loosen nut (51, and remove holder (4). (See
1. Hoses (I). (See Fl) F3)
2. R.H. control valve main relief valve (2). (See + Before loosening the nut, measure prot-
Fl) m rusion dimension b of the holder from
3. L.H. control valve main relief valve (3). (See the end face of the nut. (See F2)
Fl) m 4. Remove spring (6) and poppet (7). (See F31
5. Remove sleeve (8). then remove seat (9).
backup ring (I 01, spring (I I), and valve
(I 2). (See F3)
6. Remove snap ring (14) from sleeve (I 3).
INSTALLATION OF MAIN (See F3)
7. Remove backup ring (151 from sleeve (13).
RELIEF VALVE ASSEMBLY
(See F3)

removal.
II 1x1
ASSEMBLY OF MAIN
m Main relief valve: RELIEF VALVE ASSEMBLY
1. Assemble backup ring (I 5) and O-ring in
l After installing the main relief valve on
sleeve (I 3). (See F3)
the machine, adjust the set pressure.
2. Install snap ring (I 4) to sleeve (I 3). (See F3)
3. Assemble backup ring (IO) and O-ring to
ING, Adjusting main relief valve.
seat (91, then install valve (I 2). spring (I I),
seat (91, and sleeve (81 to sleeve (13). (See
F3)
4. Assemble poppet (7) and spring I6). (See
F3)
5. Assemble nut (5) and O-ring to holder (41,
and install to sleeve (I 3). (See F3)
* Adjust so that protrusion dimension b
of the holder from the end face of the
nut is the same as when it was dis-
assembled, then secure with the nut.
(See F2)
6. Assemble retainer (3). (See F3)
7. Assemble nut (21 and O-ring to plug (I I, and
install to sleeve (I 3). (See F3)
* Adjust so that protrusion dimension a
of the plug from the end face of the nut
is the same as when it was disassem-
bled, then secure with the nut. (See F2)
30-72
0
a
-----
205FO5489
205FO5490
F3
205FO5491
30-73
a
REMOVAL OF TVC VALVE REMOVAL OF SERVO
ASSEMBLY VALVE ASSEMBLY
1. Wiring connector (I 1. (See Fl) 1. CO l NC valve assembly

2. TVC valve assembly (2). (See Fl I l Remove CO l NC valve assembly.
For details, see REMOVAL OF CO l NC
VALVE.
2. Servo valve assembly (I 1. (See F3)
INSTALLATION OF TVC
VALVE ASSEMBLY
INSTALLATION OF SERVO
VALVE ASSEMBLY
removal.
removal.
REMOVAL OF CO-NC
VALVE ASSEMBLY
1. Wiring connector (I). (See F2)

2. Hose (2). (See F2)
3. Tube (3). (See F2)
4. CO l NC valve assembly (4). (See F2)
+ Remove the rear pump CO *NC valve
together with the TVC valve.
INSTALLATION OF CO-NC
VALVE ASSEMBLY

removal.
30674
Fl F3
\ F20505330
30675
REMOVAL OF WORK INSTALLATION OF WORK
EQUIPMENT PPC VALVE EQUIPMENT PPC VALVE
ASSEMBLY ASSEMBLY
*qLower the work equipment to the ground * Carry out installation in the reverse order
and stop the engine. Operate the control to removal.
levers several times to release the re- a
maining pressure in the hydraulic piping. * Fit the slide stopper securely into the
Then loosen the oil filler cap slowly to inside lever.
release the pressure inside the hydraulic
tank.
1. Plate (1). (See Fl)
2. Seat assembly (2). (See Fl)
3. Wiring connector (3). (See F2)
4. Lever assembly (4). (See F2)
5. Cover (5). (See F2) m
6. Bracket (6). (See F3)
* Remove the mounting bolts, and
move the bracket towards the win-
dow.
7. Hoses (7). (See F3)
* Disconnect 6 hoses.
8. PPC valve assembly (8). (See F3)
jr Remove the mounting bolts, then
remove the valve assembly together
with the hose.
30676
Fl
F20505369 1
F2
I
F3
I
F20505371
30677
DISASSEMBLY OF WORK ASSEMBLY OF WORK
EQUIPMENT PPC VALVE EQUIPMENT PPC VALVE
ASSEMBLY ASSEMBLY
PC200,2OOLC-5 Serial No: 45001 - 58018 PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613 PC220,22OLC-5 Serial No: 35001 - 36613
1. Remove nut (I), then remove disc (2). 1. Assembly of valve assembly
(See Fl) Assemble shim (IS), spring (17), and re-
2. Remove joint (3), then remove plate (4). tainer (16) to valve (19), and push down
(See Fl) retainer (16) to install collar (15). (See
3. Remove piston assembly (5). (See Fl) Fl)
4. Disassembly of piston assembly 2. Assemble spring (14) and install valve
Remove the following parts from piston assembly (13). (See Fl)
(6). (See Fl) 3. Assembly of piston assembly
1) Remove collar (7), then remove dust Assemble the following parts to piston
seal (8). (See Fl) (6).
2) Remove collar (9), then remove seal 1) Assemble spring (12) and piston (11).
(10). (See Fl) (See Fl)
3) Remove piston (11) and spring (12).
& Piston: Grease (G2-LI)
(See Fl)
2) Fit seal (10) to collar (9) and as-
5. Remove valve assembly (13), then remove
semble. (See Fl)
spring (14). (See Fl)
3) Fit dust seal (8) to collar (7) and as-
6. Disassembly of valve assembly
semble. (See Fl)
Push retainer (16) to remove collar (15),
4. Install piston assembly (5). (See Fl)
then remove retainer (16), spring (17),
5. Fit plate (4) and install joint (3). (See Fl)
and shim (18) from valve (19). (See Fl)
W Joint:
6. Fit disc (2) and install nut (1). (See Fl)
* Adjust the clearance between disc (2)
and piston (6).
For details, see TESTING AND AD-
JUSTING, Adjusting PPC valve for
work equipment.
m Nut:
30-z7-1
Fl
r @-8 1
o
@ -7
-10
@j-9
/5
0
I-
-
s S/l2
g,ll
A
@--15
@-1s
g.17
,“>18 ,13
fi -19
205FO5493
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY

1. Remove nut (I), then remove disc (2) and

boot (3).
2. Remove joint (4), then remove plate (5).
3. Remove seal (6) and collar (7).
4. Pull out piston (8), and remove retainer (9),

springs (10) and (1 I), and shim (12).
* Spring (10) consists of two sets of two
types of spring with different installed
loads, so check the installation position
(hydraulic port) and fit tags to prevent
mistakes when installing.
5. Pull out valve (13) from body (14).
20TF01235
30-&7-3
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY

1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve

(13).
3. Assemble spring (IO), retainer (9), and piston

(8).
Sr Spring (10) consists of spring with a dif-
ferent number of coils for each hydraulic
port. The number of coils and position of
use are as follows.
a
*
t
es9
* The position of each port is stamped on

the bottom of the valve body.
& Piston: Grease (LG-2)
jr When assembling piston (18), coat the

outer circumference of the piston and the
inner circumference of the body hole with
grease.
4. Fit O-ring to collar (7), then assemble in

body (14), and install seal (6).
5. Install plate (5).

m Mounting bolts: See MAINTENANCE
STANDARDS.
ZOTF01235
6. Install joint (4).
a Sliding portion of joint: Grease (LG-2)
& Joint: Thread tightener (LT-2)
m Joint: See MAINTENANCE STANDARDS.
* Keep strictly to the standard value for the

tightening torque of the joint.
7. Assemble disc (2), and tighten with nut (1).

w Nut: See MAINTENANCE STANDARDS.
or After assembling the disc, adjust the assem-

bled height of the disc:For details, see TEST-
ING AND ADJUSTING, Adjusting PPC valve.
30-z7-4
REMOVAL OF TRAVEL PPC DISASSEMBLY OF TRAVEL
VALVE ASSEMBLY PPC VALVE ASSEMBLY
U&Lower the work equpment to the ground 1. Remove plate (I), then remove piston as-
4
and stop the engine. Operate the control sembly (2). (See F21
levers several times to release the remaining 2. Disassembly of piston assembly
pressure in the hydraulic piping. Then Remove collar (4) from piston (31, then
loosen the oil filler cap slowly to release the remove seal (5). (See F2)
pressure inside the hydraulic tank. 3. Remove valve assembly (61, then remove
1. Yokes (I 1. (See Fl) spring (7). (See F2)
2. Hose (2). (See Fl I 4. Disassembly of valve assembly
* Disconnect 6 hoses. Push retainer (9) to remove collar (81, then
3. Travel PPC valve assembly (3). (See Fl) remove retainer (9). spring (10). and shim
(I I) from valve (I 2). (See F2)
INSTALLATION OF TRAVEL
PPC VALVE ASSEMBLY ASSEMBLY OF TRAVEL
PPC VALVE ASSEMBLY
removal. 1. Assembly of valve assembly
Assemble shim (1 I), spring (I 01, and retain-
er (9) in valve (I 21, then push down retainer
(91 to install collar (8). (See F2)
2. Assemble spring (71, and install valve as-
sembly (6). (See F2) g
3. Assembly of piston assembly g
Assemble seal (5) to collar (41, and install to z
piston (31. (See F2)
4. Assemble piston assembly (21, and install
plate (I 1. (See F2)
2
205FO5494
2-4
L
r
6-4
205FO5495
30-79
0
REMOVAL OF BOOM DISASSEMBLY OF BOOM
HOLDING VALVE ASSEMBLY HOLDING VALVE ASSEMBLY
%&Lower the work equipment to the ground + The set pressure of the safety valve cannot
4
and release the remaining pressure in the be adjusted when the safety valve is in-
circuit. For details, see TESTING AND AD- stalled on the machine, so do not disassem-
JUSTING, Releasing pressure in hydraulic ble it.
circuit for machines with PPC valve. 1. Remove safety valve assembly (I 1. (See F2)
1. Hoses (I 1. (See Fl) 2. Remove plug (2). then remove spacer (3).
2. Tubes (2). (See Fl) spring (4). seat (51, and spool (6). (See F2)
3. Boom holding valve assembly 13). (See Fl) 3. Remove body (71, then remove spring (8)
and check valve (9). (See F2)
INSTALLATION OF BOOM
HOLDING VALVE ASSEMBLY ASSEMBLY OF BOOM
HOLDING VALVE ASSEMBLY
removal. 1. Assemble check valve (9) and spring (81,
l Refilling with oil then fit O-ring and install body (7). (See F2)
Sr Refill to the specified level, and run the W Mounting bolt:
engine to circulate the oil through the See Standard Value Table for
system. Then check the oil level again. Tightening Torques
2. Fit seat (5) to spool (6) and insert in body
(71, then install spring (4). spacer (31, plug
(2) and O-ring. (See F2)
W Plug:
3. Fit O-ring and install safety valve (I). (See
F2)
m Safety valve:
30-80
0
Fl
205FO.5496
1
205FO5497
30-81
0
REMOVAL OF PPC INSTALLATION OF PPC
SHUTTLE VALVE ASSEMBLY SHUTTLE VALVE ASSEMBLY
*yLower the work equipment to the ground l Carry out installation in the reverse order to
and stop the engine. Operate the control removal.
1. PPC shuttle valve assembly for arm,
swing
I) Hoses (II. (See Fl)
+ Disconnect 4 hoses.
2) Hoses (2). (See Fl 1
3) PPC shuttle valve assembly (3) for arm,
swing. (See Fl)
2. PPC shuttle valve assembly for boom
bucket, travel
I) Hoses (4). (See Fl)
2) Hoses (5). (See Fl)
3) Pressure switch (6). (See Fl)
4) PPC shuttle valve assembly (7) for
boom, bucket, travel. (See F 1)
Fl
I I
205FO5498
REMOVAL OF BOOM INSTALLATION OF BOOM
CYLINDER ASSEMBLY CYLINDER ASSEMBLY
A Extend the arm and bucket fully, lower the l Carry out installation in the reverse order to
work equipment to the ground, and operate removal.
the control levers 2 or 3 times.
1. Hose (1). (See Fl)
2. Lock bolt (2). (See Fl) 1 + Tighten with the locknut so that the
3. Pin (3). (See Fl) ml )I I=1 clearance between the boom boss and
* Sling the boom cylinder assembly, and nut is 0.5 - 1.5 mm. (See F4)
remove the pin. m
A Start the engine, and retract the rod of A When aligning the position of the pin
the boom cylinder, tie the rod with wire hole, run the engine at low idling. Never
to prevent it from coming out, then insert your fingers in the pin hole.
lower it onto the block.
*‘Release the remaining pressure in the Adjust with shims so that the clear-
circuit. For details, see TESTING AND ance between cylinder rod (7) and
ADJUSTING, Releasing pressure in hy- plate (8) is less than 1 mm. (See F5)
draulic circuit for machines with PPC * There are two type of shim thick-
valve. ness: 0.8 mm, 1.5 mm
4. Hose (4). (See F2)
5. Pin (5). (See F3) WI WI Adjust with shims so that the clear-
* Sling the boom cylinder assembly, then ance between cylinder bottom (9) and
use forcing screws 0 to remove the bracket (IO) is less than 1 mm.
pin. (See F6)
6. Boom cylinder assembly (6). (See F3)
Inside surface of bushing: LM-P
& kg See Weight Table For grease, use LM-G.
l Bleeding air
* Bleed the air from the cylinder.
ING, Bleeding air from hydraulic cylinder.
* After bleeding the air from the cylinder,
check the level of the oil in the hydraulic
tank.
30-:3-l
F20505401
F2
F20505332 F20505402 1
F3
F20505333
F4
I I
0.5 - 1.5 mm
2OSF6065
30-:3-2
REMOVAL OF ARM INSTALLATION OF ARM
A Set block @ between the arm and the l Carry out installation in the reverse order to
boom, then extend the arm fully, lower the removal.
work equipment to the ground, and operate
* Sling the arm cylinder assembly. AWhen aligning the position of the pin
1. Pin (1). (See Fl) ml j] hole, run the engine at low idling. Never
A the
Start the engine,
arm cylinder,
and
then
retract
tie the
the rod of
rod with m
insert your fingers in the pin hole.
wire to prevent it from coming out. * Adjust with shims so that the clear-
?&Release the remaining pressure in the ance between cylinder bottom (6) and
circuit. For details, see TESTING AND bracket (7) is less than 1 mm.
ADJUSTING, Releasing pressure in hy- (See F2)
draulic circuit for machines with PPC * There are two type of shim thick-
valve. ness: 0.8 mm, 1.5 mm
2. Hose (2). (See Fl 1 m
3. Hose (3). (See Fl) & Inside surface of bushing: LM-P
4. Pin (4). (See Fl) ia ml * For grease, use LM-G.
5. Arm cylinder assembly (5). (See Fl)
l Bleeding air
& kg See Weight Table * Bleed the air from the cylinder.
tank.
Fl
I I
F20505334
F2
REMOVAL OF BUCKET INSTALLATION OF BUCKET
A Set block @ between the link and the arm,
and sling the bucket cylinder assembly. * Tighten with the locknut so that the
1. Lock bolt (1). (See Fl) m clearance between the link boss and nut
2. Pin (2). (See Fl) mj PI jE5) is 0.5 - 1.5 mm. (See F2)
A Start the engine, and retract the rod of m

the bucket cylinder, then tie the rod A When aligning the position of the pin
with wire to prevent it from coming out. hole, run the engine at low idling. Never
*y Release the remaining pressure in the insert your fingers in the pin hole.
circuit. For details, see TESTING AND
n31
ADJUSTING, Releasing pressure in hy- t Adjust with shims so that the clear-
draulic circuit for machines with PPC ance between link (6) and link (7) is
valve. less than 1 mm. (See F3)
3. Hose (3). (See Fl) * There are two type of shim thick-
4. Pin (4). (See Fl) WI 1x1 ness: 0.8 mm, 1.5 mm
5. Bucket cylinder assembly (5). (see Fl) m
* Adjust with shims so that the clear-
fi kg See Weight Table ance between cylinder bottom (8) and
bracket (9) is less than 1 mm.
(See F4)
m
xrz1, Inside surface of bushing: LM-P
* For grease, use LM-G.
l Bleeding air
+ Bleed the air from the cylinder.
tank.
30-g-1
Fl
F20505335
F2
-4--I
0.5 - 1.5 mm
2OSF6065
F3
6 7
mm
F20505404 1
F4
3o-k5-2
DISASSEMBLY OF
HYDRAULIC CYLINDER
3. Disassembly of piston assembly
ASSEMBLY
1) Remove ring (12). (See F5)
2) Remove wear ring (13). (See F5)
1. Cylinder assembly 3) Remove piston ring (14). (See F5)
I) Remove mounting bolts, and disconnect
head assembly (I). (See Fl)
2) Pull out piston rod assembly (2). (See
FII
* Place a container to catch the oil
under the cylinder.
2. Piston rod assembly 4. Disassembly of cylinder head assembly

I) Set piston rod assembly (21 in tool EI. 1) Remove snap ring (I 51, then remove
(See F2) dust seal (I 6). (See F6)
2) Using hydraulic pump, remove nut (3). 2) Remove rod packing (I 7). (See F6)
(See F2) 3) Remove buffer ring (I 8). (See F6)
* Width across flats of nut 4) Remove bushing (I 9). (See F6)
mm
3) Remove piston assembly (4). (See F3)

4) Remove retainer (5) and plunger (6).
(See F3)
l Retainer (5) is f6r PC220 boom
cylinder only.
l Plunger (6) is for PC200, PC220
boom, arm cylinders only.
5) Remove collar (7). (See F3)
l For PC200, PC220 boom, arm cylin-
ders only
6) Remove head assembly (8). (See F3)
7) Remove cap (9), and pull out 12 balls

(I 01, then remove plunger (I I).(See F4)
l For PC200, PC220 arm cylinder only
30-86
0
Fl
202FO548’ I
F5.i
6
12
12
13
14
13
202FO5485
19
18
16
17
15
M
202FO5482 202FO5486
202FO5483
F4
I 202FO5501 -K
30-87
0
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
21 Assemble head assembly (8). (See F6)
3) Assemble collar (7). (See F6)
* Be careful not to damage the packings, dust
l For PC200, PC220 boom, arm cylin-
seals, and O-rings.
ders only
I. Assembly of head assembly
4) Assemble plunger (6) and retainer (5).
I) Press fit bushing (I 91. (See Fl)
(See F6)
2) Assemble buffer ring (I 8). (See Fl)
l Plunger (6) is for PC200, PC220
3) Assemble rod packing (I 7). (See Fl)
boom, arm cylinders only.
4) Assemble dust seal (I 61, and secure
l Retainer (5) is for PC220 boom
with snap ring (I 5). (See Fl)
cylinder only.
5) Assemble piston assembly (4). (See F6)
2. Assembly of piston assembly 6) Set piston rod assembly (2) in tool El.
11 Using tool E2, expand piston ring (14). (See F7)
(See F2) 71 Using hydraulic pump, tighten nut (3).
* Set the piston ring in tool E2. and
Xn, Nut: Thread tightener (LT-3)
turn the handle 8 - 10 turns to
@a Nut:
expand.
21 Set tool E3 in position, and compress
piston ring (I 4). (See F3)
3) Assemble wear ring (I 3). (See F4) 4. Cylinder assembly

4) Assemble ring (I 2). (See F4) I) Assemble piston rod assembly (2). (See
jr Be careful not to open the end gap FS)
of the ring too far.
& Seal: Grease (G2-LI)
& Ring groove: Grease (G2-LI) jr Set the end gap of the ring at the
horizontal (side) position, align the
center of shaft and cylinder tube,
then insert. (See F8I
+ After inserting, check that the ring is
not broken and has not come out,
then push in fully.
2) Tighten head assembly (I) with mount-
ing bolts. (See FSI
3. Piston rod assembly W Mounting bolt;

I) Set plunger (I 1) in piston rod, then See Tightening Torques and
assemble 12 balls (IO), and secure with Standard Values Table
cap (9). (See F5)
+ Check that there is a certain amount
of plug at the tip of the plunger.
l For PC200, PC220 arm cylinder only
30-88
a
Fl 6
202F0548E 202FO5483
:7
u
202FO548;
A-4 202FO5488
M
202FO5482
F4 8
12
12:m
202FO5485 202FO5489
F5 9
202FO5501 -K 202FO5481
30;89
REMOVAL OF WORK INSTALLATION OF WORK
EQUIPMENT ASSEMBLY EQUIPMENT ASSEMBLY
A Extend the arm and the bucket fully and l Carry out installation in the reverse order to
lower the work equipment completely, then removal.
operate the control levers 2 or 3 times.’
1. Hose (1). (SeeFl)
2. Lock bolt (2). (See Fl 1m + When tightening the locknut, tighten so
3. Pin (3). (See Fl) ml 1-1 [m that the clearance between the boss of
* Sling the boom cylinder assembly and the boom and the nut is “0.5 - 1.5
remove the pin. mm”. (See F5)
A Start the engine and retract the m
boom cylinder rod fully, then tie the A When aligning the position of the pin
rod with wire to prevent it from hole, run the engine at low idling, and
coming out, and lower it onto the align slowly. Never insert your fingers in
block. the pin hole.
t Disconnect the boom cylinder on the m
opposite side in the same way. t Adjust with shims so that the clear-
*A&Release the remaining pressure in ance between cylinder rod (8) and
* the circuit. For details, see TESTING plate (9) is less than 1 mm. (See F6)
AND ADJUSTING, Releasing pres- * There are two type of shim thick-
sure in hydraulic circuit for machines ness: 0.8 mm, 1.5 mm
with PPC valve. a
4. Hoses (4). (See F2) * Adjust with shims so that the clear-
5. Wiring (5). (See F2) ance between boom (10) and bracket
6. Pin (6). (See F3) ml mi (11) is less than 1 mm. (See F7)
Sr Sling work equipment assembly (7), * There are two type of shim thick-
then using tool F, remove the pin. (See ness: 0.8 mm, 1.5 mm
F3) m
7. Work equipment assembly (‘7). (See F4) a Inside surface of bushing: LM-P
fi kg See Weight Table
l Bleeding air
+ After bleeding the air from the cylinder,
check the level of the hydraulic tank.
Fl F5
0.5 - 1.5mm
\ 205FO5499 2OSF6065
205FO5500 F20505406
F3 F7
‘\o ”\ ”
Max. 1 mm
205FO5501 F20505407
F4.
II
205FO5502
REMOVAL OF BUCKET REMOVAL OF ARM
ASSEMBLY ASSEMBLY
A Set the back of the bucket facing down, 1. Bucket assembly

lower the work equpment to the ground, l Remove bucket assembly.
and operate the control levers 2 or 3 times. For details, see REMOVAL OF BUCKET
1. Lock bolt (1). (See Fl) 1 ASSEMBLY.
2. Plate (2). (See Fl 1 m 2. Work equipment set
3. Pin (3). (See Fl) m * Secure the bucket cylinder assembly to
4. Lock bolt (4). (See Fl) m the arm, pull in the arm, and lower it
5. Pin (5). (See Fl) m onto block 0. (See F4)
6. Bucket assembly (6). (See Fl) 3. Pin (4). (See F4) m
Ir Raise the work equipment and discon- + Sling the arm cylinder assembly, and
nect the arm from the bucket. remove the pin.
A Start the engine, and retract the rod of
+I kg See Weight Table the arm cylinder, then tie the rod with
y &wire to prevent it from coming out.
* Release the remaining pressure in the
INSTALLATION OF BUCKET ADJUSTING, Releasing pressure in hy-
draulic circuit for machines with PPC
ASSEMBLY valve.
4. Hose (2). (See F4)
l Carry out installation in the reverse order to 5. Pin (3). (See F4)
removal. 6. Arm assembly (4). (See F4)
* Raise the boom and disconnect the
boom from the arm. ::
Tighten with the locknut so that the 0”
clearance between the bucket boss and zr
nut is 0.5 - 1.5 mm. (See F2)
INSTALLATION OF ARM
Adjust the shim thickness so that the ASSEMBLY
clearance between bucket boss (7) and
spacer (8) is 2 mm. (See F3)
removal.
m
When aligning the position
hole, run the engine at low idling. Never
of the pin
A When aligning the position of the pin
m
ance between boom (5) and arm (6) is
less than 1 mm. (See F5)
* There is only one type of shim thick-
ness: 0.8 mm
j
& Inside surface of bushing: LM-P
l Bleeding air
+ After bleeding the air from the cylinder,
tank.
30&92
Fl
F20505338
F2 F5
0.-11.5mm’ 2OSF6065
F20505408
F3
7 8 Shim
Clearance 2 d mm
_[_
F20505337
REMOVAL OF ARM, INSTALLATION OF ARM,
BUCKET ASSEMBLY BUCKET ASSEMBLY
1. Pin (1). (See Fl) m FFi w
* Set block @ between the arm and the A When aligning the position of the pin
boom, then sling the arm cylinder as- hole, run the engine at low idling. Never
sembly, and remove the pin. (See Fl) insert your fingers in the pin hole.
A Start the engine, and retract the rod of m
the arm cylinder, then tie the rod with * Adjust with shims so that the clear-
wire to prevent it from coming out. ance between boom (5) and arm (6) is
*yRelease the remaining pressure in the less than 1 mm. (See F3)
circuit. For details, see TESTING AND t There is only one type of shim
ADJUSTING, Releasing pressure in hy- thickness: 0.8 mm
draulic circuit for machines with PPC m
valve. x11, Inside surface of bushing: LM-P
2. Hose (2). (See F2) * For grease, use LM-G.
3. Pin (3). (See F2) wti m
Sr Sling the arm and bucket assembly, l Bleeding air
then remove the pin. * Bleed the air from the cylinder.
4. Arm and bucket assembly (4) For details, see TESTING AND ADJUST-
kg
r?YI See Weight Table * After bleeding the air from the cylinder,
tank. 0”
Lo
0
z
Fl
I
I
II I
I
F2
u
F20505340
F3
6 5
30-95
@
REMOVAL OF BOOM INSTALLATION OF BOOM
ASSEMBLY ASSEMBLY
1. Arm and bucket assembly

l Remove arm and bucket assembly. l Carry out installation in the reverse order
For details, see REMOVAL OF ARM, to removal.
BUCKET ASSEMBLY.
2. Hose (1). (See Fl)
3. Lock bolt (2). (See Fl) m Sr Tighten with the locknut so that the
4. Pin (3). (See Fl) ml mj jr1 clearance between the boom boss and
t Sling the boom bylinder assembly, and nut is 0.5 - 1.5 mm.
remove the pin. m
A the
Start the
boom
engine,
cylinder,
and retract
tie the rod with
the rod of
wire
A When aligning the position of the pin
to prevent it from coming out, then insert your fingers in the pin hole.
lower it onto the block. pziJ
Sr Disconnect the boom cylinder assembly * Adjust with shims so that the clear-
on the opposite side in the same way.
ance between cylinder rod (8) and
*y Release the remaining pressure in the
plate (9) is less than 1 mm. (See F5)
* There are two type of shim thick-
ADJUSTING, Releasig pressure in hy-
ness: 0.8 mm, 1.5 mm
draulic circuit for machines with PPC
m
valve.
5. Hose (4). (See F2)
ance between boom (10) and bracket
6. Wiring (5). (See F2)
(11) is less than 1 mm (See F6)
7. Pin (6). (See F5) m] m
* There are two type of shim thick-
* Sling the boom assembly, then use tool 0”
ness: 0.8 mm, 1.5 mm
F to remove the pin. (See F3) 0”
8. Boom assembly (7). (See F4)
l Bleeding air
Sr Bleed the air from the cylinder.
-k After bleeding the air from the cylinder,
tank.
30-g5- 1
Fl F5
205FO5499
F2 F6
Max. 1 mm
205FO5.500
F.20505411
F3
I I
205FO5501
F4
F20505341
30-:5-2
REMOVAL OF OPERATOR’S REMOVAL OF
CAB ASSEMBLY COUNTERWEIGHT
1. Seat assembly (I 1. (See F I) 1. Counterweight (I 1. (See F4) m

* Using eyebolts, sling the counterweight,
6 kg See Weight Table then remove the mounting bolts.
2. Wiper motor wiring (2). (See Fl) + Width across falts of bolt: 41 mm
3. Antenna wiring (3). (See F2)
4. Room lamp wiring (4). (See F2) fi kg See Weight Table
5. Ground connection (5). (See F2)
6. Instrument panel assembly (6). (See F2)
J, Remove the cover, then loosen the
mounting bolts, and move the instru-
ment panel assembly towards the inside.
INSTALLATION OF
7. Cab assembly (7). (See F3)
COUNTERWEIGHT
b kg See Weight Table
removal.
/
INSTALLATION OF m Mounting bolt:
OPERATOR’S CAB .See Tightening Torques and
ASSEMBLY Standard Values Table

removal.
30-96
a
Fl
r
-1
I-
.2
I
F20505372
/ ===xzE
--
/--- I/
d
. k20505342
_F:2
205FO5504
F3
205FO5505
30-97
0
REMOVAL OF ENGINE REMOVAL OF MONITOR
THROTTLE CONTROLLER PANEL ASSEMBLY
1. Pump controller assembly. 1. Screws (I 1. (See F5)

For details, see REMOVAL OF PUMP CON- Sr Remove 4 screws, and move the moni-
TROLLER ASSEMBLY. tor panel assembly upward.
2. Wiring connector (I 1. (See Fl) 2. Wiring connector (2). (See F5)
* Disconnect the connector from the 3. Monitor panel assembly (3). (See F5)
wiring clamp.
3. Bracket (2). (See Fl) INSTALLATION OF
4. Wiring connector (3). (See Fl I
MONITOR PANEL
5. Bracket (4). (See Fl 1
* Remove the mounting bolts, and move
ASSEMBLY
the bracket towards the inside.
6. Egnine throttle controller assembly (5). (See l Carry out installation in the reverse order to
F2) removal.
INSTALLATION OF ENGINE
THROTTLE CONTROLLER

removal.
REMOVAL OF PUMP
CONTROLLER ASSEMBLY
1. Box assembly (I 1. (See F31

Sr Disconnect the antenna wiring of the
radio, the wiring connectors, and the
ground connection, then remove togeth-
er with the radio.
2. Wiring connector (2). (See F4)
3. Pump controller assembly (3). (See F4)
INSTALLATION OF PUMP
CONTROLLER ASSEMBLY

removal.
30-98
0
Fl
\ /I
F2050.5373 F20505377
F2
F20505374
F20505375
2 3 F20505376
PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT
* When carrying out flushing to remove the dirt in the hydraulic circuit, use the following procedure.
Select one of the patterns below to match the level of contamination in the hydraulic circuit.
Flushing
Contamination level
nattern
I I 1
Hydraulic equipment is broken; there are
metal particles in the circuit I
A
Parts in the circuit have been disassembled

2 and assembled
B
(there are no metal particles in the circuit)
3 Periodic flushing
After assembly at jobsite following

4 C
disassembly and transportation
1. Parts to prepare
+ The figures in the table below show the number of parts required.
Flushing pattern
No. Part Name Part No.
A B C
1 Flushing element 209-60-31130 2 1 1
2 Standard element 07063-01210 1 1 1
3 Pilot filter 704-28-02751 2 1 1
4 Is mall strainer / 206-60-41221 1 1 / 1 [ 1
Flange for short-

5
circuiting piping
Main valve blind plug 07222-00312 4 4 -

6
and sleeve nut 07221-20315
Extension nipple for

7 07 102-20340
PPC circuit 1414/-
Extenion nipple for

21 T-04-1 1580
PPC circuit
l In addition to these, a stopper is also needed as a blind plug for the hydraulic tank filter case.
* For details, see “Installation of filter element.”
30-l 00
0
2. Order of operations
The following explanation describes the procedure for short-circuiting the piping, installation of
the filter element, cleaning of the cylinder, and flushing of the PPC circuit that is carried out in the
operation for each flushing pattern.
I) Short-circuiting the piping
Using the piping short-circuiting flange, short circuit the following piping.
Method for short circuiting piping

All the hydraulic circuit, including the
‘osi-
hoses and tubes is flushed, so short cir-
tion
cuit the supply and return pipes in the
circuit.
2 / Arm 1 (Cl and (D) 1205-62-747301 1
3 1 Bucket / (A) and (B) 107377-00615 1 1
4 Swing ( I ) and (J) 07377-00615 1

I I I
5 ) Travel ) ~‘,“1~~&~ )07377-00615 / 2
I I I I
Flange
F2050537I 3
L
F20505379
30201
2) Installation of filter element
(Replace with new one)
F20505380
When removing the element from the return

filter, use the stopper to prevent the dirt Stopper
inside the filter case from entering the tank.
l Inside diameter of hole: 35.7 mm
Filter case
When parts have been removed for short
circuiting, clean the individual parts and
blow with air, then mask with tape to pre-
vent dirt from entering, and store in a safe
place until assembling again.
F20505381
3) Cleaning cylinder
Ir Disassemble all cylinders and clean
Cylinder Rod Head
them.
i) Remove cylinder head, then pull out
I \ /
piston rod.
F20505382
ii) Fix cylinder at an angle, then use a

pump to clean with flushing fluid.
Pump
Sr If no pump is available, use a Cylinder
\
crane, collect the flushing fluid
at the bottom end, shake well,
then drain the flushing fluid, and
blow with air.
Flushing fluid
F20505383
iii) Apply flushing fluid to the cylinder

head and piston and brush well with
Rod Piston Sunken
a nylon brush, then blow with air.
Ir Dirt is likely to collect particularly
in the inset portions, so clean
these parts well.
F20505384
iv) Check inside of cylinder for damage.

Any vertical scratches in
cylinder.
Wear Piston Wear
Any breakage or seizure of wear
rings or piston rings.
Scratches on piston.
If there is any scuffing of the
piston or cylinder, replace the
assembly.
If only the wear ring or piston
ring are damaged, replace the
damaged part with a new part,
and use again. F20505385
30-Ao3
4) Flushing PPC circuit
Disconnect PPC hose from

It is not necessary to remove main valve, then fit
noses for port P and port T. nd plug in main valve
From
pump
Use nipple to connect hose
D
1
Replace element and clean
Using extension hose, small strainer
return PPC circuit hose
directly to hydraulic filter case
F20505386
i) Disconnect PPC circuit hose from

control valve, and return directly to
hydraulic tank filter case.
Sr Carry out the operation for one
PPC valve.
ii) Run the engine at high idling, oper-
ate the control lever in each direction
and hold it for 2 minutes in each
position.
iii) Repeat the procedure in Step ii) at
least 5 times.
iv) Carry out the procedure in Steps i),
ii), and iii) for each PPC circuit.
30-l 04
0
3. Flushing pattern [Al
1) Disassembly, cleaning, reassembly iii) Run the engine at high idling and
i) Failed parts carry out the following operation.
* If any part is badly damaged, re- l Operating pattern
place it. Boom RAISE - Boom LOWER -
ii) Hydraulic tank Arm IN - Arm OUT - Bucket
iii) Suction strainer CURL - Bucket DUMP - Right
iv) Oil cooler swing - Left swing - Left travel
* If excessive amounts of dirt and -Right travel
dust are stuck in the core, l Operating time
replace. Hold the lever in each position
VI Cylinder for 2 minutes.
+ For details, see “Cleaning l Number of times of operation
cylinder”. Repeat the above pattern at
vi) Other hydraulic equipment least 5 times.
2) Preparatory work for flushing 4) Restoring cylinder circuit, swing motor

i) Install the flushing element, clean circuit
the small strainer, then install it as it i) Restore the cylinder circuit and
is. Replace the pilot filter with a new swing motor circuit to the standard
part. circuit.
* For details, see “Installing filter Jr Keep the travel motor circuit
element”. short-circuited.
ii) Short circuit the cylinder circuit, ii) Add hydraulic oil to the specified
swing motor circuit, and travel level.
motor circuit. iii) Bleed the air from the main pump,
* For details, see “Short circuiting cylinders, and swing motor.
piping”.
iii) Add hydraulic oil to the specified 5) Flushing center swivel joint
level. i) Run the engine at high idling and
iv) Bleed the air from the main pump. carry out the following operation.
l Operation pattern
3) Flushing cylinder circuit, swing motor Left and right FORWARD +90”
circuit, travel motor circuit swing
i) Run the engine at low idling for 30 Left and right REVERSE +90”
minutes. swing
* The control levers must not be Ir Swing 90” to either the left
moved during this time. or right, but swing in the
ii) Run the engine at midrange speed same direction each time.
for 30 minutes. l Operating time
J, The control levers must not be Hold the lever in each position
moved during this time. for 2 minutes.
* If the oil tempefature is low, increase l Number of times of operation
the length of the operation in Steps Repeat the above pattern 4
i) and ii) to raise the temperature. times, and rotate the swing one
The oil temperature should be 50 - turn.
80°C. Sr The purpose of swinging
90” each is to remove the
dirt inside the center swivel
for the whole circumference
of the oil groove on the rotor
side and shaft side.
30-l 05
0
4. Flushing pattern [Bl
6) Restoring travel circuit 1) Preparatory work for flushing
i) Restore the travel circuit to the stan- Install the flushing element.
dard circuit. Sr For details, see “Installing filter
ii) Replace the flushing element with a element”.
new part. 2) Flush PPC circuit
Ir For details, see “Installing filter Flush the PPC circuit
element”. or For details, see “Flushing PPC
iii) Bleed the air from the travel motor. circuit”.
3) Restoring PPC circuit
7) Flushing PPC circuit Restore the PPC circuit to the standard
i) Flush the PPC circuit circuit.
Jr For details, see “Flushing PPC 4) Flushing during actual operation
circuit”. With the flushing element installed,
carry out normal operations for 10 -
8) Restoring PPC circuit 20 hours.
i) Restore the PPC circuit to the stan- * If the oil temperature is low, carry
dard circuit. out the warming-up operation.
5) Replacing element
9) Flushing during actual operation Replace the return filter with a standard
i) With the flushing element installed, element, clean the small strainer and in-
carry out normal operations for 10 stall it as it is.
- 20 hours. Replace the pilot filter with a new part.
Sr If the oil temperature is low, Sr For details, see “Installing filter ele-
carry out the warming-up ment”.
0”
operation. z
z
IO) Replacing element
i) Replace the return filter with a stan-
dard element, clean the small strain-
er and install it as it is.
Replace the pilot filter with a new
part.
Ir For details, see “Installing filter
element”.
ii) Add hydraulic oil to the specified
level.
iii) Bleed the air from the main pump.
30-106
0
5. Flushing pattern [Cl
_* If the cylinder piping is connected and 3) Restoring cylinder circuit
the cylinder is operated before the i) Restore the cylinder circuit to the
system flushed, there is danger that the standard circuit.
dirt that entered during assembly opera- ii) Add hydraulic oil to the specified
tions will circulated inside the cylinder. level.
Therefore, do not flush the system after iii) Bleed the air from the main pump
completion of assembly; carry out flush- and cylinders.
ing before connecting the piping to the 4) Flushing during actual operation
cylinder. i) With the flushing element installed,
1) Preparatory work for flushing carry out normal operations for 10
i) Short circuit the cylinder circuit. - 20 hours.
Ir For details, see “Short-circuiting * If the oil temperature is low,
piping”. carry out the warming-up
ii) Install the flushing element. operation.
* For details, see “Installing filter 5) Replacing element
element”. i) Replace the return filter with a stan-
2) Flushing dard element, clean the small strain-
i) Run the engine at low idling for 30 er and install it as it is.
minutes. Replace the pilot filter with a new
* The control levers must not be part.
moved during this time. * For details, see “Installing filter
ii) Run the engine at midrange speed element”.
for 30 minutes. ii) Add hydraulic oil to the specified
Sr The control levers must not be level.
moved during this time. iii) Bleed the air from the main pump.
iii) Run the engine at high idling and
carry out the following operation.
l Operating pattern
Boom RAISE - Boom LOWER -
Arm IN - Arm OUT - Bucket
CURL -Bucket DUMP
l Operating time
Hold the lever in each position
for 2 minutes.
l Number of times of operation
Repeat the above pattern at
least 5 times.
30-107
0
40 MAINTENANCE STANDARD
Final drive . ... . 40- 2

Swing machinery.. . 40- 4
Swing circle . . . . . 40- 6
Track frame and recoil sprig . 40- 7
Idler . . . . ... . 40- 8
Track roller . . .. . . 40-10
Carrier roller . . . . . 40-11
Track _______.___.____._____. 40-12
Hydraulic pump . . 40- 13-2
Charging pump and relief valve 40-14
Control valve . . 40-15
Swing motor _..___._..___.__ 40-22
Center swivel joint 40-23
Travel motor . . . . . . . 40-24
PPC valve . . . . . . . . . . 40-25
Boom holding valve . . . . 40-27
Hydralic cylinder _ . . . . . . . . . 40-28
Work equipment . . . ... . . 40-30
40-l
a
FINAL DRIVE
-47.5 + 2.5 kam
m Initial tightening torque: 80 kgm

Additional tightening angle: 9r+‘i
kgm_
11.25 f 1.25 kgrn~duh
-11.25 +I.25 kgm
205FO5182-1
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
i Backlash between No. 1 sun

gear and No. 1 planet gear
0.19 - 0.54 1 .oo
I I I
I
2 Backlash between No. 1 planet 0.21 - 0.62 1.10

gear and No. 1 ring gear
8 Backlash between No. 1 planetary 0.06 - 0.22 -

carrier and idle gear
Replace
4 Backlash between No. 2 sun 0.19 - 0.54 1.00
gear and No. 2 planet gear
Backlash between No. 2 planet 1.10

5 0.21 - 0.62
gear and ring gear
between No. 2
6 Backlash planetary 0.40 - 0.70 1.20
carrier and No. 1 sun gear
7 End play of sprocket shaft 0.05 - 0.15 -
8 Amount of wear on sprocket tooth Repair limit: 6
Rebuild
Standard size Repair limit
or
9 Width of sprocket tooth replace
71 68
I
SWING MACHINERY
205FO5 183
40-4
Unit: mm
Check item Criteria
shaft and drive gear - 0.18

0.07
een sun gear

0.17 - 0.49
contacting with oil seal
0.08 - 0.32
SWING CIRCLE
94.5 2 10 kgm
Section A-A
205FO5184
Unit: mm
Standard size Clearance limit

Axial clearance of bearing
1 Replace
(When mounted on machine)
0.5 - 1.6 3.2
40-6
0
TRACK FRAME AND RECOIL SPRING
* The drawing shows the PC200-5
2 ,
k
\
3 205FO5185
Unit: mm
-
NO. Check item Criteria Remedy
Standard size Tolerance Repair limit
Track frame 107

1 Vertical width of idler guide
Rebuild or
Idler support 105
replace
-
Track frame 250

I
II I
/
2 Horizontal width of idler guide
Idler support
Free Installation Installation Free Installation

length length load length load
3 Recoil spring Replace

PC200 cj58 x 238 437 11,100 kg 534 8,900 kg
PC2OOLC
603.5 x
PC220 239 466 12,900 kg 576 10,300 kg
PC22OLC
40-7
IDLER
205FO5186
40-8
Unit: mm
:: 1 Outside diameter of protrusion

560 -
Z
hl
0
2 Outside diameter of tread 520 508 Rebuild or
replace
3 Width of protrusion 85 -
4 Total width I 164 -
5 Width of tread 39.5 45.5
Replace
bushing
Clearance between shaft and
6 I
bushing
- -
65 0.250 +0.074 0.214 1.5
- 0.350 - 0.035 0.424
Clearance between shaft and - 0.250 -0.110 0.030 -

7 Replace
support 65 - 0.290 - 0.220 0.180 -
Tolerance
Standard Standard Interference
size interference limit
Interference between idler and Shaft Hole
8
bushing
+0.089 -0.006 0.065 -
72 Replace
+0.059 - 0.072 0.161 -
bushing

E:Ghylearance of idler
9
0.39 - 1.00 1.5
40-9
TRACK ROLLER
w 44.5 * 4.5 kgm
A. I I I .I
/_ 3 _14_1
205FO5187
Unit: mm
::
Z
No Check item Criteria Remedy
g

I I
Outside diameter of flange
(outside) -
186
I
Outside diameter of tread 154 142
Width of tread 44.5 52
Width of flange 24.5 -
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between shaft and Shaft Hole
bushing
-
60 -0.215 +0.195 0.215 1.5
-0.315 0 0.510
Replace
bushing
Tolerance
Standard Standard Interference
size interference limit
Interference between Shaft Hole
roller and bushing
-
67 +0.053
+0.153 0
+0.030 0.0230.153 -

Ezzh;learance of roller
7
Replace
0.41 - 0.95 1.5
40-10
CARRIER ROLLER
205FO5188
Unit: mm

-
Outside diameter of flange
1
(outside) -
165
Rebuild or
replace
Outside diameter of tread 140 I 130
Width of tread 43 50
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between Shaft Hole
shaft and bearing
50 0 0 -0.016 - -
-0.016 -0.012 0.012
Replace
Interference between 80 0 -0.021 0.008 -
5
roller and bushing -0.013 -0.051 0.05 1
I
I
6 Side clearance of roller
0.01 - 0.18 -
I
40-11
TRACK SHOE
B h
1
2@5FO5189-1
40-12
0
Unit: mm

1 Link pitch
190.25 194.25 Turn or
replace
2 Outside diameter of bushing 59.3 54.3
Triple 26 16 Lug wel-

ding,
3 Height of grouser
rebuild or
Swamp 102.5 90.5 replace
4 Height of link 105 97 Rebuild or

replace
-
6 interference of regular pin and link 38 +0.222 -0.138 0.210 0.140
+0.072 - 0.200 0.422
Replace
-
7 Interference of master pin 37.8 +0.230 +0.062 0.138 0.130 with larger
and link +0.200 0 0.230
one
8 1 Protrusion of bushing 4.85

I I
Initial tightening torque: 40 f 4 kgm

9 Tightening torque of shoe bolt Tighten
Additional tightening angle: 120 f 10”
HYDRAULIC PUMP
m m w B
m
18 + 0.4 kgm 3.15 + 0.35 kgm 5.5* 0.5 kgm 14.25 + 2.25 kgm 1.75 f 0.25 kgm 11.25 + 1.25 kgm 8 + 2 kgm 1.15 f 0. 15 kgm
-7:1 kgm -7: 1 kgm
205FO5773
4o-k?-2
CHARGING PUMP AND RELIEF VALVE
-11.5 k 1Okgm
\
5 m’5.5 * 0.5 kgm
205FO5190
Unit: mm
1 Top clearance of gear

0.090 - 0.130 0.145
-
2 Side clearance of gear 0.055 - 0.075 0.105
Clearance between gear shaft Replace

3 and bushing 0.045 - 0.076 0.13
I Standard value Repair limit
Delivery
Engine oil Revolution Delivery Revolution Delivery
4 CLASS-CD SAEI OW speed (rpm) (Urnin) speed (rpm) (Urnin)
50 -t 5°C
30 kg/cm2
3,200 72 3,200 I 68
I I
Replace
spring if
any dama-
Free length Installed Installed Free Installed
5 Charging relief valve spring ges or
x O.D. length load length load
deforma-
tions are
32.3 x 13.0 26.4 14.6 kg - 13.1 kg found
40-14
CONTROL VALVE
PC200,2OOLC-5 Serial No: 45001 - 53192

PC220,22OLC-5 Serial No: 35001 - 36052
/
m 3.0 f 0.5 kgm
D 0.9 * 0.1 kgm
w 6.0 * 1 .O kgm.
205FO5191
40-15
(@
1 .O kgm
Section B- B
m 3.0 * 0.5 kgm
5.5 1+ 0.5 kgm 5.5 f 0.5 kgm
Section A- A
205FO5192
g
L3
g
Unit: mm
Standard size I Repair limit
Main relief valve Free length Installed Installed Free installed

1
pilot poppet spring x O.D. length load length load
30.7 x 9.6 26.8 33.1 kg - 26.5 kg

- Replace
Main relief valve spring if
2 26.0 x 9.2 20.0 3.2 kg - 2.56 kg
main valve spring any dama-
ges or
Jet sensor relief valve deforma-
3 26.3 x 8.0 26.1 0.39 kg - 0.31 kg
pilot poppet spring tions are
found
Jet sensor relief valve
4 23.8 x 7.8 18.1 2.41 kg - 1.93 kg
main valve spring
Spool return spring

5 71.7x20.3 45.0 11.4kg - 9.1 kg
(Straight-travel valve)
Spool return spring

6 $7.5 x 28.0 35.5 16.2 kg - 13.0 kg
(Arm throttle valve)
L
40-16
m 10.0 * l.Okgm 1
3 & 14.5
m 5.5 * 0.5 kgm m 5.5 -t 0.5 kgm Section D -D
Section C- C
205FO5193
Unit: mm
-
-
Main relief valve

1
pilot poppet spring
30.7 x 9.6 26.8 33.1 kg - 26.5 kg
Replace
Main relief valve 26.0 x 9.2 20.0 3.2 kg - 2.56 kg spring if
2
- ges or
Jet sensor relief valve 26.3 x 8.0 26.1 0.39 kg - 0.31 kg deforma-
3
found
4 23.8 x 7.8 18.1 2.41 kg - 1.93 kg
main valve spring
-
Spool return spring
5 37.5 x 28.0 36.5 8.1 kg - 6.5 kg
(Swing priolity valve)
-
40-17
m 20.0 f 2.0 kgm
w 20.072.0 kgm
&I 20.0 * 2.0 kgm W

1 m 20.0 * 2.0 kgm
Section F- F
Section E- E
m w
m 11 .O * 1.5 kgm 11 .O f 1.5 kgm 14.5 % 2.0 kgm 3 4 7 2.3 f 0.2 kgm 4
‘W
11 .O f 1.5 kgm
15.0 * 1 .O kgm 6 5
Section G- G Section H-H
205FO5 194
40-18
Unit: mm

I

1 Check valve spring
24.5 x 1 1.6 14.5 0.76 kg - 0.61 kg
2 Check valve spring 31.8 x 7.6 26.5 0.1 kg - 0.08 kg

. Replace
spring if
3 Spool return spring 29.8 x 28.1 27.0 17.1 kg - 13.7 kg any dama-
ges or
def orma-
4 Spool return spring 41.4x 29.5 40.0 17.1 kg - 13.7 kg tions are
found
5 Spool return spring 5 1 .O x 29.6 50.0 8.6 kg - 6.9 kg
7
Spool return spring
Check valve spring ,..:;:I

40-19
5 1 -15.0* l.Okgm
m .O kgm/ \ \
15.0 * 1.0 bm 1 1 m 2.3 * 0.2 kgm B 2.3 * 0.2 kgm 2
1
Section K- K
Section J-J
11.0 2 1.5 kgm
Section L- L
205FO5195
40-20
Unit: mm

1 Spool return spring
51 .O x 29.6 50.0 8.6 kg - 6.9 kg Replace

- spring if
I I I anv dama-
2 Spool return spring 50.8 x 29.5 50.0 7.6 kg - 6.1 kg ges or
deforma-
tions are
3 Spool return spring 41.4x 29.5 40.0 17.1 kg - 13.7 kg found
4 Spool return spring 129.8x28.1 1 27.0 1 17.1 kg 1 - 1 13.7kg 1

I
5 Check valve srping 46.8 x 26.2 25.0 0.76 kg - 0.61 kg
40-2 1
PC200, 2OOLC-5 Serial No: 53193 and up
PC200, 2OOLC-5 MIGHTY
PC220, 22OLC-5 Serial No: 36053 and up
w 3.0 k 0.5 kgm'
m 0.9 -t0.1 kgm

cd
I-E A-l
A-i,-/
w 6.0 t 1.0 kgm
205FO57.35
40-2 1-2
\‘E>
m
2 1 10.0 ir 1 .O kgm
\ I /
Section B- B
3,0 _ o.5 kgm
+
Section A - A 205FO5 IS2

205=05766
Unit: mm
No. Check item Criteria

T Remedy
Main relief valve Free length Installed Installed

pilot poppet spring x O.D. length load
30.7 x 9.6 26.8 33.1 kg
Replace
26.0 x 9.2 20.0 3.2 kg
-
ges or
Jet sensor relief valve - deforma-
3 26.3 x 8.0 26.1 0.39 kg 0.31 kg
found
A-
4 23.8 x 7.8 18.1 2.41 kg 1.93 kg
main valve spring
Spool return spring -

5 71.7x20.3 45.0 1 1.4 kg 9.1 kg
(Straight-travel valve)
Spool return spring -

6 37.5 x 28.0 35.5 16.2 kg 13.0 kg
(Arm throttle valve)
m
10.0 + 1.0 kgm ! ?
w
14.5 i 2.0
m 5.5 & 0.5 kim 5.5 + 0.5 kgm \

m 14.5 k 2.0 kgm
Section C - C Section D - D
205FO5787
Unit: mm
Main relief valve I

1
pilot poppet spring
Replace
2
ges or
Jet sensor relief valve deforma-
3
- found
4
main valve spring
Spool return spring ‘:

5 .
-L
m 20.0k 2.0kgm
/=2.0 kgm
A-1
3.5k 0.5kgm
v1 w
20.0 i 2.0 kgm
m
I’ \‘-” 20.0 + 2.0 kgm
1 B 20.0* 2.0kgm
Section F- F
Section E- E
w w
w 7.0 k 1.0 kgm m 7.0 k 1.0 kgm 13.0+ 1.0 kgm 3 4 2.3& 0.2kgm 4
w
7.0 i 1.0 kgm
m
13.O+l.bkgm 6 5
205FO5788
Unit: mm
No.
1
Check item
Check valve spring

Free length
x O.D.
Standard
Installed
length
size
Criteria
Installed
load
I
Free
length
Repair limit
Installed
load
F
Remedy
24.5 x 1 1.6 14.5 0.76 kg - 0.61 kg

Replace
spring if
any dama-
2 Check valve spring 31.8 x 7.6 26.5 0.1 kg - 0.08 kg
ges or
- deforma-
tions are
3 Spool return spring 29.8 x 28.1 27.0 17.1 kg - 13.7 kg
found
5 Spool return spring 5 1 .O x 29.6 50.0 8.6 kg - 6.9 kg
6 Spool return spring 32.0 x 13.1 32.0 0 kg 31 -

w 13.0il.Okgm
il.0 kgm m 2.3 + 0.2 kgm

i i
2.3 k 0.2 kgm 13.0 i 1.0 kgm
Section J -J Section K - K
m 7.0 * 1.0kgm
7.0 i 1.0 kgm
Section L - L
205FO5789
Unit: mm
Free length installed Installed Free Installed

51.0x29.61 50.0 1 8.6kg / - 1 6.9kg Replace

spring if
any dama-
2 Spool return spring 50.8 x 29.5 1 50.0 1 7.6 kg 1 - 6.1 kg ges or
- deforma-
tions are
3 Spool return spring 414x29.51 40.0 1 17.1kg / - 1 13.7kg found

-

PC200,2OOLC-5 MIGHTY (with 2PlA circuit)
w 0.9 O.lkgm
w \
205FO5854
- 1 .Okgm
Section B - B
4 3w Qa Qz
5.5i0.5kgm 5.5+0.5kgm 3.010.5kgm
Section A - A
z
205F05855
z
Unit: mm
Main relief valve Free length Installed Installed Free Installed

1
30.7 x 9.6 26.8 33.1 kg - 26.5 kg
Replace
2 Main relief valve 26.0 x 9.2 20.0 3.2 kg - 2.56 kg spring if
ges or
3 Jet sensor relief valve deforma-
26.1 0.39 - 0.31
pilot poppet spring 26.3 x 8.0 kg kg tions are
found
4 Jet
mainsensor
valve relief
springvalve 23.8 x 7.8 18.1 2.41 kg - 1.93 kg

(Straight-travel valve) 7 1.7 x 20.3 45.0 11.4kg - 9.1 kg

(Arm throttle valve) 37.5 x 28.0 35.5 16.2 kg - 13.0 kg
m
10.0 / l.Okgm
.3kgm-
'1
m 5.5 r 0.5k;,,,
& 5.5 0.5kgrri
- 14.5 'Z.Okgnl
Section C - C Section D - D
205FO5856
Unit: mm
Main relief valve Free length Installed Installed Free Installed

1
30.7 x 9.6 26.8 33.1 kg - 26.5 kg
Replace
2 Main relief valve 26.0 x 9.2 20.0 3.2 kg - 2.56 kg spring if
ges or
3 Jet sensor relief valve 26.3 x 8.0 26.1 0.39 kg - 0.31 kg deforma-
found
4 Jet sensor relief valve
I main valve spring I 23.8 x 7.8 18.1 2.41 kg - 1.93 kg
I
5
I
Spool return spring
I37.5 x 28.0 36.5 8.1 kg - 6.5 kg
I
w 20.0 ' 2.0kgm
B
20.0' 2.0kgw
20.0.2.0kgm
1 \
1 w 20.0 ~2.0kgm
Section F- F
Section E - E
w
m 7.0 1 l.Okjiw m 13.0t l.Okgm 3 4 2.3- 0.2kgnl 4
.Okgm
3-- -3
4’ ‘4 m/
13.O?l.Okgm
205FO5857
4o-z-13
Unit: mm
No.
-
Check item
Check valve spring

Free length
x O.D.
Standard
Installed
length
size
Criteria
Installed
load
Free
length
Repair limit
Installed
load
5 Remedy
24.5 x 1 1.6 14.5 0.76 kg - 0.61 kg

Replace
spring if
any dama-
Check valve spring 31.8 x 7.6 26.5 0.1 kg - 0.08 kg
ges or
deforma-
tions are
found

-
5 Spool return spring 51.0x29.6 50.0 8.6 kg - 6.9 kg

-
6 Spool return spring 32.0x 13.1 32.0 0 kg 31 -
40-G-14
5 1 m 13.0 f l.Okgrn
\ I
.O+_l.Okgm 1 1w w i ti 2.3'0.2kgm
2.3+0.2kgm 13.01 1 .Okgm
7.0 1 l.Okgnr
Section L - L
205FO5858
Unit: mm

-
I Standard size I Repair limit
Spool return spring
5 1 .O x 29.6 50.0 8.6 kg - 6.9 kg Replace

spring if
any dama-
Spool return spring 50.8 x 29.5 50.0 7.6 kg - 6.1 kg ges or
deforma-
tions are
3 Spool return spring 41.4 x 29.5 40.0 17.1 kg - 13.7 kg found

-
TRAVEL SHUTTLE VALVE
w 2.25 + 0.25 kgm

I
m 2.25 + 0.25 kgm
/
m 2.25 k 0.25 kgm
205FO5863
Unit: mm
Standard size Repair limit Replace

spring if
Fry$;$h Installed any dama-
1 Spool return spring Installed Free installed
length ges or
load length load
deforma-
tions are
53.7 x 13.4 34.0 4.6 kg 3.7 kg found
SWING MOTOR
1 -18.0 r+ 1 .O kgm
m 17.0 2 2.0 kgm m 38.0 k’5.0 kgm
205FO5196
Unit: mm
No
I
Check item Criteria Remedy

Replace if
any dama-
Free length Installed Installed Free installed
1 ges or
Check valve spring x O.D. length load length load
deforma-
tions are
62.5 x 20.0 35 0.36 kg - 0.29 kg found
CENTER SWIVEL JOINT
Unit: mm
Standard size Standard clearance Clearance limit

1 Clearance between
Replace
rotor and shaft
90 0.056 - 0.105 0.1 11
40-23
0
TRAVEL MOTOR
m 1.15 2 0.15 kgm
6.0 kgm
m / m
4.0 k 0.5 kgm 2.4 k 0.4 kgm
/
w
0.9 * 0.1 kgm
w 28.0 ? 3.0 kgm
4.7 kgm
m 7.5 f 1.0 kgm w 12.8 f 1.7 kgm
205FO5197
Unit: mm

1 Spool selector spring
Replace if
any dama-
49.8 x 33.0 42.0 43.1 kg - 34.9 kg ges or
deforma-
tions are
2 Check valve spring 5 1.4 x 17.3 30.5 0.2 kg - 0.16 kg found
3 Regulator piston spring 55.0 x 9.0 50.0 lO.Okg - 8.0 kg

PPC VALVE
PC200,2OOLC-5 Serial No: 45001 - 58018
PC220,22OLC-5 Serial No: 35001 - 36613
.5 * 1.5 kgm
1 .O kgm
.5 * 1 .O kgm
1.8 -t 0.4 kgm
F 3.5 I 0.5 kgm
205FO5 198
Unit: mm

Pilot spring
Replace if
any dama-
12.6 x 3.85 11.9 0.018 kg - 0.16 kg ges or
deforma-
tions are
Metering spring 31.4x7.4 29.4 1.7kg - 1.4 kg found
Centering spring (For Ps, P4) 47.4 x 16.8 36.5 2.3 kg - 1.8 kg
4 Centering spring (For P 1,P 2) 45.2 x 16.8 36.5 3.8 kg - 3.0 kg
40625
PC200,2OOLC-5 Serial No: 58019 an up
11.5 + 1.5 kgm
1.35 i 0.5 kgm
1.8 k 0
Section A - A Section B- B
m 4+ 0.5 kgm
Section 0 - D
20TF01075
Section C - C
Unit: mm
1 Standard size Repair limit t

Installed Installed Free Installed
Centering spring
1 length load length load
(for P,, P, ports) Replace
spring if
44.6 x 15.5 2.3 kg 1.8 kg any dama-
es or de-
3ormations
2 Metering spring 26.5 x 8.2 1.7 kg 1.4 kg are found
Centering spring
43.2 x 15.5 3.8 kg 3.0 kg
(for P,, P, ports)
t
FOR TRAVEL
l-
2-
km
D Min. 3 kgm
.8 f 0.4 kgm
205FO5199
Unit: mm
Free length Installed lnstaled Free Installed Replace if

1 Metering spring
x O.D. length load length load any dama-
ges or
deforma-
31.4 x 7.4 29.4 1.7 kg - 1.4 kg
tions are
found
2 Centering spring 47.4 x 16.8 36.5 2.3 kg - 1.8 kg

BOOM HOLDING VALVE
PC200,2OOLC-5 Serial No: 45001 - 53229

PC220,22OLC-5 Serial No: 35001 - 36052
Section A-A -19.0 i l.Okgm SectionB-B
205FO5200
Unit: mm
Free length Installed Installed Free Installed Replace if

Pilot valve spring length load length load any dama-
x O.D.
ges or
def orma-
38.2 x 17.0 36.0 1.1 kg - 0.88 kg
tions are
found
Check valve spring 26.5 x 1 1.2 25.0 0.48 kg - 0.38 kg

Section B - B Section A - A
m 15.0 3~ 1.0 kgm
1-A
205FO5790
Unit: mm
No.
I Criteria Remedy
I
Check item
Free length installed installed Free installed Replace if

1 Pilot valve spring
x O.D. length load length load any dama-
ges or
deforma-
38.2 x 17.0 36.0 1.1 kg - 0.88 kg
)
tions are
found
26.5 x 1 1.2 25.0 0.48 kg - 0.38 kg
4027-2
i
HYDRAULIC CYLINDER
PC200,2OOLC-5
* The drawing shows boom cylinder
QS3 Boom: 27.5 * 4.0 kgm w Boom: 720 F 72 kgm (Width across flats: 85)
Arm: 38.0 * 5.5 kgm Arm: 1040 * 104 kgm (Width across flats: 95)
Bucket: 27.5 k 4.0 kgm Bucket: 720 * 72 kgm (Width across flats: 85)
205FO5201 A
::
Unit: mm g
N
0
Tolerance
Cylinder Standard Standard Clearance
name size clearance limit
Shaft Hole
Clearance between - -
Boom 85 0.036 +0.222 0.083 0.412 Replace
1 piston rod and - 0.090 +0.047 0.312
bushing
bushing
-
Arm 95 -0.036 +0.222 0.083 0.412
- 0.090 +0.047 0.312
- -
Bucket 80 0.030 +0.258 0.073 0.434
-0.076 +0.048 0.334
-
- -
Boom 80 0.030 +0.457 0.400 1 .o
- 0.060 +0.370 0.517
Clearance between
- -
2 piston rod support Arm 80 0.030 +0.457 0.400 1 .o
- 0.076 +0.370 0.533
and bushing
- -
Bucket 70 0.030 +0.424 0.380 1 .o
- 0.076 +0.350 0.500 Replace
- pin and
Boom 70 - 0.030 +0.424 0.380 - 1 .o bushing
- 0.060 +0.350 0.484
Clearance between
- -
3 cylinder bottom Arm 80 0.030 +0.457 0.400 1 .o
-0.076 +0.370 0.523
support and bushing
- -
Bucket 70 0.030 +0.424 0.380 1 .o
-0.076 +0.350 0.500
-
PC220 * 22OLC-5
+ The drawing shows boom cylinder
w Boom: 27.5 f 4.0 kgm B Boom: 1040 k 104 kgm (Width across flats:
Arm: 38.0 f 5.5 kgm Arm: 1040 f 104 kgm (Width across flats:
Bucket: 27.5 f 4.0 kgm Bucket: 1040 -t 104 kgm (Width across flats:
205F05202A
Unit: mm
No Remedy
Clearance between
Replace
1 piston rod and
bushing
Clearance between
2 piston rod support
and bushing
Replace
- pin and
bushing
Clearance between
3 cylinder bottom
support and bushing
WORK EQUIPMENT
5
\
Section A- A
Section E-E
Section B-B
Section F - F
Section C- C
Section K- K
Section D-D Section G - G
205F05203A
4oci30
Unit: mm
Clearance between bushing and

1 connecting pin of revolving
frame and boom
2 Clearance between bushing and

connecting pin of boom and arm
8 Clearance between bushing and Replace

connecting pin of arm and link
4 Clearance between bushing and

connecting pin of arm and bucket
Clearance between bushing and

5
connecting pin of link and bucket
Clearance between bushing and ~

6
connecting pin of link and link
7 Bucket clearance (a) 0.5 - 1 .o

- Shim
Idjust
8 Bucket clearance (b) 2.0
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

Sebda2050508 SM PC220-5 PDF

Încărcat de

Informații document

Descriere originală:

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Sebda2050508 SM PC220-5 PDF

Încărcat de

Drepturi de autor:

Formate disponibile

SEBMA2050508

PC2004 45001 and up

l PC200, 2OOLG5,MIGHTY mount the S6D95L engine;

10 STRUCTURE AND FUNCTION ................ lo-1

20 TESTING AND ADJUSTING .................. ~~-1

30 DISASSEMBLY AND ASSEMBLY ......:..... 3o_1

40 MAINTENANCE STANDARD ................. 4o_1

Not to be reproduced in whole or in part without the prior written permission of

actions be taken to these pages according to the

0 Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Timeof

. oo- 1 lo- 1 IO-23 10-45-6 1O-69

. oo- 2 lo- 2 IO-24 0 10-45-7 . 10-69-I

l oo- 2-l . IO- 3 IO-25 0 10-45-8 1O-69-2

. oo- 2-2 0 lo- 3-1 lo-26 0 10-45-g 1O-69-3

l 00- 2-3 IO- 4 lo-27 0 1O-45-10 1O-69-4

l 00- 2-4 IO- 4-1 lo-28 0 1o-45-11 IO-70

l oo- 3 IO- 4-2 10-29 0 1O-45-12 IO-71

l oo- 4 l IO- 5 IO-30 IO-46 IO-72

l oo- 5 l IO- 6 IO-31 10-47 . IO-73

. 00- 6 lo- 7 IO-32 lo-48 . IO-74

. oo- 7 lo- 8 IO-33 10-49 IO-75

l 00- 8 lo- 9 10-34 10-49-I IO-76

l oo- 9 IO-IO 10-35 10-50 l IO-77

l 00-10 IO-11 lo-36 1o-51 1o-77-1

. 00-11 IO-12 l IO-37 IO-52 l 1O-77-2

. 00-12 l IO-13 . IO-38 1o-53 . 1o-77-3

l 00-13 0 IO-14 IO-39 1o-54 10-77-4

. 00-14 10-15 . IO-40 1O-56 . IO-78

l 00-15 l lo-16 IO-41 10-57 l IO-79

l 00-16 . 10-17 IO-42 IO-58 IO-80

0 00-17 l IO-18 IO-43 IO-59 lo-81

0 00-18 IO-19 10-44 IO-60 IO-82

0 00-19 0 10-19-I IO-45 IO-61 lo-83

0 00-20 10-20 l 10-45-I IO-62 . lo-84

0 00-21 10-20-l 10-45-Z IO-65 1O-85

0 00-22 10-20-2 1o-45-3 l IO-66 l 1O-86

0 00-23 IO-21 10-45-4 IO-67 IO-87

0 00-24 IO-22 10-45-5 IO-68 l 10-88

1O-89 0 IO-118 20-19 20-51 0 20-100

l 1O-89-1 10-118-1 0 20-20 20-52 0 20-101

1O-89-2 10-118-2 0 20-21 20-53 20-102

l 1O-89-3 l IO-119 0 20-22 20-54 . 20-103

1O-89-4 l 10-120 20-23 20-55 20-104

1O-89-5 0 10-121 0 20-24 20-56 . 20-104-I

. 1O-89-6 10-122 l 20-25 20-57 20-105

0 1O-89-8 lo-123 20-26 20-58 0 20-106

1O-90 lo-124 20-27 20-59 20-107

l 1o-91 10-124-I l 20-28 20-60 0 20-107-l

l 1o-92 10-124-2 a 20-28-I 20-61 20-107-2

1o-93 10-124-3 20-28-2 20-62 20-108

1o-94 10-124-4 20-28-3 20-63 20-109

1o-95 IO-125 20-29 20-64 20-110

1O-96 IO-126 20-30 20-65 20-111

1o-97 l IO-127 20-31 20-66 20-113

1 O-97-1 . IO-128 20-32 20-67 . 20-114

1o-97-2 IO-129 20-33 l 20-68 20-115

l 1o-97-3 IO-130 20-33-I l 20-69 . 20-116

1O-98 IO-131 20-34 l 20-70 0 20-117