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SEBM024300

PC20 0, 20 0LC-7PC220, 220LC-7

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CONTENTS

No. of page

01 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD. 10-1

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

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

90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00

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SAFETY SAFETY NOTICE

SAFETYSAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service and

repair techniques recommended by Komatsu and described in this manual are both effective

and safe. Some of these techniques require the use of tools specially designed by Komatsu for

the specific purpose.

To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this manual.

The cautions accompanying these symbols should always be followed carefully. If any danger-

ous situation arises or may possibly arise, first consider safety, and take the necessary actions

to deal with the situation.

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous.

Read the Operation and Maintenance Manual care-

fully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read

all the precautions given on the decals which are

fi d h hi

6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools

and parts in their correct places. Always keep

the work area clean and make sure that there is

no dirt or oil on the floor. Smoke only in the areas

provided for smoking. Never smoke while work-

ing.

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SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK

11.When removing the oil filler cap, drain plug or

hydraulic pressure measuring plugs, loosen

them slowly to prevent the oil from spurting out.

Before disconnecting or removing components

of the oil, water or air circuits, first remove the

pressure completely from the circuit.

12.The water and oil in the circuits are hot when the

engine is stopped, so be careful not to get

burned.

Wait for the oil and water to cool before carry-

ing out any work on the oil or water circuits.

13.Before starting work, remove the leads from the

battery. Always remove the lead from the nega-

tive (–) terminal first.

14.When raising heavy components, use a hoist or

crane.

Check that the wire rope, chains and hooks are

free from damage.

Always use lifting equipment which has ample

capacity.

Install the lifting equipment at the correct places.

Use a hoist or crane and operate slowly to pre

19.Be sure to assemble all parts again in their origi-

nal places.

Replace any damaged parts with new parts.

• When installing hoses and wires, be sure

that they will not be damaged by contact

with other parts when the machine is being

operated.

20.When installing high pressure hoses, make sure

that they are not twisted. Damaged tubes are

dangerous, so be extremely careful when install-

ing tubes for high pressure circuits. Also, check

that connecting parts are correctly installed.

21.When assembling or installing parts, always use

the specified tightening torques. When installing

protective parts such as guards, or parts which

vibrate violently or rotate at high speed, be par-

ticularly careful to check that they are installedcorrectly.

22.When aligning two holes, never insert your fin-

gers or hand. Be careful not to get your fingers

caught in a hole.

23.When measuring hydraulic pressure, check that

the measuring tool is correctly assembled before

taking any measurements

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FOREWORD GENERAL

FOREWORDGENERALThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an

accurate understanding of the product and by showing him the correct way to perform repairs and make judge-

ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service

workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-

standing of the structure, but also serves as reference material for troubleshooting.

In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-

nance standards.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to

be made at completion of the checks and repairs.

Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLY

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FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMESShop manuals are issued as a guide to carrying out

repairs. They are divided as follows:

Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series

Electrical volume:

Attachments volume:

These various volumes are designed to avoid dupli-

cating the same information. Therefore, to deal with

all repairs for any model , it is necessary that chas-

sis, engine, electrical and attachment volumes be

available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be

sent to KOMATSU distributors. Get the most up-to-

date information before you start any work.

FILING METHOD

1. See the page number on the bottom of the page.

File the pages in correct order.

2 Following examples show how to read the page

REVISED EDITION MARK

When a manual is revised, an edi t ion mark( 1 2 3 ....) is recorded on the bottom of the pages.

REVISIONS

Revised pages are shown in the LIST OF REVISED

PAGES next to the CONTENTS page.

SYMBOLS

So that the shop manual can be of ample practical

use, important safety and quality portions are

marked with the following symbols.

Symbol Item Remarks

¤

Safety

Special safety precautions

are necessary when per-

forming the work.

s

Caution

Special technical precau-

tions or other precautions

for preserving standards

h

}·

Each issued as one

volume to cover all

models

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FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

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

with a hoist, etc. In the DISASSEMBLY

AND ASSEMBLY section, every part

weighing 25 kg or more is indicated clearly

with the symbol 4

• If a part cannot be smoothly removed from the

machine by hoisting, the following checks

should be made:

1) Check for removal of all bolts fastening the

part to the relative parts.

2) Check for existence of another part causing

interference with the part to be removed.

WIRE ROPES

1) Use adequate ropes depending on the

weight of parts to be hoisted, referring to

the table below:

Wire ropes

(Standard "Z" or "S" twist ropes

without galvanizing)

Slinging near the edge of the hook may cause

the rope to slip off the hook during hoisting, and

a serious accident can result. Hooks have max-

imum strength at the middle portion.

3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically

wound onto the load.¤ Slinging with one rope may cause turning

of the load during hoisting, untwisting of

the rope, or slipping of the rope from its

original winding position on the load, which

can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a

wide hanging angle from the hook

SAD00479

41%71%79%88%100%

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FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, releasethe residual pressure from the hydraulic tank.

For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic

tank.

¤ Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out

when the hose is disconnected. Accordingly,

prepare an oil receiving container.

Disconnection

1) Release the residual pressure from the hydrau-

l ic tank. For detai ls, see TESTING AND

ADJUSTING, Releasing residual pressure from

hydraulic tank.

2) Hold adapter (1) and push hose joint (2) intomating adapter (3). (See Fig. 1)

The adapter can be pushed in about 3.5

mm.

Do not hold rubber cap portion (4).

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

press rubber cap portion (4) against (3) until it

clicks. (See Fig. 2)

Type 1

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FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 2 Type 3

D i s a s s e m b l y

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-

vention ring (1) contacts contact surface a of

the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn

lever (4) to the right (clockwise).

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-

vention ring (1) contacts contact surface a of


2) Hold in the condition in Step 1), and push

until cover (3) contacts contact surface a of


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FOREWORD COATING MATERIALS

COATING MATERIALS

The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly

and assembly are listed below.

For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

Adhesives

LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets,

rubber cushions, and cock plugfrom coming out.

LT-1B 790-129-9050 20 g

(2 pcs.)Polyethylene

container

• Used in places requiring an imme-diately effective, strong adhesive.Used for plastics (except polyeth-ylene, polyprophylene, tetrafluor-oethlene and vinyl chloride),rubber, metal and non-metal.

LT-2 09940-00030 50 g Polyethylene

container

• Features: Resistance to heat andchemicals

• Used for anti-loosening and seal-ant purpose for bolts and plugs.

LT-3

790-129-9060(Set of

adhesive andhardening

agent)

Adhesive:1 kg

Hardening

agent:500 g

Can

• Used as adhesive or sealant formetal, glass and plastic.

LT 4 790 129 9040 250 Polyethylene

t i

• Used as sealant for machined

h l

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FOREWORD COATING MATERIALS

Category Komatsu code Part No. Q'ty Container Main applications, features

Adhesives

LG-7 790-129-9070 1 g Tube

• Features: Silicon based, quickhardening type

• Used as sealant for flywheelhousing, intake manifold, oil an,thermostat housing, etc.

Three bond1211

790-129-9090 100 g Tube • Used as heat-resisting sealant for

repairing engine.

Molybdenumdisulphidelubricant

LM-G 09940-00051 60 g Can • Used as lubricant for sliding por-

tion (to prevent from squeaking).

LM-P 09940-00040 200 g Tube

• Used to prevent seizure or scuf-fling of the thread when press fit-ting or shrink fitting.

• Used as lubricant for linkage,bearings, etc.

Grease

G2-LI

SYG2-400LI

SYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

• General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

• Used for normal temperature,light load bearing at places in con-tact with water or steam.

M l bd 400 U d f l ith h l d

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FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in

the table below.

Thread diameterof bolt

Width acrossflats

mm mm Nm kgm

6

8

10

12

14

10

13

17

19

22

13.20

1.4

310

3

660

7

113 0 10

1770

19

1.350

0.15

3.20

0.3

6.70

0.7

11.5 0 1

180

2

16

18

2022

24

24

27

3032

36

2790

30

3820

39

5490

597450

83

9270

103

28.50

3

390

4

560

6760

8.5

94.50

10.5

27

30

33

36

39

41

46

50

55

60

13200

140

17200

190

22100

240

27500

290

32900

340

1350

15

1750

20

2250

25

2800

30

3350

35

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TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the

table below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

10

12

16

14

17

22

65.70

6.8

1120

9.8

2790

29

6.70

0.7

11.50

1

28.50

3

Norminal No.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

02

03, 04

05 06

14

20

24

Varies depending

t f

34.30

4.9

93.1 0 9.8

142 1 19 6

3.50

0.5

9.5 0 1

14 5 2

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TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.

Thread diameter Tightening torque

mm Nm kgm

68

10

12

100

2240

4

430

6

770

12

1.020

0.202.450

0.41

4.380

0.61

7.850

1.22

Thread diameter Tightening torque

mm Nm kgm

6

8

80

2

100

2

0.810

0.20

1.020

0.20

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FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODEIn 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

Norminalnumber

Copper wire

Cable O.D.(mm)

Currentrating(A)

Applicable circuitNumber of

strands

Dia. ofstrands(mm2)

Crosssection(mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signaletc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

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FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the

method of using the Conversion Table, see the example given below.

EXAMPLE

• Method of using the Conversion Table to convert from millimeters to inches

1. Convert 55 mm into inches.

(1) Locate the number 50 in the vertical column at the left side, take this as A , then draw a horizontal line

from A .

(2) Locate the number 5 in the row across the top, take this as B , then draw a perpendicular line down

from B .

(3) Take the point where the two lines cross as C . This point C gives the value when converting from mil-

limeters to inches. Therefore, 55 mm = 2.165 inches.2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the

left) to convert it to 55 mm.

(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.

(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point

one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

B

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Liter to U.S. Gallon

1l

= 0.2642 U.S. Gal

Liter to U.K. Gallon

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.642

5.283

7.925

10.567

13.209

15.850

18.492

21.134

23.775

0.264

2.906

5.548

8.189

10.831

13.473

16.115

18.756

21.398

24.040

0.528

3.170

5.812

8.454

11.095

13.737

16.379

19.020

21.662

24.304

0.793

3.434

6.076

8.718

11.359

14.001

16.643

19.285

21.926

24.568

1.057

3.698

6.340

8.982

11.624

14.265

16.907

19.549

22.190

24.832

1.321

3.963

6.604

9.246

11.888

14.529

17.171

19.813

22.455

25.096

1.585

4.227

6.869

9.510

12.152

14.795

17.435

20.077

22.719

25.361

1.849

4.491

7.133

9.774

12.416

15.058

17.700

20.341

22.983

25.625

2.113

4.755

7.397

10.039

12.680

15.322

17.964

20.605

23.247

25.889

2.378

5.019

7.661

10.303

12.944

15.586

18.228

20.870

23.511

26.153

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kgm to ft. lb1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

0

72.3

144.7

217.0

289.3

361.7

434.0

506.3

578.6

651.0

723.3

795.6

868.0

940.3

1012.6

7.2

79.6

151.9

224.2

296.6

368.9

441.2

513.5

585.9

658.2

730.5

802.9

875.2

947.5

1019.9

14.5

86.8

159.1

231.5

303.8

376.1

448.5

520.8

593.1

665.4

737.8

810.1

882.4

954.8

1027.1

21.7

94.0

166.4

238.7

311.0

383.4

455.7

528.0

600.3

672.7

745.0

817.3

889.7

962.0

1034.3

28.9

101.3

173.6

245.9

318.3

390.6

462.9

535.2

607.6

679.9

752.2

824.6

896.9

969.2

1041.5

36.2

108.5

180.8

253.2

325.5

397.8

470.2

542.5

614.8

687.1

759.5

831.8

904.1

976.5

1048.8

43.4

115.7

188.1

260.4

332.7

405.1

477.4

549.7

622.0

694.4

766.7

839.0

911.4

983.7

1056.0

50.6

123.0

195.3

267.6

340.0

412.3

484.6

556.9

629.3

701.6

773.9

846.3

918.6

990.9

1063.2

57.9

130.2

202.5

274.9

347.2

419.5

491.8

564.2

636.5

708.8

781.2

853.5

925.8

998.2

1070.5

65.1

137.4

209.8

282.1

354.4

426.8

499.1

571.4

643.7

716.1

788.4

860.7

933.1

1005.4

1077.7

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kg/cm2 to lb/in2

1kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

0

142.2

284.5

426.7

568.9

711.2

853.4

995.6

1138

1280

1422

1565

1707

1849

1991

14.2

156.5

298.7

440.9

583.2

725.4

867.6

1010

1152

1294

1437

1579

1721

1863

2005

28.4

170.7

312.9

455.1

597.4

739.6

881.8

1024

1166

1309

1451

1593

1735

1877

2020

42.7

184.9

327.1

469.4

611.6

753.8

896.1

1038

1181

1323

1465

1607

1749

1892

2034

56.9

199.1

341.4

483.6

625.8

768.1

910.3

1053

1195

1337

1479

1621

1764

1906

2048

71.1

213.4

355.6

497.8

640.1

782.3

924.5

1067

1209

1351

1493

1636

1778

1920

2062

85.3

227.6

369.8

512.0

654.3

796.5

938.7

1081

1223

1365

1508

1650

1792

1934

2077

99.6

241.8

384.0

526.3

668.5

810.7

953.0

1095

1237

1380

1522

1664

1806

1949

2091

113.8

256.0

398.3

540.5

682.7

825.0

967.2

1109

1252

1394

1536

1678

1821

1963

2105

128.0

270.2

412.5

554.7

696.9

839.2

981.4

1124

1266

1408

1550

1693

1835

1977

2119

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Temperature

Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-

tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn of figures.

These figures refer to the temperature in either Fahrenheit or Centigrade degrees.

If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of

Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of

Centigrade values, and read the corresponding Fahrenheit temperature on the right.

1°C = 33.8°F

°C °F °C °F °C °F °C °F

–40.4

–37.2

–34.4

–31.7

–28.9

–28.3 –27.8

–27.2

–26.7

–26.1

–25.6

–25.0

–40

–35

–30

–25

–20

–19 –18

–17

–16

–15

–14

–13

–40.0

–31.0

–22.0

–13.0

–4.0

–2.2 –0.4

1.4

3.2

5.0

6.8

8.6

–11.7

–11.1

–10.6

–10.0

–9.4

–8.9 –8.3

–7.8

–7.2

–6.7

–6.1

–5.6

11

12

13

14

15

1617

18

19

20

21

22

51.8

53.6

55.4

57.2

59.0

60.862.6

64.4

66.2

68.0

69.8

71.6

7.8

8.3

8.9

9.4

10.0

10.611.1

11.7

12.2

12.8

13.3

13.9

46

47

48

49

50

5152

53

54

55

56

57

114.8

116.6

118.4

120.2

122.0

123.8125.6

127.4

129.2

131.0

132.8

134.6

27.2

27.8

28.3

28.9

29.4

30.030.6

31.1

31.7

32.2

32.8

33.3

81

82

83

84

85

8687

88

89

90

91

92

117.8

179.6

181.4

183.2

185.0

186.8188.6

190.4

192.2

194.0

195.8

197.6

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FOREWORD UNITS

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).

As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:

N {kg}

Nm {kgm}

MPa {kg/cm2}

kPa {mmH2O}

kPa {mmHg}

kW/rpm {HP/rpm}

g/kWh {g/HPh}

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01 GENERAL

Specification Dimension DrawingsPC200-7, PC200LC-7 . . . . . . . . . . . 01-2PC220-7, PC220LC-7 . . . . . . . . . . . 01-4

SpecificationsPC200-7, PC200LC-7 . . . . . . . . . . . 01-6PC220-7, PC220LC-7 . . . . . . . . . . . 01-8

Weight TablePC200-7, PC200LC-7 . . . . . . . . . . 01-10PC220-7, PC220LC-7 . . . . . . . . . . 01-12

Fuel, Coolant, And Lubricants. . . . . . . 01-14

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GENERAL SPECIFICATION DIMENSION DRAWINGS

12DIMENSIONS

Item Unit PC200-7 PC200LC-7

A Overall length mm 9,425 9,425

B Overall height mm 3,000 3,000

C Overall width mm 2,800 3,080

D Track shoe width mm 600 700

E Height of cab mm 3,000 3,000

F Tail swing radius mm 2,750 2,750G Track overall length mm 4,080 4,450

H Length of track on ground mm 3,270 3,640

Min. ground clearance mm 440 440

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PC220-7, PC220LC-7

DIMENSIONS

WORKING RANGES

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12DIMENSIONS

Item Unit PC220-7 PC220LC-7

A Overall length mm 9,885 9,885

B Overall height mm 3,160 3,160

C Overall width mm 2,980 3,280

D Track shoe width mm 600 700

E Height of cab mm 3,015 3,015

F Tail swing radius mm 2,940 2,940

G Track overall length mm 4,250 4,640

H Length of track on ground mm 3,460 3,845

Min. ground clearance mm 440 400

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GENERAL SPECIFICATIONS

SPECIFICATIONS

PC200-7, PC200LC-7

Machine model PC200-7 PC200LC-7

Serial Number 200001 and up

Bucket capacity m³ 0.8 0.8

Operating weight kg 19,300 20,700

P e r f o

r m a n c e

W o r k i n g r a

n g e s

Max. digging depth

Max. vertical wall depth

Max. digging reach

Max. reach at ground level

Max. digging height

Max. dumping height

mm

mm

mm

mm

mm

mm

6,620

5,980

9,875

9,700

10,000

7,110

6,620

5,980

9,875

9,700

10,000

7,110

Max. digging force

(using power max. function)

Swing speed

Swing max. slope angle

Travel speed

Gradeability

Ground pressure

kN {kg}

rpm

deg.

km/h

deg.

kPa {kg/cm²}

138.3 {14,100}

(149.1 {15,200})

12.420

Lo: 3.0 ( Mi: 4.1)

Hi: 5.5

35

44 1 {0 45}

138.3 {14,100}

(149.1 {15,200})

12.420

Lo: 3.0 ( Mi: 4.1)

Hi: 5.5

35

36 3 {0 37}

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12



E n g i n

e

Model

Type

No. of cylinders - bore x stroke

Piston displacement

mm

l ll l {cc}

SAA6D102E-2-A

4-cycle, water-cooled, in-line, vertical, direct

injection, with turbo charger

6 - 102 x 120

5.883 {5,883}

P e r f o r m a

n c e

Flywheel horsepower

Max. torque

Max. speed at no load

Min. speed at no load

Min. fuel consumption

kW/rpm {HP/rpm}

Nm/rpm {kgm/rpm}

rpm

rpm

g/kWh {g/HPh}

106.7/1,950 {143/1,950}

610.0/1,500 {62.2/1,500}

2,150

1,030

215 {160}

Starting motor

Alternator

Battery

24V, 4.5 kW

24V, 35 A

12V, 110 Ah x 2

Radiator core type Corrugated CWX-4

U n d e r -

c a r r i a g e

Carrier roller 2 on each side

Track roller 7 on each side 9 on each side

Track shoe

Assembly-type triple

grouser, 45 on each

side


grouser, 49 on each

side

c HPV95+95, variable displacement


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PC220-7, PC220LC-7

Machine model PC220-7 PC220LC-7 Serial Number 60001 and up

Bucket capacity m³ 1.0 1.0

Operating weight kg 22,700 24,130

P e r f o

r m a n c e

W o r k i n g r a

n g e s

Max. digging depth

Max. vertical wall depth

Max. digging reach

Max. reach at ground level

Max. digging height

Max. dumping height

mm

mm

mm

mm

mm

mm

6,920

6,010

10,180

10,020

10,000

7,035

6,920

6,010

10,180

10,020

10,000

7,035

Max. digging force

(using power max. function)

Swing speed

Swing max. slope angle

Travel speed

Gradeability

Ground pressure

kN {kg}

rpm

deg.

km/h

deg.

kPa {kg/cm²}

158.9 {16,200}

(171.6 {17,500})

11.725

Lo: 3.1 ( Mi: 4.2)

Hi: 5.5

35

50 0 {0 51}

158.9 {16,200}

(171.6 {17,500})

11.725

Lo: 3.1 ( Mi: 4.2)

Hi: 5.5

35

41 2 {0 42}


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E n g i n e

Model

Type

No. of cylinders - bore x stroke

Piston displacement

mm

l ll l {cc}

SAA6D102E-2-C

4-cycle, water-cooled, in-line, vertical, direct

injection, with turbo charger

6 - 102 x 120

5.883 {5,883}

P e r f o r m a n c

e Flywheel horsepower

Max. torque

Max. speed at no load

Min. speed at no load

Min. fuel consumption

kW/rpm {HP/rpm}

Nm/rpm {kgm/rpm}

rpm

rpm

g/kWh {g/HPh}

125/2,000 {167/2,000}

686/1,500 {70/1,500}

2,260

1,060

212 {153}

Starting motor

Alternator

Battery

24V, 4.5 kW

24V, 35 A

12V, 110 Ah x 2

Radiator core type Corrugated CF19-5

U n d e r -

c a r r i a g e

Carrier roller 2 on each side

Track roller 8 on each side 10 on each side

Track shoe


grouser, 47 on each

side


grouser, 51 on each

side

GENERAL WEIGHT TABLE

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12WEIGHT TABLE

PC200-7, PC200LC-7

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

Unit: kg


Serial Number 200001 and up 200001 and up

Engine assembly

• Engine

• Damper

• Hydraulic pump

749

598

6

145

749

598

6

145

Radiator oil cooler assembly 110 110

Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123

Fuel tank (excluding fuel) 121 121

Revolving frame 1,729 1,729

Operator’s cab 278 278

Operator’s seat 35 35

Counterweight 3,735 3,735

Swing machinery 160 160


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12

Unit: kg



Track shoe assembly

• Standard triple grouser shoe (600 mm)


• Wide triple grouser shoe (800 mm)

• Road liner (rubber pad type) (600 mm)

1,215 x 2

1,405 x 2

1,530 x 2

1,470 x 2

1,325 x 2

1,530 x 2

1,670 x 2

1,600 x 2

Boom assembly 1,408 1,408

Arm assembly 653 653

Bucket assembly 628 628

Boom cylinder assembly 172 x 2 172 x 2


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PC220-7, PC220LC-7

Unit: kg



Engine assembly

• Engine

• Damper

• Hydraulic pump

749

598

6

145

749

598

6

145

Radiator oil cooler assembly 119 119

Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123

Fuel tank (excluding fuel) 121 121

Revolving frame 2,048 2,048Operator’s cab 278 278

Operator’s seat 35 35

Counterweight 5,056 5,056

Swing machinery 237 237

Control valve 263 263

Swing motor 60 60


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12

Unit: kg



Track shoe assembly



• Wide triple grouser shoe (800 mm)

• Road liner (rubber pad type) (600 mm)

1,340 x 2

1,470 x 2

1,600 x 2

1,535 x 2

1,455 x 2

1,595 x 2

1,735 x 2

1,665 x 2

Boom assembly 1,825 1,825

Arm assembly 1,213 1,213

Bucket assembly 722 722

Boom cylinder assembly 195 x 2 195 x 2

GENERAL FUEL, COOLANT, AND LUBRICANTs

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GENERAL FUEL, COOLANT, AND LUBRICANTs

12FUEL, COOLANT, AND LUBRICANTS

RESERVOIRKINDOF

FLUID

AMBIENT TEMPERATURE CAPACITY (l ll l )

-22 -4 14 32 50 68 86 104°F-30 -20 -10 0 10 20 30 40°C

Specified Refill

Engine oil pan 26.3 24

Engine

oil

SAE 30

SAE 10W

SAE 10W-30

SAE 15W-40

Damper case 0.75 —

Swing machinery case 6.6 6.6

Final drive case (each side) SAE 30 4.7 4.5

Idler (1 each) 0.07-0.08 0.07-0.08

Track roller (1 each) 0.19-0.20 0.19-0.20

Carrier roller (1 each) 0.075-0.085 0.075-0.085

SAE 10W

SAE 10W 30

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10 STRUCTURE, FUNCTION, AND

MAINTENANCE STANDARD

1252Engine Related Parts . . . . . . . . . . . . . .10-2Radiator Oil Cooler • Aftercooler . . .10-3Power Train . . . . . . . . . . . . . . . . . . . . .10-4

Final Drive . . . . . . . . . . . . . . . . . . . . . .10-6Swing Machinery

PC200-7, PC200LC-7. . . . . . . . . . . .10-8PC220-7, PC220LC-7. . . . . . . . . . .10-10

Swing CirclePC200-7, PC200LC-7. . . . . . . . . . .10-12PC220-7, PC220LC-7. . . . . . . . . . .10-13

Track Frame • Recoil Spring . . . . . . .10-14Idler. . . . . . . . . . . . . . . . . . . . . . . . . . .10-16Carrier roller. . . . . . . . . . . . . . . . . . . .10-18Track roller . . . . . . . . . . . . . . . . . . . . .10-19Track Shoe . . . . . . . . . . . . . . . . . . . . .10-20Hydraulic Equipment Layout Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24Hydraulic Tank . . . . . . . . . . . . . . . . . .10-26

Hydraulic CylinderPC200-7, PC200LC-7 . . . . . . . . . 10-134PC220-7, PC220LC-7 . . . . . . . . . 10-136

Work Equipment. . . . . . . . . . . . . . . 10-138Air Conditioner . . . . . . . . . . . . . . . . 10-146Engine Control . . . . . . . . . . . . . . . . 10-147Electronic Control System . . . . . . . 10-155Multi Monitor System . . . . . . . . . . 10-1807-Segment Monitor System . . . . . 10-202Sensor . . . . . . . . . . . . . . . . . . . . . . . 10-209

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

RADIATOR OIL COOLER •

AFTERCOOLER

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, ,

12

RADIATOR • OIL COOLER • AFTERCOOLER

SWP08671

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN

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12

POWER TRAIN

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE

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12

FINAL DRIVE

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE

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12

1. Level plug

2. Drain plug

3. Cover

4. No. 2 sun gear (No. of teeth: 21)

5. No. 1 sun gear (No. of teeth: 10)

4. No. 1 planetary carrier

6. Cover


8. Sprocket

9. Floating seal

10. Travel motor

11. Hub12. No. 2 planetary gear (No. of teeth: 36)

13. Ring gear (No. of teeth: 95)

14. No. 1 planetary gear (No. of teeth: 42)

SPECIFICATIONS

Reduction ratio:

00.57121

9521

10

9510−=+

+×

+−

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY

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12

SWING MACHINERYPC200-7, PC200LC-7


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12

1. Swing pinion (No. of teeth: 15)2. Spacer

3. Case


5. No. 2 sun gear

6. Ring gear

7. No. 1 sun gear

8. Swing motor

9. Oil level gauge

10. No. 1 planetary gear11. No. 1 planetary carrier

12. No. 2 planetary gear

13. Drain plug

SPECIFICATIONS

Reduction ratio:

627.1818

5818

17

5817=

+×

+


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PC220-7, PC220LC-7


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12

1. Swing pinion (No. of teeth: 13)2. Spacer

3. Case


5. No. 2 sun gear

6. Ring gear

7. No. 1 sun gear

8. Swing motor

9. Oil level gauge

10. No. 1 planetary gear11. No. 1 planetary carrier

12. No. 2 planetary gear

13. Drain plug

SPECIFICATIONS

Reduction ratio:

689.2214

5814

17

5817=

+×

+

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE

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SWING CIRCLEPC200-7, PC200LC-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE

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12

PC220-7, PC220LC-7

S*P09097

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING

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12

TRACK FRAME • RECOIL SPRING


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12

Standard shoe

Model

ItemPC200-7 PC200LC-7 PC220-7 PC220LC-7

Shoe width 600 mm 700 mm 600 mm 700 mm

Link pitch 190 mm 190 mm 190 mm 190 mm

No. on track (one side) 45 (pieces) 49 (pieces) 47 (pieces) 51 (pieces)


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12

IDLER

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12

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12

CARRIER ROLLER


12

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12

TRACK ROLLER

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE

12

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12

TRACK SHOE

TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE


12

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12

Unit: mm

No

.Check item Criteria Remedy

1 Link pitchStandard size Repair limit

Reverse

or

replace

190.25 194.25

2 Bushing outside diameterStandard size

When turned

Normal load Impact load

59.3 — 54.3

3 Link heightStandard size Repair limit

Repair or

replace

105 97

4Thickness of link metal

(bushing press-fitting portion)28.5 20.5

5

Shoe bolt pitch

160.4

6 62

7 18

8

Link

Inside width 84.8

9 Overall width 45.4


12

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12

Unit: mm

No. Check item Criteria Remedy

20Shoe bolt

a. Regular link

Tightening torque

(Nm {kgm})

Additional tightening

angle (deg.)

Retighten

Triple shoe 490 ± 49 {50 ± 5}

120 ± 10

Road liner

(Rubber pad type)

549 ± 59

{56 ± 6}—

b. Master link

Tightening torque

(Nm {kgm})

Additional tightening

angle (deg.)

Lower limit torque

(Nm {kgm})

— — —

No. of shoes (each side)PC200-7: 45, PC200LC-7: 49

PC220-7: 47, PC220LC-7: 51—

21Interference between

bushing and link

Standard

size

Tolerance Standard

interferenceShaft Hole

59+0.304

+0.394

+0.074

00.320 - 0.434

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HYDRAULIC EQUIPMENT LAYOUT

DRAWING

12

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HYDRAULIC EQUIPMENT LAYOUT DRAWING

1. Bucket cylinder

2. Arm cylinder

3. Boom cylinder

4. Hydraulic tank

5. Hydraulic filter

6. R.H. travel motor

7. Swing motor

8. Hydraulic pump

9. Control valve

10. Oil cooler

11. L.H. travel motor

12. Multi-pattern selector valve

13. L.H. PPC valve

14. Safety lever (electric type)

15. Center swivel joint

16. R.H. PPC valve

17. Travel PPC valve

18. Attachment circuit selector valve


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Millimeters to Inches

1 mm = 0.03937 in

Kilogram to Pound

1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

0.394

0.787

1.181

1.575

1.969

2.362

2.756

3.150

3.543

0.039

0.433

0.827

1.220

1.614

2.008

2.402

2.795

3.189

3.583

0.079

0.472

0.866

1.260

1.654

2.047

2.441

2.835

3.228

3.622

0.118

0.512

0.906

1.299

1.693

2.087

2.480

2.874

3.268

3.661

0.157

0.551

0.945

1.339

1.732

2.126

2.520

2.913

3.307

3.701

0.197

0.591

0.984

1.378

1.772

2.165

2.559

2.953

3.346

3.740

0.236

0.630

1.024

1.417

1.811

2.205

2.598

2.992

3.386

3.780

0.276

0.669

1.063

1.457

1.850

2.244

2.638

3.032

3.425

3.819

0.315

0.709

1.102

1.496

1.890

2.283

2.677

3.071

3.465

3.858

0.354

0.748

1.142

1.536

1.929

2.323

2.717

3.110

3.504

3.898

0 1 2 3 4 5 6 7 8 9


HYDRAULIC EQUIPMENT LAYOUTDRAWING

12

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANK

12HYDRAULIC TANK

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HYDRAULIC TANK

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

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HYDRAULIC PUMP

HPV95 + 95


12

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Function

• The rotation and torque transmitted to the

pump shaft are converted into hydraulic

• Rocker cam (4) has flat surface A, and shoe

(5) is always pressed against this surface


12

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Operation

1) Operation of pump

i Cylinder block (7) rotates together withshaft (1), and shoe (5) slides on flat surface

A.

When this happens, rocker cam (4) moves

along cylindrical surface B, so angle αbetween center line X of rocker cam (4) and

the axial direction of cylinder block (7)

changes. (Angle α is called the swash plate

angle.)ii Center line X of rocker cam (4) maintains

swash plate angle α in relation to the axialdirection of cylinder block (7), and flat sur-

face A moves as a cam in relation to shoe

(5).

In this way, piston (6) slides on the inside of

cylinder block (7), so a difference between

volumes E and F is created inside cylinder

block (7). The suction and discharge is car-

ried out by this difference F - E.

In other words, when cylinder block (7)

rotates and the volume of chamber E

becomes smaller, the oil is discharged dur-

ing that stroke. On the other hand, the vol-

ume of chamber F becomes larger, and as

the volume becomes bigger the oil is


122) Control of discharge amount

If th h l t l b l

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• If the swash plate angle α becomes larger,the difference between volumes E and F

becomes larger and discharge amount Q

increases.

• Swash plate angle α is changed by servopiston (12).

• Servo piston (12) moves in a reciprocal

movement (↔) according to the signalpressure from the PC and LS valves. This

straight line movement is transmitted

through rod (13) to rocker cam (4), and

rocker cam (4), which is supported by the

cylindrical surface to cradle (2), slides in a

rotating movement in direction of arrow.

• With servo piston (12), the area receiving

the pressure is different on the left and

the right, so main pump discharge pres-

sure (self pressure) PP is always brought

to the chamber receiving the pressure at

the small diameter piston end.

• Output pressure Pen of the LS valve is

brought to the chamber receiving thepressure at the large diameter end. The

relationship in the size of pressure PP at

the small diameter piston end and pres-

sure Pen at the large diameter end, and

the ratio between the area receiving the

pressure of the small diameter piston and

the large diameter piston controls the


12

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LS VALVE

1. Plug

2. Locknut

3. Sleeve4. Spring

5. Seat

6. Spool

7. Piston

8. Sleeve

PP : Pump port

PDP : Drain port

PLP : LS control pressure output portPLS : LS pressure input port

PPL : PC control pressure input port

PSIG : LS mode selection pilot port


12Function

(1) LS valve

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(1) LS valve

The LS valve detects the load and controls the

discharge amount.

This valve controls main pump discharge

amount Q according to differential pressure∆PLS (=PP - PLS) [called the LS differentialpressure] (the difference between main pump

pressure PP and control valve outlet port

pressure PLS).

Main pump pressure PP, pressure PLS {called

the LS pressure} coming from the control

valve output, and pressure Psig {called the

LS selector pressure} from the proportional

solenoid valve enter this valve. The relation-

ship between discharge amount Q and differ-

ential pressure ∆PLS, (the difference betweenmain pump pressure PP and LS pressure

PLS) (= PP - PLS) changes as shown in the

diagram at the right according to LS pressure

selector current isig of the LS-EPC valve.

When isig changes between 0 and 1A, the set

pressure of the spring changes according tothis, and the selector point for the pump dis-

charge amount changes at the rated central

valve between 0.69 ↔ 2.2 MPa {7 ↔ 22 kg/ cm²}.

(2) PC valve

When the pump discharge pressure PP1


12OPERATION

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SDP08884


12

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SDP08885

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12

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SDP08887


12

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12

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SDP08889


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• Port C of the PC valve is connected to port E

of the LS valve (see (1) LS valve). Self pres-

sure PP1 enters port B and the small diame-

ter end of servo piston (9), and other pump

pressure PP2 enters port A.

• When pump pressures PP1 and PP2 are

small, spool (3) is on the left. At this point,

port C and D are connected, and the pressureentering the LS valve becomes drain pressure

PT. If port E and port G of the LS valve are

connected (see (1) LS valve), the pressure

entering the large diameter end of the piston

from port J becomes drain pressure PT, and

servo piston (9) moves to the right. In this

way, the pump discharge amount moves in

the direction of increase.

• As servo piston (9) moves further, springs (4)

and (6) expand and the spring force becomes

weaker. When the spring force becomes

weaker, spool (3) moves to the right, so the

connection between port C and port D is cut,

and the pump discharge pressure ports B and

C are connected. As a result, the pressure at

C i d h h l


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• The relation of average pump pressure

(PP1 + PP2)/2 and the position of servo

piston (9) forms a bent line because of

the double-spring effect of springs (4)

and (6). The relationship between aver-

age pump pressure (PP1 + PP2)/2 and

pump discharge amount Q is shown in

the figure at the right.

• If command voltage X sent to PC-EPC

valve solenoid (1) increases further, the

relationship between average pump

pressure (PP1 + PP2)/2, and pump dis-

charge amount Q is proportional to the

pushing force of the PC-EPC valve sole-

noid and moves in parallel. In other

words, the pushing force of PC-EPCsolenoid (1) is added to the force push-

ing to the left because of the pump pres-

sure applied to the spool (3), so the

relationship between the average pump

pressure (PP1 + PP2)/2 and Q moves

from ➀ to ➁ in accordance with the

increase in X.


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12

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12

LS(PC)-EPC VALVE

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LS(PC)-EPC VALVE


12O

FUNCTION

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FUNCTION

• The EPC valve consists of the proportional

solenoid portion and the hydraulic valve

portion.

• When it receives signal current i from the

pump controller, it generates the EPC out-

put pressure in proportion to the size of the

signal, and outputs it to the LS valve.

OPERATION

1. When signal current is 0 (coil deener-

gized)


2. When signal current is very small (coil

energized)

• When a very small signal current flows to

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• When a very small signal current flows to

coil (5), coil (5) is energized, and a propul-

sion force is generated which pushes

plunger (6) to the left.• Push pin (4) pushes spool (2) to the left,

and pressurized oil flows from port PEPC

to port PSIG(PM).

• When the pressure at port PSIG(PM) rises

and the load of spring (3) + the force acting

on surface a of spool (2) becomes greater

than the propulsion force of plunger (6),

spool (2) is pushed to the right. The circuit

between port PEPC and port PSIG(PM) is

shut off, and at the same time, port

PSIG(PM) and port PT are connected.

• As a result, spool (2) is moved up or down

until the propulsion force of plunger (6) is

balanced with the load of spring (3) + pres-

sure of port PSIG(PM).

• Therefore, the circuit pressure between the

EPC valve and the LS valve is controlled inproportion to the size of the signal current.

3. When signal current is maximum (coil

energized)

• When the signal current flows to coil (5),

coil (5) is energized.

08891

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

12CONTROL VALVEPC200-7, PC200LC-7

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A1 : To bucket cylinder head

A2 : To left travel motor

A3 : To boom cylinder bottom

A4 : To swing motor

A5 : To right travel motor

A6 : To arm cylinder head

A-1 : To attachment

B1 : To bucket cylinder bottom

B2 : To left travel motor

B3 : To bottom cylinder head

P9 : From right travel PPC valve


P11 : From arm PPC valve


P-1 : From service PPC valve


BP1 : Boom RAISE PPC output pressure

BP5 : From attachment circuit selector solenoid

valve

PLS1: To rear pump control

1. 6-spool valve

2. Cover 1

3. Cover 2

4. Pump merge-divider valve

5. Back pressure valve

6. Boom lock valve

7. Service valve

OUTLINE

• This control valve consists of a 6-spool

valve (unit type), 1 service valves, a pump

merge-divider valve, a back pressure valve,

and a boom hydraulic drift prevention

valve.

• Since all the valves are assembled together

with connecting bolts and their passes are

connected to each other inside the assem-

bly, the assembly is small in size and easyto maintain.

• Since one spool of this control valve is

used for one work equipment unit, its struc-

ture is simple.


12

7-spool valve

(6-spool valve + 1 service valves)

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(1/9)


12

(2/9)

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S*P09099


12

(3/9)

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12

(4/9)

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(4/9)


12

(5/9)

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12

(6/9)

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Unit: mm

No Check item Criteria Remedy

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18 Relief spring

Standard size Repair limit

If damaged or

deformed, replace

spring

Free length x

Outside diameter

Installed

length

Installed

load

Free

length

Installed

load

30.7 x 9.6 25.9406.7 N

{41.5 kg}—

325.6 N

{33.2 kg}

19 Valve spring 24.3 x 8 19.569.6 N

{7.1 kg}—

55.7 N {5.7 kg}

20 Unload spring 31.5 x 10.2 26.970.6 N

{7.2 kg}—

56.4 N

{5.8 kg}

21Regeneration valve

spring31.5 x 10.3 19

6.2 N

{0.6 kg}—

4.9 N

{0.5 kg}

22 Piston return spring 48.1 x 10.8 2817.5 N

{1.8 kg}—

14.0 N {1.4 kg}


{8.1 kg}—

63.5 N

{6.5 kg}


{3 kg}

—23.5 N

{2.4 kg}


(7/9)

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BUCKET CONTROL VALVE

1. Safety-suction valve

2 Spool

SERVICE VALVE


8 Spool

(7/9)

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12

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(8/9)


Unit: mm


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y

21 Regeneration valve spring


If damaged ordeformed, replace

spring

Free length x

Outside diameter

Installed

length

Installed

load

Free

length

Installed

load

31.5 x 10.3 196.2 N

{0.6 kg}—

4.9 N

{0.5 kg}


{1.8 kg}—

14.0 N {1.4 kg}


{3 kg}—

23.5 N

{2.4 kg}

24 Load spring 30.4 x 16.7 27428.3 N

{43.7 kg}—

343 N

{35.0 kg}

25 Check valve spring 13.6 x 5.5 103.0 N

{0.3 kg}—

2.4 N {0.25 kg}


{3.6 kg}—

28.2 N

{2.9 kg}

27 Check valve spring 16.4 x 8.9 11.513.7 N

{1.4 kg}

—11.0 N

{1.1 kg}

28 Spool return spring 30.7 x 20.5 2350.0 N

{5.1 kg}—

40.0 N {4.1 kg}


12

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(9/9)


Unit: mm

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17 Valve spring



spring

Free length x

Outside diameter

Installed

length

Installed

load

Free

length

Installed

load

24.3 x 8 19.569.6 N

{7.1 kg}—

55.7 N

{5.7 kg}

18 Unload spring 31.5 x 10.2 2683.4 N

{8.5 kg}—

66.7 N

{6.8 kg}


{0.15 kg}—

1.2 N {0.12 kg}

20 Spool return spring 46.6 x 21.8 3.3156.8 N

{16.0 kg}—

125.5 N

{12.8 kg}


{18.1 kg}—

142.0 N

{14.5 kg}

22 Sequence valve spring 70.9 x 18.0 59199.8 N

{20.4 kg}—

160.0 N

{16.3 kg}


{1.1 kg}—

8.3 N

{0.8 kg}

24 Relief spring 34.7 x 10.4 32.3430.2 N

{43.9 kg)—

344.2 N

{35.1 kg}


CONTROL VALVEPC220-7, PC220LC-7

1 6 spool valve OUTLINE

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A1 : To bucket cylinder head

A2 : To left travel motor

A3 : To boom cylinder bottom

A4 : To swing motorA5 : To right travel motor

A6 : To arm cylinder head

A-1 : To attachment

B1 : To bucket cylinder bottom

B2 : To left travel motor

B3 : To bottom cylinder head

B4 T i t




P12 : From arm PPC valveP-1 : From service PPC valve


BP1 : Boom RAISE PPC output pressure

BP5 : From attachment circuit selector solenoid

valve

PLS1: To rear pump control

PLS2 T f t t l

1. 6-spool valve

2. Cover 1

3. Cover 24. Pump merge-divider valve

5. Back pressure valve

6. Boom lock valve

7. Service valve

OUTLINE

• This control valve consists of a 6-spoolvalve (unit type), 1 service valves, a pump

merge-divider valve, a back pressure valve,

and a boom hydraulic drift prevention

valve.

• Since all the valves are assembled together

with connecting bolts and their passes are

connected to each other inside the assem-

bly, the assembly is small in size and easy

to maintain.

• Since one spool of this control valve is

used for one work equipment unit, its struc-

ture is simple.


12

7-spool valve

(6-spool valve + 1 service valves)

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(1/9)


12

(2/9)

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S*P09102


12

(3/9)

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12

(4/9)

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S*P09104


12

(5/9)

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12

(6/9)

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S*P09105


Unit: mm


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18 Relief spring


If damaged or

deformed, replace

spring

Free length xOutside diameter

Installedlength

Installedload

Freelength

Installedload

34.7 x 10.4 32.3430.2 N

{43.9 kg}—

344.2 N

{35.1 kg}

19 Valve spring 10.45 x 7 4.83.1 N

{0.32 kg}—

2.5 N {0.26 kg}

20 Unload spring 31.5 x 10.2 26.970.6 N

{7.2 kg}—

56.4 N

{5.8 kg}

21Regeneration valve

spring31.5 x 10.3 19

6.2 N

{0.6 kg}—

4.9 N

{0.5 kg}


{1.8 kg}—

14.0 N {1.4 kg}


{8.1 kg}—

63.5 N

{6.5 kg}


{3 kg}—

23.5 N

{2.4 kg}


(7/9)

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BUCKET CONTROL VALVE


2 Spool

SERVICE VALVE


8 Spool

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12

(8/9)

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(8/9)


Unit: mm

N Ch k it C it i R d

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21 Regeneration valve spring



spring

Free length x

Outside diameter

Installed

length

Installed

load

Free

length

Installed

load

31.5 x 10.3 196.2 N

{0.6 kg}—

4.9 N

{0.5 kg}


{1.8 kg}—

14.0 N

{1.4 kg}

23 Piston return spring 36.9 x 11.1 28 29.4 N {3 kg}

— 23.5 N {2.4 kg}

24 Load spring 30.4 x 16.7 27428.3 N

{43.7 kg}—

343 N

{35.0 kg}


{0.3 kg}—

2.4 N

{0.25 kg}


{3.6 kg}—

28.2 N

{2.9 kg}


{1.4 kg}—

11.0 N {1.1 kg}


{5.1 kg}—

40.0 N

{4.1 kg}


12

(9/9)

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Unit: mm

No Check item Criteria Remedy

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17 Valve spring



spring

Free length x

Outside diameter

Installed

length

Installed

load

Free

length

Installed

load

10.45 x 7 4.83.1 N

{0.32 kg}—

2.5 N

{0.26 kg}

18 Unload spring 31.5 x 10.2 26.870.6 N

{7.2 kg}—

56.4 N

{5.8 kg}

19 Check valve spring 11.5 x 4.6 8.5 1.5 N {0.15 kg}

— 1.2 N {0.12 kg}


{16.0 kg}—

125.5 N

{12.8 kg}


{18.1 kg}—

142.0 N

{14.5 kg}

22 Sequence valve spring 70.9 x 18.0 59199.8 N

{20.4 kg}—

160.0 N

{16.3 kg}


{1.1 kg}—

8.3 N {0.8 kg}

24 Relief spring 34.7 x 10.4 32.3430.2 N

{43.9 kg)—

344.2 N

{35.1 kg}


MAIN RELIEF VALVE

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FUNCTION

• The relief valve set pressure is set to 2 stages.

1. Spring2. Poppet


12

VARIABLE PRESSURE COMPENSATION VALVE

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS

12

CLSS

OUTLINE OF CLSS

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Basic principle

1) Control of pump swash plate

• The pump swash plate angle (pump dis-

charge amount) is controlled so that LS dif

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charge amount) is controlled so that LS dif-

ferential pressure ∆PLS (the differencebetween pump pressure PP and control

valve outlet port LS pressure PLS) (load

pressure of actuator) is constant.

(LS pressure ∆PLS = Pump discharge pres-sure PP – LS pressure PLS)


2) Pressure compensation

• A pressure compensation valve is installed to

the outlet port side of the control valve to bal-

ance the load.

In this way, the flow of oil from the pump is

divided (compensated) in proportion to the

area of opening S1 and S2 of each valve.

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• When two actuators are operated together,this valve acts to make pressure difference ∆Pbetween the upstream (inlet port) and down-

stream ( outlet port) of the spool of each valve

the same regardless of the size of the load

(pressure).

p g

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE

SELF PRESSURE REDUCING VALVE

FUNCTION

• This value reduces the discharge pressure

f th i d li it t l

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of the main pump and supplies it as control

pressure for the solenoid valves, PPCvalves, etc..

OPERATION

1. When engine is stopped

• Puppet (11) is pressed by spring (12)

against the seat and port PR is not con-

nected to TS.

• Valve (14) is pressed by spring (13) against

the left side and port P2 is connected to PR.

• Valve (7) is pressed by spring (8) against

the left side and port P2 is not connected to

A2.

(See Fig. 1.)

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE

12

4. When abnormally high pressure is

generated

• If the PR pressure on the self-pressure

reducing valve rises high abnormally, ball

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reducing valve rises high abnormally, ball

(16) separates from the seat against theforce of spring (15) and the hydraulic oil

flows from output port PR to TS. Accord-

ingly, the PR pressure lowers. By this oper-

ation, the hydraulic devices (PPC valves,

solenoid valves, etc.) are protected from

abnormal pressure. (See Fig. 4.)

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR

12

SWING MOTOR

KMF125ABE-5

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12

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12

Operation of swing lock

1. When swing lock solenoid valve is deacti-

vated

When the swing lock solenoid valve is deacti-

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vated, the pressurized oil from the main pump isshut off and port B is connected to the tank cir-

cuit.

As a result, brake piston (7) is pushed down by

brake spring (1), discs (5) and plates (6) are

pushed together, and the brake is applied.

2. When swing lock solenoid valve is excited

Wh h i l k l id l i i d


12

RELIEF VALVE PORTION

1) Outline

The relief portion consists of check valves

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The relief portion consists of check valves

(2) and (3), shuttle valves (4) and (5), and

relief valve (1).

2. Function

When the swing is stopped, the outlet port

circuit of the motor from the control valve

is closed, but the motor continues to rotate

under inertia, so the pressure at the output

side of the motor becomes abnormally

high, and this may damage the motor.To prevent this, the abnormally high pres-

sure oil is relieved to port S from the outlet

port of the motor (high-pressure side) to

prevent any damage.

3. Operation

1) When starting swing

• When the swing control lever is operatedto swing right, the pressure oil from the

pump passes through the control valve and

is supplied to port MA. As a result, the

pressure at port MA rises, the starting

torque is generated in the motor, and the

motor starts to rotate The oil from the out-

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE

12

REVERSE PREVENTION VALVE

Operation diagram

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1. Valve body

2. Spool (MA side)

3. Spring (MA side)

4. Plug

5. Spool (MB side)

6. Spring (MB side)

7. Plug

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE

12

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Outline

This valve reduces the swing back genera-

tion in the swing body by the inertia of the

swing body, the backlash and rigidity of the

machinery system, and the compression of

the hydraulic oil when the swing is

stopped. This is effective in preventing

spillage of the load and reducing the cycle

time when stopping the swing (the posi-tioning ability is good and it is possible to

move swiftly to the next job.

Operation

1) When brake pressure is being gener-

ated at port MB

• Pressure MB passes through the notch and

goes to chamber d, spool (5) pushes spring

(6) according to the difference in area D1 >

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CENTER SWIVEL JOINT

12

CENTER SWIVEL JOINT

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

TRAVEL MOTOR

HMV110-2

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12

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OPERATION OF MOTOR

1) Motor swash plate angle at maximum

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SJP08742

OR

08893


12

2) Motor swash plate angle at minimum

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SJP08743

OR

08894


12

OPERATION OF PARKING BRAKE

1) When starting to travel

When the travel lever is operated, the pres-

i d il f th t t

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surized oil from the pump actuates coun-terbalance valve spool (19), opens the

circuit to the parking brake, and flows into

chamber A of the brake piston (12).

It overcomes the force of spring (11), and

pushes piston (12) to the left in the direc-

tion of the arrow.

When this happens, the force pushing plate

(13) and disc (14) together is lost, so plate

(13) and disc (14) separate and the brake isreleased.

1. When stopping travel

When the travel lever is placed in neutral,

counterbalance valve spool (19) returns to

SJP08744

OR

08895


OPERATION OF BRAKE VALVE

• The brake valve consists of a suction safety

valve (18A), counterbalance valve (18) in a

circuit as shown in the diagram on the

right. (Fig. 1)

• The function and operation of each compo-

nent is as given below

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nent is as given below.

1) Counterbalance valve, check valve

Function

• When traveling downhill, the weight of the

machine makes it try to travel faster than

the speed of the motor.

As a result, if the machine travels with the

engine at low speed, the motor will rotatewithout load and the machine will run

away, which is extremely dangerous.

To prevent this these valves act to make the

machine travel according to the engine

speed (pump discharge amount).

Operation when pressure oil is supplied

• When the travel lever is operated, the pres-surized oil from the control valve is sup-

plied to port PA. It pushes open suction

safety valve (18A) and flows from motor

inlet port MA to motor outlet port MB.

However, the motor outlet port is closed by

suction safety valve (18B) and spool (19),

SAP03482

OR

08897


Operation of brake when traveling downhill

• 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 S1

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will drop, and the pressure in chamber S1through orifices E1 and E2 will also drop.

When the pressure in chamber S1 drops

below the spool switching pressure, spool

(19) is returned to the left, in the direction of

the arrow by spring (20), and outlet port MB

is throttled.

As a result, the pressure at the outlet port

side rises, resistance is generated to the rota-

tion of the motor, and this prevents themachine from running away.

In other words, the spool moves to a position

where the pressure at the outlet port MB bal-

ances the pressure at the inlet port and the

force generated by the weight of the

machine. It throttles the outlet port circuit

and controls the travel speed according to

the amount of oil discharged from the pump.(Fig. 4)

2) Safety valve

Function

• When travel is stopped (or when traveling

downhill), the circuits at the inlet and outlet

ports of the motor are closed by the counter


2) When starting travel (or during normal

travel)

• When the travel

SM PC200-7 SEBM024300 s_n 200001 Up

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