Engine Control

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1.
2.
3.
4.
5.
6.
7.
8.
Hot water pickup piping

Air conditioner compressor
Refrigerant piping
Condenser
Receiver tank
Hot water return piping
Air conditioner unit
Duct
10-146
A. Fresh air
B. Recirculated air
C. Hot air/cold air
PC200-7
ENGINE CONTROL
ENGINE CONTROL
OUTLINE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Battery relay
Battery
Starting switch
Fuel control dial
Linkage
Starting motor
Engine throttle and pump controller
Fuel injection pump
Governor motor
PC200-7
The engine can be started and stopped with

only starting switch (3).
The engine throttle and pump controller(7)
reveives the signal of fuel control dial (4) and
transmits the drive signal to governor motor
(9) to control the governor lever angle of fuel
injection pump (8) and control the engine
speed.
10-147
ENGINE CONTROL
12
1. OPERATION OF SYSTEM
Starting engine
When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, and the starting motor
turns to start the engine.
When this happens, the engine throttle and
pump controller checks the signal from the
fuel control dial and sets the engine speed
to the speed set by the fuel control dial.
Engine speed control

The fuel control dial sends a signal to the
engine throttle and pump controller
according to the position of the dial. The
engine throttle and pump controller calculates the angle of the governor motor
according to this signal, and sends a signal
to drive the governor motor so that it is at
that angle.
When this happens, the operating angle of
the governor motor is detected by the
potentiometer, and feedback is sent to the
engine throttle and pump controller, so
that it can observe the operation of the
governor motor.
Stopping engine
When the starting switch is turned to the
STOP position, the engine throttle and
pump controller drives the governor motor
so that the governor lever is set to the NO
INJECTION position.
When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle and pump
controller itself drives the battery relay.
10-148
08903
08904
08905
PC200-7
ENGINE CONTROL
12
1. COMPONENT
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
The fuel control dial is installed under the
monitor panel, and a potentiometer is
installed under the knob. The potentiometer shaft is turned by turning the knob.
As the potentiometer shaft is turned, the
resistance of the variable resistor in the
potentiometer changes and a throttle signal is sent to the engine throttle and pump
controller.
The hatched area in the graph shown at
right is the abnormality detection area.
PC200-7
10-149
ENGINE CONTROL
Governor motor
1.
2.
3.
4.
5.
6.
7.
8.
Potentiometer
Cover
Shaft
Dust seal
Bearing
Motor
Gear
Connector
Function
The motor is turned according to the drive
signal from the engine throttle and pump
controller to control the governor lever of the
fuel injection pump.
This motor used as the motive power source
is a stepping motor.
10-150
A potentiometer for feedback is installed to

monitor the operation of the motor.
Revolution of the motor is transmitted
through the gear to the potentiometer.
Operation
While motor is stopped
Electric power is applied to both phases A
and B of the motor.
While motor is running
The engine throttle and pump controller supplies a pulse current to phases A and B, and
the motor revolves, synchronizing to the
pulse.
PC200-7
ENGINE CONTROL
Engine throttle and pump controller
10-152
PC200-7
ENGINE CONTROL
12
Input and output signals
CN-1
CN-2
Pin
Signal name
No.
1 Boom bottom pressure sensor
Input/
output
Input
CN-3
Pin
No.
1 NC
Signal name
Input/
output
Output
Input/
output
Input
Pin
Signal name
No.
1 VB (controller power)
R pump pressure sensor
Input
Swing emergency switch
Input
VIS (solenoid power)
Arm angle potentiometer
Input
NC
Input
SOL_COM (solenoid common gnd)
Signal GND
Input
232C_RxD
Input
Battery relay drive
Output
Abnormality in auto-greasing controller
Input
Overload sensor (ON/OFF)
Input
Governor motor A phase (+)
Output
Overload alarm valid switch
Input
LS-EPC
Output
NC
Input
Model selection 4
Input
Travel junction SOL
Output
Overload sensor (analog)
Input
Attachment circuit selector signal
Output
NC
Output
F boom pressure sensor
Input
NC
Output
Bucket CURL pressure SW
Boom angle potentiometer
Input
10
NC
Input
10
Boom RAISE pressure SW
Input
10
Signal GND
Input
11
NC
Output
11
VB (controller power)
Input
11
Knob SW
Input
12
CAN shield
12
VIS (solenoid power)
Input
12
NC
Input
13
Model selection 5
Input
13
13
Governor motor FB potentiometer
Input
14
232C_TxD
Output
14
KEY_SIG
14
Boom head pressure sensor
Input
15
NC
Input
15
Governor motor A phase (-)
Output
Output
15
NC
16
SENS_PWR
17
Key Switch (Terminal C)
Input
Input
Input
Input
16
Travel steering signal pressure SW
Input
16
PC-EPC
Output
17
Model selection 3
Input
17
Pump merge/divider solenoid
Output
Input
18
Relay drive signal for arm crane
Output
18
Heater relay drive
Output
18
NC
Input
19
NC
Output
19
Bucket DUMP pressure switch
Input
19
Throttle potentiometer
Input
20
NC
Input
20
Boom LOWER pressure switch
Input
Input
21
S_NET
Input/
output
21
GND (controller GND)
22
VIS (solenoid PWR)
CAN0_L
Input/
output
23
24
KEY_SIG
23
CAN1_L
Input/
output
25
Governor motor B phase (+)
26
Service flow adjustment EPC (1)
Output
24
Flash memory write permission signal
Input
27
Travel Hi/Lo selector solenoid
Output
28
2-stage relief solenoid
Output
25
NC
Input
29
Swing pressure switch
Input
26
NC
Input
30
Arm IN pressure switch
Input
27
Model selection 2
Input
31
28
NC
Input
32
29
GND (pulse GND)
33
30
NC
31
GND (S_NET GND)
20
NC
21
GND (analog GND)
22
POT_PWR
23
Key switch (terminal ACC)
24
Arm crane relay actuation observaInput

tion
Output
Input
22
Input
Output
34
NC
35
Governor motor B phase (-)

NC
Output
Output
32
CAN0_H
Input/
output
36
37
Swing parking brake solenoid
Output
33
CAN1_H
Input/
output
38
NC
Output
39
Travel pressure switch
Input
40
Arm OUT pressure switch
Input
34
PC200/220(LC)-7
Input
Input
GND (232C GND)
35
Service valve pressure switch
Input
36
NC
Input
37
Model selection switch 1
Input
38
Swing lock switch
Input
39
GND (pulse GND)
40
Engine speed sensor
Input
10-153
(10)
ELECTRONIC CONTROL SYSTEM
Control function
1
Engine/Pump composite control function
2
Pump/Valve control function
3
One-touch power maximizing function
4
Auto-deceleration function
5
Auto-warm-up/Overheat prevention function
Electronic control system

6
Swing control function
7
Travel control function
8
ATT flow control, circuit selector function (if equipped)
Self-diagnosis function
a For the self-diagnosis function, see "TROUBLE SHOOTING".
PC200/220(LC)-7
10-155
(11)
MACHINE CONTROL SYSTEM DIAGRAM
10-156
(4)
PC200/220(LC)-7
PC200/220(LC)-7
10-157
(11)
1. Engine and Pump control function
SJP08754
OR
08908
10-158
PC200-7
FUNCTION
The operator can set the work mode switch

on the monitor panel to mode A, E, or B (or
L) and select proper engine torque and
pump absorption torque according to the
type of work.
The engine throttle and pump controller
detects the speed of the engine governor set
with the fuel control dial and the actual
engine speed and controls them so that the
pump will absorb all the torque at each output point of the engine, according to the
pump absorption torque set in each mode.
: The L mode is on the multi-monitor specification machine only.
PC200/220(LC)-7
10-159
(4)
12
1) Control method in each mode
Mode A
Matching point in mode A: Rated speed
Model
Mode A
SJP08758
PC200-7, PC220-7
106.6 kW/1,900 rpm {143 HP/1,900 rpm}
OR
08912
If the pump load increases and the pressure

rises, the engine speed lowers.
At this time, the controller lowers the pump
discharge so that the engine speed will be
near the full output point. If the pressure lowers, the controller increases the pump discharge so that the engine speed will be near
the full output point.
By repeating these operations, the controller
constantly uses the engine near the full output point.
SJP08759
OR
08913
SJP08760
OR
08914
10-160
PC200/220(LC)-7
12
Mode E / Mode B / (Mode
Mode
Partial output point
L)
Digging
Breaker
Finishing
85%
75%
70%
Model
PC200-7, PC220-7
Mode E
123 HP / 1,750 RPM
Mode B
108 HP / 1,650 RPM
(Mode L)
99 HP / 1,800 RPM
At this time, the controller keeps the pump

absorption torque along the constant horsepower curve and lower the engine speed by
the composite control of the engine and
pump.
By this method, the engine is used in the low
fuel consumption area.
PC200/220(LC)-7
10-161
(4)
12
2) Function to control pump during
travel
If the machine travels in mode A, either of
engine speed and pump absorption torque
does not change.
If the machine travels in mode E or B, the
working mode does not change, but the
engine speed and pump absorption torque
rise to the same value as in mode A.
SJP08764
OR
08920
If the machine travels in mode L, the working mode and engine speed do not change,
but the pump absorption torque is
increased.
3) Function to control when emergency

pump drive switch is turned ON
Even if the controller or a sensor has a
trouble, the functions of the machine can
be secured with pump absorption torque
almost equivalent to mode E by turning on
emergency pump drive switch (10).
In this case, a constant current flows from
the battery to the EPC valve for PC and the
oil pressure is sensed by only the EPC
valve for PC.
10-162
PC200/220(LC)-7
12
2. Pump/Valve control function
SJP08765
OR
08921
Function
The machine is matched to various types of
work properly with the 2-stage relief function
to increase the digging force, etc.
PC200/220(LC)-7
10-163
(11)
12
1) LS control function
The change point (LS set differential pressure)
of the pump discharge in the LS valve is
changed by changing the output pressure
from the LS-EPC valve to the LS valve according to the operating condition of the actuator.
By this operation, the start-up time of the
pump discharge is optimized and the composite operation and fine control performance is improved.
2) Cut-off function
When the cut-off function is turned on, the
PC-EPC current is increased to near the maximum value.
By this operation, the flow rate in the relief
state is lowered to reduce fuel consumption.
Operating condition for turning on cut-off
function
08922
Condition
The average value of the front and rear

pressure sensors is above 27.9 MPa {285
kg/cm} and the one-touch power maximizing function is not turned on
The cut-off function does not work, however,

while the machine is travelling in mode A, the
arm crane operation, or swing lock switch is
turned on.
1. 2-stage relief function
The relief pressure in the normal work is 34.8
MPa {355 kg/cm}. If the 2-stage relief function is turned on, however, the relief pressure
rises to about 37.2 MPa {380 kg/cm}.
By this operation, the hydraulic force is
increased further.
Operating condition for turning on 2-stage
relief function
Condition
During travel
When swing lock switch is
turned on
When boom is lowered
When one-touch power maximizing function is turned on
When L mode is operated
10-164
(4)
Relief pressure
34.8 MPa
{355 kg/cm}
37.2 MPa
{380 kg/cm}
PC200/220(LC)-7
12
1) One-touch power maximizing function

When the operator needs more digging force
to dig up a large rock, etc., if the left knob
switch is pressed, the hydraulic force is
increased about 7% to increase the digging
force.
If the left knob switch is turned on in working
mode "A" or "E", each function is set automatically as shown below.
Working mode
A, E
10-166
(4)
Engine/Pump control
2-stage relief function
Operation time
Matching at rated output point
34.8 MPa {355 kg/cm}
37.2 MPa {380 kg/cm}
Automatically
reset at 8.5 sec
Software cut-off function

Cancel
PC200/220(LC)-7
12
4. Auto-deceleration function
SJP08767
OR
08924
FUNCTION
If the all control levers are set in NEUTRAL

while waiting for a dump truck or work, the
engine speed is lowered to the medium level
automatically to reduce the fuel consumption
and noise.
If any lever is operated, the engine speed
rises to the set level instantly.
PC200-7
10-167
12
OPERATION
WHEN CONTROL LEVERS ARE SET IN NEUTRAL
If all the control levers are set in NEUTRAL

while the engine speed is above the decelerator operation level (about 1,400 rpm), the
engine speed lowers instantly to the first
deceleration level about 100 rpm lower than
the set speed.
If 4 more seconds pass, the engine speed
lowers to the second deceleration level
(about 1,400 rpm) and keeps at that level until
any lever is operated again.
WHEN ANY CONTROL LEVER IS OPERATED
If any control lever is operated while the

engine speed is kept at the second deceleration level, the engine speed rises instantly to
the level set with the fuel control dial.
10-168
PC200-7
12
1. Auto-warm-up/Overheat prevention
function
SJP08768
OR
08925
FUNCTION
After the engine is started, if the engine coolant temperature is low, the engine speed is
raised automatically to warm up the engine.
If the engine coolant temperature rises too
high during work, the pump load is reduced
to prevent overheating.
PC200/220(LC)-7
10-169
(11)
12
1) Auto-warm-up function
After the engine is started, if the engine coolant temperature is low, the engine speed is
raised automatically to warm up the engine.
Operating condition (All)
Operated
Coolant temperature: Below 30C.

Engine speed: Max. 1,200 rpm
Engine speed: Max. 1,200 rpm
Resetting condition (Any one)
Reset
Coolant temperature: Above 30C

Auto
Auto-warm-up operation time: Min. 10 minutes
Manual
2) Overheat prevention function

If the engine coolant temperature rises too
high during work, the pump load and engine
speed are reduced to prevent overheating.
Operating condition
Operating condition
(11)
This function is turned on when the coolant

temperature rises above 95C.
Operation/Remedy
Resetting condition
Work mode: Any mode

Engine speed: Low idle
Monitor alarm lamp: Lights up
Alarm buzzer: Sounds
Coolant temperature: Below 105C

Fuel control dial: Return to low idle
position once.
Under above condition, controller
is set to condition before operation
of function. (Manual reset)
Work mode: Mode A, E, OR B

Engine speed: Keep as is.
Monitor alarm lamp: Lights up.
Lower pump discharge.
Resetting condition
Operation/Remedy
Operating condition
Operation/Remedy
Operating condition
10-170
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec.

or longer
Work mode: Mode A

Lower pump discharge.
Resetting condition
Operation/Remedy
Work mode: Travel

Lower travel speed.

of function. (Automatic reset)

Resetting condition

PC200/220(LC)-7
12
6. Swing control function
SJP08769
OR
08926
FUNCTION
The swing lock and swing holding brake functions are installed.
PC200/220(LC)-7
10-171
(11)
12
1) Swing lock and swing holding brake

functions
The swing lock function (manual) is used to
lock machine from swinging at any position.
The swing holding brake function (automatic)
is used to prevent hydraulic drift after the
machine stops swinging.
Swing lock switch and swing lock/holding
brake
Lock
Lock
Function
switch lamp
OFF
ON
OFF
ON
2) Quick hydraulic oil warm-up function

when swing lock switch is turned on
If swing lock switch (4) is turned on, the
pump-cut function is cancelled and the relief
pressure rises from 34.8 MPa {355 kg/cm} to
37.2 MPa {380 kg/cm}. If the work equipment
is relieved under this condition, the hydraulic
oil temperature rises quickly and the warm-up
time can be shortened.
Operation
Swing
holding
brake
If swing lever is set in neutral, swing brake operates in

about 5 sec. If swing lever is
operated, brake is released
and machine can swing
freely.
Swing
lock
Swing lock operates and

machine is locked from
swinging. Even if swing
lever is operated, swing lock
is not reset and machine
does not swing.
Operation of swing holding brake release

switch
If the controller, etc. has a problem, the swing
holding brake does not work normally, and
the machine cannot swing, the swing lock can
be reset with the swing holding brake release
switch.
Swing holding brake

release switch
Swing lock
switch
Swing brake
ON
(When control has
trouble)
ON
OFF
OFF
(When controller is
normal)
ON
OFF
Swing
Swing lock Swing lock Swing lock
holding
is turned is canis turned
brake is
on.
celed.
on.
turned on.
a Even if the swing holding brake release

switch is turned on, if the swing lock switch is
turned on, the swing brake is not released.
a If the swing lock is reset, swinging is stopped
by only the hydraulic brake of the safety
valve. Accordingly, if swinging is stopped on
a slope, the upper structure may drift hydraulically.
10-172
PC200/220(LC)-7
12
7. Travel control function
SJP08770
OR
08927
FUNCTION
The pumps are controlled and the travel

speed is changed manually or automatically,
to secure proper travel performance matched
to the type of work and jobsite during travel.
PC200/220(LC)-7
10-173
(11)
12
1) Pump control function during travel
If the machine travels in a work mode other
than mode A, the work mode and the engine
speed are kept as they are and the pump
absorption torque is increased.
a For details, see ENGINE/PUMP COMPOSITE
CONTROL FUNCTION.
2) Travel speed change function
i) Manual change with travel speed switch
If the travel speed switch is changed
between Lo, ( Mi), and Hi, the engine
throttle and pump controller controls the
pump capacity and motor capacity at each
gear speed as shown at right to change
the travel speed.
Travel speed
switch
Lo (Low
speed)
Pump capacity (%)

Motor capacity
Travel speed
(km/h)
Mi) (Middle Speed)
Hi (High
speed)
60
90
100
Max.
Max.
Min.
3.0
4.1
5.5
ii) Automatic change by engine speed

If the engine speed is lowered to 1,500
rpm or less with the fuel control dial during travel;
the travel speed does not change even if
the travel speed switch is changed from
Lo, ( Mi) to Hi,
the travel speed changes to Mi level automatically if the travel speed has been Hi.
iii) Automatic change by pump discharge
pressure
While the machine is traveling with the
travel speed switch at Hi, if the load is
increased because of an upslope ground,
etc. and the travel pressure keeps above
24.5 MPa {250 kg/cm} for 0.5 seconds, the
travel motor capacity is changed automatically and the travel speed is lowered (to
the Mi level) (The travel speed switch is
kept at Hi, however).
While the machine is travelling at Mi
level, if the load is reduced on a flat or
downslope ground, etc. and the travel
pressure keeps below 14.7 MPa {150 kg/
cm} for 0.5 seconds, the travel motor
capacity is changed automatically and the
travel speed is set to Hi again.
: The "Mi" mode is on the multi-monitor specification machine only.
10-174
(4)
08928
PC200/220(LC)-7
8. ATT flow control, circuit selector function (option)
FUNCTION
This function is available only with the ATT specification. The function acts as follows according to
the flow command and working mode from the
monitor.
1) It throttles the ATT PPC pressure and controls
the flow when the pedal is depressed fully.
2) In mode B and the other modes, it switches to
ATT single acting (B) or double acting (other
modes).
: The ATT flow control adjustment function is
on the multi-monitor specification machine
only.
PC200/220(LC)-7
10-175
(11)
9. System component parts

1) Engine revolution sensor
1.
2.
3.
4.
Sensor
Locknut
Wiring harness
Connector
FUNCTION
The engine revolution sensor is installed to

the ring gear of the engine flywheel. It electrically calculates the number of the gear teeth
which pass in front of it and transmits the
result to the engine throttle and pump controller.
A magnet is used to sense the gear teeth.
Each time a gear tooth passes in front of the
magnet, a current is generated.
10-176
PC200/220(LC)-7
12
2) PPC oil pressure switch
1. Plug
2. Switch
3. Connector
SPECIFICATIONS
Type of contacts: Normally open contacts
Operating (ON) pressure: 0.5 0.1 MPa
{5.0 1.0 kg/cm}
Resetting (OFF) Pressure: 0.3 0.5 MPa
{3.0 0.5 kg/cm}
FUNCTION
The junction block has 9 pressure switches,

which check the operating condition of each
actuator by the PPC pressure and transmit it
to the governor/pump controller.
PC200-7
10-177
12
3) Pump pressure sensor
1. Sensor
2. Connector
FUNCTION
The pump pressure sensor is installed to the

inlet circuit of the control valve. It converts
the pump discharge pressure into a voltage
and transmits it to the governor/pump controller.
OPERATION
The oil pressure applied from the pressure

intake part presses the diaphragm of the oil
pressure sensor, the diaphragm is deformed.
The gauge layer facing the diaphragm measures the deformation of the diaphragm by
the change of its resistance, then converts the
change of the resistance into a voltage and
transmits it to the amplifier (voltage amplifier).
The amplifier amplifies the received voltage
and transmits it to the governor/pump controller.
Relationship between pressure P (MPa {kg/
cm}) and output voltage (V) is as follows.
V = 0.08 [0.008] x P + 0.5
10-178
SJP08774
OR
08930
PC200-7

Engine Control

Uploaded by

Copyright:

Available Formats

Engine Control

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine Control

Uploaded by

Copyright:

Available Formats

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

Hot water pickup piping

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

The engine can be started and stopped with

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

Engine speed control

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

A potentiometer for feedback is installed to

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

Engine throttle and pump controller

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

R pump pressure sensor

Swing emergency switch

VIS (solenoid power)

Arm angle potentiometer

SOL_COM (solenoid common gnd)

Battery relay drive

Abnormality in auto-greasing controller

Overload sensor (ON/OFF)

Governor motor A phase (+)

Overload alarm valid switch

Travel junction SOL

Overload sensor (analog)

Attachment circuit selector signal

F boom pressure sensor

Bucket CURL pressure SW

Boom angle potentiometer

Boom RAISE pressure SW

VIS (solenoid power)

SOL_COM (solenoid common gnd)

Governor motor FB potentiometer

Boom head pressure sensor

Governor motor A phase (-)

Key Switch (Terminal C)

Travel steering signal pressure SW

Pump merge/divider solenoid

Relay drive signal for arm crane

Heater relay drive

Bucket DUMP pressure switch

Boom LOWER pressure switch

GND (controller GND)

VIS (solenoid PWR)

SOL_COM (solenoid common gnd)

Governor motor B phase (+)

Service flow adjustment EPC (1)

Flash memory write permission signal

Travel Hi/Lo selector solenoid

2-stage relief solenoid

Swing pressure switch

Arm IN pressure switch

GND (controller GND)

GND (controller GND)

GND (pulse GND)

GND (controller GND)

GND (S_NET GND)

GND (analog GND)

Key switch (terminal ACC)

Arm crane relay actuation observaInput