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HYDRAULIC EXCAVATOR
13 April 2006
AT
PC200-8
KAP TRAINING CENTRE
KI Page 1 / 54
Course Program
PC200-8 Page 2 / 54
PC200-8
Major Improvement From dash 7 to
dash 8
PC200-8
Overall Layout
Pilot filter (for ATT specification-based machines alone)
Single action/double action Fuel pre-filter
selector valve Control (with water separator)
Engine oil filter
(For ATT specification-based Battery Fuel tank valve Hydraulic oil tank
machines alone)
Main pump
Low-pressure
accumulator
(For ATT specification-
based machines
alone)
Swing motor/
swing machinery Fuel main filter
Swivel joint
Engine
(Tier 3 supported)
Multi pattern selector valve
(OPT)
Radiator
CAB
Oil cooler
After cooler
Fuel cooler
PC200-8 Page 4 / 54
Major Improvement
(A) Engine
PC200-8 Page 5 / 54
Engine
SAA6D102E (145PS) to SAA6D107 (150PS),
PC200-8 PC200-7
Fuel main filter Fuel filter
2m to be replaced at every 1000h 25m to be replaced at every 500h
Engine oil filter
Engine oil filter
Governor motor
Engine controller
Priming pump
Employment of
(manual)
two internal pipes
30 to 60 times
Pre-filter (10m)
Glass wool
Muffler cover
Water separator
PC200-8 Page 7 / 54
Action against POOR FUEL for Common Rail system
For Poor Fuel Quality area like a South East Asia, China, Africa and
etc
Set up a NEW Filtering system for POOR FUEL.
Main Filter : Two 2 Filter (same as current Filter but add One
more)-Join in series
Additional Water Separator (same as current, used in Tier 1 /Tier2
107& 114 Eng = add 1 unit, 125 and bigger Eng = add 2 units
(parallel)
2. For non Tier3 Region = S.E.Asia, China, Africa and etc -> Add +
10pre-filter + 2main filter + (2main filter + Water separator)
PC200-8 Page 8 / 54
Layout of additional fuel main filter2 + water
separator
Standard spec For poor fuel quality country
Tier2
Tier 2 Before C/M At the (Tier2
first time of CRI engine (Tier2) introduction, injector worn were appeared. NASWater contents
NAS
Std 55
Main
(before C/M) 8
grade 0.1%
For poor fuel arrangement 10
Pre- 10
55
Main 11 grade
+
0.6%
W/S
W/separator (before C/M)
()
(current)
Tier2
Tier2 After C/M (
By this measure, the problem was solved considerably.
Tier3Current
Tier3 for USA, etc NAS
NASWater contents
10
Pre- 10
Global standard 2 2
Main
+
)
(current) 13 grade
0.6%
W/S
W/separator
(current)
()
Tier3 New poor fuel However, the further measure is required to aim at market introduction
( NAS Water
NAS contents
New
for SEFiltering System
Asia, China, of PC200-8 in comfort to fuel with much water of Indonesia,
etc
and fuel with much dust of China.
Tier2,Tier3
10
Pre- 10 2 2
Main
Std + )
(current) 13 grade
0.6%
W/S
W/separator
()
(current)
Particle
size(m 6 7 8 9 10 11 12
515 16,000 32,000 64,000 128,000 256,000 512,000 1,024,000
1525 2,850 5,700 11,400 22,800 45,600 91,200 182,400
2550 506 1,012 2,025 4,050 8,100 16,200 32,400
50100 90 180 360 720 1,440 2,880 5,760
>100 16 32 64 128 256 512 1,024
Unit: pieces in 100 cc oil
Note: Tier 3 is possible to use max. NAS 13 class fuel, however we request fuel contamination control
PC200-8 Page 11 / 54
Counter-measure for Indonesia Market
PC200-8 Page 12 / 54
WATER SEPARATOR EFFICIENCY
CURRENT COUNTERMEASURE
The fuel circuit is installed with two water separator in series connection of which its filtering
efficiency is upto 95%.
When 2% of water is mixed with fuel, the output of the filtering effect is acceptable.
PC200-8
Changes done around Engine
Change in engine mount structure
PC200-8 PC200-7
Change in stopper
structure
Change in lock
PC200-8 Page 14 / 54
Changes done around Engine
Change in air cleaner and intake port
PC200-8 PC200-7
Intake port
PC200-8 Page 15 / 54
Cooling
Change in Cooling
PC200-8 PC200-7
Radiator
After cooler
Oil cooler
Oil cooler
Radiator
After cooler
Fuel cooler
Condenser of air conditione
Condenser of air conditioner
PC200-8 Page 16 / 54
Cooling
Change in Cooling
PC200-8 PC200-7
Radiator
Oil cooler
After cooler
Radiator
Fuel cooler Oil cooler
After cooler
Condenser of
air conditioner
PC200-8 Page 18 / 54
Electrical equipment on Machine Body
Change in harness
PC200-8 PC200-7
All connectors were abolished Divided by connectors
and replaced with harnesses
To controller and To sensors on the
monitor machine body
To controller and To sensors on the
monitor machine body
Change in clip
PC200-8 PC200-7
PC200-8 Page 19 / 54
Electrical equipment on Machine Body
Change in travel alarm
Reduction in size of travel alarm
Model 7
Model 8
PC200 107dB
PC200 97dB
PC220 107dB
PC220 107dB
Alternator
PC200-8 Page 21 / 54
Major Improvement
PC200-8 Page 22 / 54
Hydraulic Equipment and Pipe related Changes
New junction valve
Overview of Hydraulic Equipment EPC valve has been employed for the control of converging
and Pipe related Changes and dividing of main and LS (currently the control is done by
ON or OFF of the solenoid valve)
PPC circuit: Pressure sensor Pressure switch Employment of control valve-contained cooler check valve
PC200-8 Page 23 / 54
Hydraulic Equipment and Pipe related Changes
Overview of Hydraulic Equipment and Pipe related Changes
Reduction of hydraulic oil tank capacity 190L 200L
Changes in the control valve mounting method (employment of bottom tightening) Changes in the discharge port (drawn out sideways)
PC200-8 Page 24 / 54
Hydraulic Equipment and Pipe related Changes
Changes in Control Valve Mounting Method
PC200-8 PC200-7
Return Return
PC200-8 Page 26 / 54
Hydraulic Equipment and Pipe related Changes
PC200-7
PC200-8
PC200-8 Page 27 / 54
Hydraulic Equipment and Pipe related Changes
Employment of Arm Quick Return Valve
B
From cylinder
PC200-8 Page 28 / 54
Hydraulic Equipment and Pipe related Changes
To boom cylinder bottom
Replacement of Arm Dump Side Safety
Valve with Centralized Safety Valve
Boom valve
Pump circuit
Centralized
safety valve
Arm valve
Tank circuit
Pump circuit
PC200-8 Page 29 / 54
Hydraulic Equipment and Pipe related Changes
Improvement in Oil Pressure Loss through
Employment of new Converging and Dividing Control
When flows from pumps are converged When pumps are divided
Converging and
dividing of the pumps
are executed
corresponding to the
pump pressures and
work patterns.
50 kg/cm2
Converged 150 kg/cm2 150 kg/cm2
150 kg/cm2
100 L/min
100 L/min 100 L/min 100 L/min
PC200-8 Page 30 / 54
Hydraulic Equipment and Pipe related Changes
Improvement in Oil Pressure Loss through Employment of new Converging and Dividing Control
PC200-8 PC200-7
Pressure
LS line SW
LS line Pressure
Pump sensor
Main line Main line
Pressure
sensor Pump
Pump Pump F Pump
F R Pressure
Pump sensor
R
LS valve LS valve LS valve LS valve
LS_EPC LS_EPC
Controller
PC_EPC_R PC_EPC
ON/OFF solenoid
Controller
PC_EPC_F
valve for converging
Converging/ and dividing
dividing LS selector
proportional solenoid
Converging/
dividing main selector
proportional solenoid
PC200-8 Page 31 / 54
Hydraulic Equipment and Pipe related Changes
Changes conducted on main Pump
PC200-8 Page 32 / 54
Major Improvement
PC200-8 Page 33 / 54
Revolving frame
Enlargement of Opening below Engine
PC200-8 PC200-7
Engine controller Supply pump
Injection pump
604 500
300
562.5
PC200-8 Page 34 / 54
Operator Cab and inside Cab
Employment of Operator Protective Cab Structure in Tipping Over
PC200-8 Page 35 / 54
Operator Cab and inside Cab
Employment of Operator Protective Cab Structure in Tipping Over
Revolving frame
Details of stopper
PC200-8 Page 36 / 54
Operator Cab and inside Cab
Cab Equipment One-touch storage of the
front window's lower glass
Grade up of monitor panel
PC200-8 Page 37 / 54
Operator Cab and inside Cab
Electrical Equipment in rear side of CabPump controller
KOMTRAX
Air-con. controller
Change of relay
PC200-8 Page 38 / 54
Operator Cab and inside Cab
Pump Controller
PC200-8 PC200-7
RH console
Light switch
(3-position type)
PC200-8 Page 40 / 54
Operator Cab and inside Cab
Monitor Panel
Functional integration
PC200-8 PC200-7
Monitor panel Monitor panel KOMTRAX controller
Communication terminal
Display unit Display unit (Dopa)
Control unit
Control unit GPS terminal
and storage
Switch unit
KOMTRAX Switch unit Control unit
(including air
communication terminal
conditioner switch)
Communication terminal
GPS function (Dopa) CAN
Switch unit
PC200-8 Page 41 / 54
Machine Cab
Overview of Changes conducted on Machine Cab
PC200-8 PC200-7
gas dumper
PC200-8 Page 42 / 54
Machine Cab
New Employment of PC200-8 PC200-7 (Existing machine)
Protrusion Type Slip-proof
Abrasive paper type
PC200-8 Page 43 / 54
Machine Cab
Field of Vision complied with New ISO Standard
PC200-8 PC200-7
Size: W200 H280 Size: 250 Size: W130 H280
Curvature: 1000 Curvature: 400 Curvature: 620
PC200-8 Page 44 / 54
Machine Cab
Employment of Press Type Frame
Sounds of wind suctioned from the fan
PC200-8 PC200-7 is absorbed in the fan
PC200-8
PC200-8 Page 45 / 54
Machine Cab
Employment of Gas Dumper for Opening and Closing of Engine Hood
PC200-8 PC200-7
Allows easy opening with a single hand Gas dumper Torsion bar
PC200-8 Page 46 / 54
Major Improvement
PC200-8 Page 47 / 54
Swing Machinery
Remote Draining of Swing Machinery
Remote draining of swing machinery has been made easier
PC200-8 PC200-7
Drain plug
PC200-8 Page 48 / 54
Swing Machinery
Swing motor
Shape of the motor case has been modified
PC200-8 PC200-7
KMF125ABE-6.
Reverse
prevention
valve
PC200-8 Page 49 / 54
Travel Machinery
Travel motor
PC200-8 PC200-7
PC200-8 Page 50 / 54
Undercarriage-related Changes
Travel Motor
PC200-8 PC200-7
PC200-8 Page 51 / 54
Work Equipment
Current bushing at the arm tip has been replaced with CRHF
Bushing at Arm Tip bushing excelling in seizure resistance and wear resistance.
CRHF
CRHF
Bucket side end face:
IQT Sprayed with WC (tungsten)
(Hardening and tempering)
PC200-8 Page 52 / 54
Engine/Pump Matching Control
Control of Model 8 Thus, two engine curbs are used on this Model 8.
Matching points are selectively used depending
Common rail type engine has been newly installed on the operation pattern.
Model 8.
Control of the engine is done with the engine controller. It (When the fuel dial is full in P mode)
is capable of controlling fuel injection.
PC200-8 Page 53 / 54
Major Improvement
PC200-8 Page 54 / 54
Compatibility Information by Device
Designation PC200-7
Compatibility
Reasons why compatibility
Advice when there is no compatibility
Remarks
with PC200-7 was judged absent
Ass'y
Engine assembly X Tier3,UP(1110inch)
Tier3-complied common rail engine, Increase in air cleaner size (1110inch)
Unit
M/C Now Change in pulley ratio (0.870.96), Increase in engine output (150PS145PS)
X (0.870.96),UP(150PS145PS)
Ass'y
Main pump assembly X ,PCFR,LS
Changes in discharge port position, Independent control of F and R, Change in
M/C Now LS set
X
Ass'y
Control valve assembly X (),,
Installation method (tightening at bottom), Addition of arm quick return, Employment of built-in cooler check valve
M/C Now
X LS,Ass'y
Spool stroke has been modified due to change in LS set. Not identical with the converging and dividing assembly.
Ass'y
Swing motor assembly X
Reduction in weight ()
Compatibility will be generated if the machinery oil
M/C Now
X
refill tube (including bracket) is modified.
Ass'y
Travel motor assembly X ASS'Y
There is compatibility for final assembly and
M/C Now
X motor assembly
Boom cylinder 0
M/C Now
0
Arm cylinder X
Direction of pipes is not identical
Compatible including hose
M/C Now
X
Bucket cylinder X
Direction of pipes is not identical
Compatible including hose
M/C Now
X
Center swivel 0
M/C Now
0
Swing circle M/C X Now
Number of teeth is not identical
X
Swing machinery M/C X Now
Number of pinion teeth is not identical
X
Idler 0
M/C Now
0
Idler cushion 0
M/C Now
0
Track roller 0
M/C Now
0
Carrier roller X
Installation method is not identical
M/C Now
X
Track shoe 0
M/C Now
0
PC200-8 Page 55 / 54
Compatibility Information by Device
PC200-7
Designation Compatibility Reasons why compatibility Advice when there is no compatibility Remarks
with PC200-7 was judged absent
Ass'y X
Cooling assembly M/C Now Employment of side-by-side
X
arrangement
X
Operator cab M/C Now Structure is not identical
X
M/C X Now
Operator's seat X Move of armrest to console
X ,
Hydraulic oil tank M/C Now Reduction in capacity, Change on
X
return port
X
Fuel tank M/C Now Pipe mouthpiece is not identical
X
Ass'y 0
Boom assembly M/C Now Including pipe
0
Ass'y 0
Arm assembly M/C Now Including pipe
0
Ass'y X
Bucket assembly M/C Now End face processing is not identical
0
X ,
Revolving frame M/C Now Change of engine position, Change in installation method resulted from
X
employment of side-by-side arrangement
X
Track frame M/C Now Carrier roller installation method is not identical
X
X ASS'Y
Final M/C Now There is compatibility for final assembly
X
and motor assembly
0
Sprocket M/C Now
0
X ,,,
Machine cab M/C Now Hood, door, frame and partition are not
X
identical
X ,
Controller M/C Now Change in contents of control, Change
X
of connector
X 7,,KOMTRAX
Monitor M/C Now
X Provided with 7-LCD, air conditioner switch and KOMTRAX function
X
Engine control M/C Now Supports common rail engine
X
0
Work equipment PPC valve M/C Now
0
0
Travel PPC valve M/C Now
0
PC200-8 Page 56 / 54
Compatibility Information by Device
Designation PC200-7
Compatibility
Reasons why compatibility
Advice when there is no compatibility
Remarks
with PC200-7 was judged absent
Dumper 0
M/C Now
0
Solenoid valve 0 Ass'y
Not identical among
M/C Now
0 assemblies
Air conditioner X
Switch function has been moved to
M/C Now monitor panel
X
Counterweight X UP(,)
Increase in capacity (weight remains the same
M/C Now and specific gravity has been increased)
X
Consumable parts
PC200-8 Page 57 / 54