(SM) pw200 - pw220 - Preliminary - Version2

UEBM00190X
PW200, 220-7K
PRE-LIMINARY VERSION 2
MACHINE MODEL SERIAL NUMBER

PW200-7K 00 K40001 AND UP 00
PW220-7K 00 K40001 AND UP 00
00 00
00 00
00 00
• This shop manual may contain attachments and optional equipment that are not available in your area.
Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
© 2003
All Rights Reserved 00-1
Printed in Belgium 04-03
CONTENTS
No. of page
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . 10-1
20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . Will Be Issued Later
90 OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00
00-2
01 GENERAL
Specification Dimension Drawings

1 Piece Boom . . . . . . . . . . . . . . . . . . . . . . . . 01-2
2 Piece Boom . . . . . . . . . . . . . . . . . . . . . . . . 01-4
Working range
1 Piece Boom . . . . . . . . . . . . . . . . . . . . . . . . 01-6
2 Piece Boom . . . . . . . . . . . . . . . . . . . . . . . . 01-7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
Weight Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
Fuel, Coolant, And Lubricants. . . . . . . . . . . . . . . . 01-13
PW200/220-7K 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS
DIMENSIONS
1 PIECE BOOM
01-2 PW200/220-7K
GENERAL DIMENSIONS
PW200/220-7K 01-3
GENERAL DIMENSIONS
DIMENSIONS
2 PIECE BOOM
01-4 PW200/220-7K
GENERAL DIMENSIONS
PW200/220-7K 01-5
GENERAL WORKING RANGES
WORKING RANGES
1 PIECE BOOM
Arm length mm (Tt/In) 1800 2400 2900 3500

A Max. digging height 9467 9883 10003 10438
B Max. dumping height 6704 7057 7229 7612
C Max. digging depth 4791 5402 5917 6500
D Min. swing radius 3906 3201 3143 3184
E’ Max. digging reach ay GL 8867 9438 9875 10478
E Max. digging reach 9067 9651 10060 10642
01-6 PW200/220-7K
GENERAL WORKING RANGES
2 PIECE BOOM
Arm length mm (Tt/In) 1800 2400 2900 3500

A Max.digging height 9532 9842 10168 10434
B Max.dumping height 6670 6982 7298 7574
C Max digging depth 5166 5785 6285 6860
D Min. swing radius 2594 3121 2745 2866
E’ Max. digging reach ay GL 8599 9144 9634 10156
E Max. digging reach 8818 9348 9822 10338
PW200/220-7K 01-7
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
PW200-7, PW220-7
PW220-7
PW200-7 PW220-7
Machine model (Heavy duty
option)
Serial Number K40001 and up
Bucket capacity Arm size m³ 0.8 1.0
Operating weight (m) kg 19,900 20,400 21,160
1.8 138.3 {14,100}
2.4 (149.1 {15,200})
Max. digging force 138.3 {14,100}
kN {kg}
(using power max. function) 2.9 (149.1 {15,200})
163 {16,621}
3.5 (176 {17,947})
Performance
Swing speed rpm 12.4

Swing max. slope angle deg. 20
Cr : 0-2
Lo : 0-9
Travel speed km/h Hi : 10-35
(Germany :10-20)
deg. 35
Gradeability kPa {kg cm²} 36.3 {0.37}
Standard Tyre Width mm 10.00 - 20 11.00 - 20
01-8 PW200/220-7K
GENERAL SPECIFICATIONS
12
Machine model PW200-7 PW220-7
Model SAA6D102E-2-A
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Performance
Flywheel horsepower kW/rpm {HP/rpm} 106.7/1,950 {143/1,950}

Engine
Max. torque Nm/rpm {kgm/rpm} 610.0/1,500 {62.2/1,500}

Max. speed at no load rpm 2,150
Min. speed at no load rpm 1,030
Min. fuel consumption g/kWh {g/HPh} 215 {160}
Starting motor 24V, 4.5 kW

Alternator 24V, 45 A
Battery 12V, 110 Ah x 2
Radiator core type Triple Cooler
Hydraulic
Type x No. HPV95+95, variable displacement

pump
Delivery l/min Piston type: 214 x 2

Set pressure MPa (kg/cm²) Piston type: 37.2 {380}
Type x No. 1 Piece Boom 6-spool + 1 service spool type x 1 Hydraulic

Control
valve
Control
method 2 Piece Boom 7-spool + 1 service spool type x 1 Hydraulic
Travel motor A6VM140 HAXT/63W-V2B380A-SK, Piston type

Hydraulic
motor
(with counter balance valve): x 1

Swing motor KMF125ABE-5, Piston type
(with safety valve, holding brake): x 1
Type Boom Arm Bucket

Hydraulic system
Double act- Double acting Double acting

1 Piece Boom
ing piston piston piston
Inside diameter of cylinder mm 120 135 115

Diameter of piston rod mm 85 95 80
Stroke mm 1,334.5 1,490 1,120
Hydraulic culinder
Max. distance between pins mm 3,204.5 3,565 2,800

Min. distance between pins mm 1,870 2,075 1,680
Adjust Boom Arm Bucket
Type
Double L.H R.H
Double acting Double acting
acting
2 Pice Boom
Double act- piston piston

piston ing piston
Inside diameter of cylinder 185 135 135 115

mm
Diameter of piston rod 120 95 95 80
mm
Stroke 626 966 1,490 1,120
mm
Max. distance between pins 1,824 2,521 3,565 2,800
mm
Min. distance between pins 1,198 1,555 2,075 1,680
mm
Hrdraulic tank Closed box type
Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
PW200/220-7K 01-9
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
PW200-7, PW220-7
This weight table is for use when handling components or when transporting the machine.
Unit: kg
PW220-7
Machine model PW200-7 PW220-7 (Heavy duty
option)
Engine assembly 749
• Engine 598
• Damper 6
• Hydraulic pump 145
Radiator oil cooler assembly 114
Hydraulic tank, filter assembly (excluding hydraulic oil) 139
Fuel tank (excluding fuel) 121
Revolving frame 2,070
Operator’s cab 286
Mechanical 38
Operator’s seat
Air Suspension 42
Counterweight 3,740 3,740 4,500
Swing machinery 160
Control valve 263
Swing motor 60
Travel motor 75
Center swivel joint 95
01-10 PW200/220-7K
12
1 PIECE BOOM
Unit: kg
Boom assembly 1,408
1.8m 523.56
2.4m 556.11
Arm assembly
2.9m 643.25
3.5m 740
Bucket assembly 628
Left Hand 250.21
Lift cylinder
Right Hand 250.79
Arm cylinder assembly 215.4
1.8m
159.8
Bucket cylinder 2.4m
135.4
assembly 2.9m
135.4
3.5m
Link assembly 104.2
Boom pin 48 + 8 x 2 + 31 + 10 + 26
Arm pin 26
Bucket pin 20.6
Link pin 20.6
PW200/220-7K 01-11
12
2 PIECE BOOM
Unit: kg
1st Boom 656.48
Boom assembly
2nd Boom 1,050.07
1.8m 523.56
2.4m 556.11
Arm assembly
2.9m 643.25
3.5m 740
Bucket assembly 628
Left Hand 250.21
Lift cylinder
Right Hand 250.79
Adjust cylinder 362.57
Arm cylinder assembly 215.4
1.8m
159.8
Bucket cylinder 2.4m
135.4
assembly 2.9m
135.4
3.5m
Link assembly 104.2
1st Boom 26.5
Boom pin
2nd Boom 26
Arm pin 26
Bucket pin 20.6
Link pin 20.6
01-12 PW200/220-7K
GENERAL FUEL, COOLANT AND LUBRICANTS
12
FUEL, COOLANT AND LUBRICANTS
KIND AMBIENT TEMPERATURE CAPACITY (l)

RESERVOIR OF -22 -4 14 32 50 68 86 104°F
FLUID Specified Refill
-30 -20 -10 0 10 20 30 40°C
SAE 30
SAE 10W
Engine oil pan 26.3 26.3
SAE 10W-30
SAE 15W-40
Engine
Damper case oil SAE 30 0.75 —
Swing machinery case 6.6 6.6
SAE 10W
SAE 10W-30
Hydraulic system 190 166
SAE 15W-40
Hydraulic
H046-HM (H)
oil
Diesel ASTM D975 No. 2

Fuel tank 370 —
fuel ASTM D975A
No.1
Cooling system Water Add antifreeze 23 —

Wide 13.5 —
Front
Narrow 11.5 —
Axles
Wide Fuchs titan hydra 20W-40 14 —
Rear
Narrow Multi oil 12 —
Transmission BP traction 8 2.9 2.9
Front Fuchs titan hydra 20W-40 2.85 —

Hubs
Rear 2.0 —
★ For the H-046-HM, use the oil recommended by Komatsu.
PW200/220-7K 01-13
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
Engine Related Parts . . . . . . . . . . . . . . . . . . . . . 10-2 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
Radiator • Oil Cooler • Charge air cooler . . . . . . 10-3 CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Centre Swivel Joint . . . . . . . . . . . . . . . . . . . . . 10-82
Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Travel PPC Pedal . . . . . . . . . . . . . . . . . . . . . . 10-83
Swing Machinery . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Work Equipment • Swing PPC Valve . . . . . . . 10-86
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Service PPC Pedal . . . . . . . . . . . . . . . . . . . . . 10-91
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . 10-95
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Travel-Boom-Stabilizer Solenoid Valve . . . . . 10-97
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 Boom Safety Valve . . . . . . . . . . . . . . . . . . . . 10-105
Clutch Control Circuit . . . . . . . . . . . . . . . . . . . . 10-25 Hydraulic Cylinder (Boom-Arm-Bucket) . . . . 10-107
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Outrigger Cylinder. . . . . . . . . . . . . . . . . . . . . 10-110
Suspension Lock Cylinder . . . . . . . . . . . . . . . . 10-33 Dozer Cylinder . . . . . . . . . . . . . . . . . . . . . . . 10-112
Braking System . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Work Equipment . . . . . . . . . . . . . . . . . . . . . . 10-114
Brake/Steer Pump . . . . . . . . . . . . . . . . . . . . . . 10-37 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . 10-122
Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 Electrical Wiring Diagram . . . . . . . . . . . . . . . 10-123
Power Brake Valve . . . . . . . . . . . . . . . . . . . . . 10-39 Engine Control System . . . . . . . . . . . . . . . . . 10-124
Accumulator for Brake System . . . . . . . . . . . . 10-40 Electronic control System . . . . . . . . . . . . . . . 10-132
Steering Train . . . . . . . . . . . . . . . . . . . . . . . . . 10-41 Machine Monitor System . . . . . . . . . . . . . . . 10-158
Steerin Column . . . . . . . . . . . . . . . . . . . . . . . . 10-42 Overload Warning Device . . . . . . . . . . . . . . . 10-179
Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
Hydraulic Layout Drawing . . . . . . . . . . . . . . . . 10-44 1st Attachment Cicuit Hydraulic Perfomance
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . 10-48 (Main Valve Bypassed) . . . . . . . . . . . . . . . . . 10-184
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . 10-49 1st Attachment Cicuit Hydraulic Perfomance
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . 10-50 (Via Main Valve) . . . . . . . . . . . . . . . . . . . . . . 10-186
Pilot Pressure Control System . . . . . . . . . . . . . 10-67
PW200-7 10-1
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE RELATED PARTS
ENGINE RELATED PARTS
6
12
A
11
10
7
8
9
1. Drive plate 5. Damper assembly

2. Torsion spring 6. Muffler
3. Stopper pin 7. Rear engine mount OUTLINE
4. Friction plate 8. Front engine mount
• The damper assembly is a wet type.
9 Brake/Steer pump 10 Oil catcher tube
Oil capacity: 0.75l
11 Breather hose 12 Breather cap
10-2 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARDRADIATOR • OIL COOLER • CHARGE AIR COOLER
RADIATOR • OIL COOLER • CHARGE AIR COOLER
2 3
7 14
4
12
10
13
View A
6
1
4 3 2
8 11 5
1. Reservoir tank 6. Oil Cooler inlet tube 11. Charge Air Oil Cooler inlet hose
2. Oil cooler 7. Radiator outlet hose 12. Net
3. Radiator 8. Radiator inlet hose 13. Shroud
4. Charge Air Cooler 9. Fan 14. Radiator Cap
5. Oil Cooler outlet tube 10. Charge Air Oil Cooler outlet hose
SPECIFICATIONS:
Combination Cooler
Oil Coolant Air

Max working pressure. bar 10 0.6 1.38
Max working temperature oC
100 100 155
Cooler volume l. 8.5 8 12
PW200-7 10-3
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1 2 3
11 5
10 9 8
13
12
18 15 17 16 15 14
1. Centre swivel joint 10. Accumulators

2. Hydraulic tank 11. Power brake valve
3. Main pump 12. Swing circle
4. Engine 13. Swing motor / machinery
5. Gear pump 14. Rear axle
6. Priority valve 15. Propshaft
7. Main control valve 16. Travel motor
8. Travel speed solenoid valve 17. Transmission
9. Clutch control valve 18. Front axle
10-4 PW200-7
12
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
10-6 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
1 Swing circle inner race (No. of teeth: 92)

2 Ball
3 Swing circle outer race
a Inner race soft zone S position
b Outer race soft zone S position
SPECIFICATIONS
Reduction ratio:
18.627 X - 92 = -142.807
12
Amount of grease: 15.8l (G2 - LI)
No Check item Criteria Remedy

Axial clearance of bearing Standard clearance Clearance limit
4 Replace
(when mounted on chassis)
PW200-7 10-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY & MOTOR
SWING MACHINERY & MOTOR
1. Swing machinery
2. Swing motor
3. Swing pinnion
4. Dipstick
10-8 PW200-7
12
PW200-7 10-9
12
10-10 PW200-7
12
1 Swing pinion (No. of teeth: 12)

2) Spacer
3) Case
4) No. 2 planetary gear
5) No. 2 sun gear
6) Ring gear
7) No. 1 sun gear
8) Swing motor
9) Oil level gauge
10) No. 1 planetary gear
11) No. 1 planetary carrier
12) No. 2 planetary carrier
13) Drain plug
SPECIFICATIONS
Reduction ratio:
17 + 58 X 18 + 58 = 18.627
17 18
Unit: mm
No. Check item Criteria Remedy
Standard
Backlash between swing motor shaft and No. 1 sun Clearance limit
14 clearance
gear
0.18 ~ 0.28 —
Backlash between No. 1 sun gear and No. 1 plane-
15 0.15 ~ 0.51 1.00
tary gear
Backlash between No. 1 planetary gear and ring
16 0.17 ~ 0.60 1.10
gear
Backlash between No. 1 planetary carrier and No. 2
17 0.40 ~ 0.75 1.20 Replace
sun gear
Backlash between No. 2 sun gear and No. 2 plane-
18 0.16 ~ 0.55 1.00
tary gear
Backlash between No. 2 planetary gear and ring
19 0.17 ~ 0.60 1.10
gear
20 Backlash between coupling and swing pinion 0.08 ~ 0.25 —
21 Backlash between swing pinion and swing circle 0.00 ~ 1.21 2.00
22 Clearance between plate and coupling 0.57 ~ 1.09 —
Standard size Repair limit Apply hard
chrome plating,
23 Wear of swing pinion surface contacting with oil seal 0
145 — recondition, or
-0.100 replace
PW200-7 10-11
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMF125ABE-5
SPECIFICATIONS
B From swing lock solenoid valve PW200-7 PW220-7

S From control valve Model KMF125ABE-5
T To tank Theoretical displacement 125.0 cm³/rev
MA From control valve Safety valve set pressure 28.4 MPa {290 kg/cm²}
MB From control valve Rated revolving speed 1,694 rpm 1,879 rpm
Brake release pressure 1.9 MPa {19 kg/cm²}
10-12 PW200-7
12
1. Brake spring 11. Valve plate

2. Drive shaft 12. Reverse prevention valve
3. Spacer 13. Centre shaft
4. Case 14. Centre spring
5. Disc 15. Safety valve
6. Plate 16. Check valve
7. Brake piston 17. Check valve spring
8. Housing 18. Shuttle valve
9. Piston 19. Shuttle valve spring
10. Cylinder block
PW200-7 10-13
12
Unit: mm
Standard size Repair limit

Free length x Out- Installed Installed Free Installed
1 Check valve spring side diameter length load length load If damaged or
3.5 N 2.8 N deformed, replace
62.5 x 20.0 35 — spring
{0.36 kg} {0.29 kg}
13.7 N 10.8 N
2 Shuttle valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.1 kg}
10-14 PW200-7
12
Operation of swing lock

1.When swing lock solenoid valve is deactivated
When the swing lock solenoid valve is deactivated,
the pressurized oil from the gear pump is shut off
and port B is connected to the tank circuit.
As a result, brake piston (7) is pushed down by
brake spring (1), discs (5) and plates (6) are pushed Gear pump
together, and the brake is applied.
AA
Gear pump
2.When swing lock solenoid valve is excited

When the swing lock solenoid valve is excited, the
valve is switched and the pressure oil from the gear
pump enters port B and flows to brake chamber a.
The pressure oil entering chamber a overcomes
brake spring (1) and pushes brake piston (7) up. As
a result, discs (5) and plates (6) are separated and
the brake is released.
AA
PW200-7 10-15
12
RELIEF VALVE PORTION

1. Outline
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 cir-
cuit 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 pressure
oil is relieved to port S from the outlet port of
the motor (high-pressure side) to prevent any
damage.
Operation
1. When starting swing
When the swing control lever is operated to
swing right, the pressure oil from the pump
passes through the control valve and is sup-
plied 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 outlet port of the motor
passes from port MA through the control valve
and returns to the tank. (Fig. 1)
2. When stopping swing
When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port MA is stopped. With the oil from
the outlet port of the motor, the return circuit to
the tank is closed by the control valve, so the
pressure at port MB rises. As a result, rotation
resistance is generated in the motor, so the
braking effect starts.
If the pressure at port MB becomes higher
than the pressure at port MA, it pushes shuttle
valve A (4) and chamber C becomes the same
pressure as port MB. The oil pressure rises
further until it reaches the set pressure of relief
valve (1). As a result, a high braking torque
acts on the motor and stops the motor. (Fig.2)
When relief valve (1) is being actuated, the
relief oil and oil from port S passes through
check valve B (3) and is supplied to port MA.
This prevents cavitation at port MA.
10-16 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD UNDERCARRIAGE
12
UNDERCARRIAGE
13
8 2
11
12
10
10-18 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD UNDERCARRIAGE
3
4
1. Undercarriage 8. Double Wheel Assy

2. Step/Wheel Chock 9. Steering Cylinder
3. Front Oscillating Steering Axle 10. Suspension
4. Rear Axle 11. Swivel Joint
5. Propshaft 12. Slew Ring
6. Travel motor 13. Axle Oscillation pin
7. Transmission
PW200-7 10-19
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
A
P
A
Engaged
Disengaged
4
2
3
SPECIFICATIONS:
1. Transmission disengagement pin (for towing)
2. Oil filler plug
3. Oil drain plug
4. Breather
Type Single motor two speed automatic powershift

Small clutch (High gear) 1.180 : 1.
Gear ratio
Large clutch (Low gear) 4.423 : 1
Pressure required to disengage 58 +/- 7 bar.
clutches (Large & Small)
Output shaft DIN 120 (8stud) fixing.
Speed sensing pump displacement 3.8cc / rev
Oil capacity 2.9 litres.
Oil change interval 1000 hours
10-20 PW200-7
TRANSMISSION
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
FUNCTION
Pressure applied in port P will disengage the small

clutch, low speed will be selected. Pressure applied
in port Q will disengage the large clutch, high speed
will be selected. No pressure in port P and Q will
engage both small and large clutches. When both
clutches are engaged this locks the input shaft of the
transmission to the housing locking the transmission,
this is used for the park brake condition.
Steering pump
Park brake switch Park brake solenoid valve
Controller Transmission clutch solenoid valve
Swivel joint
P Q
Powershift Transmission
Travel motor
Small clutch
Large clutch
Hi sun + planet locked together, planetary drive = 1:1

Lo Sun drives planets annulus is held
Planet carrier is the output.
10-21 PW200-7
TRANSMISSION
1. Sleeve 8. Roller Bearing

2. Small clutch pack (high gear) 9. Spur Gear
3. Large clutch pack (low gear) 10. Coupling
4. Ball Bearing 11. Bearing
5. Bearing 12. Flange
6. Epicyclic Gearbox 13. Pin
7. Spur Gear 14. Casing
PW200-7 10-22
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
A6VM140 HAXT/63W-V2B380A-SK
T1 M1
U
Gext
Y
T2
MA:MB
G1
X
B A
G1 X
ViewYY
SPECIFICATIONS
A Service port Type 140cc unit

B Service port Min displacement setting 47cc/rev
Port for synchronous control of a number of Brake relief valve setting 420 bar
G1 units and for remote control pressure
Counterbalance valve pressure setting 7 bar
X Pilot pressure port
FUNCTION
T1 Case drain port
T2 Case drain port The travel motor is a device for driving the transmis-
U Flushing port sion by converting the hydraulic power into mechani-
S Boosting cal torque.
Oil is delivered via the main valve to ports A/B and
MA:MB Gauge ports (one either side)
this flow rotates a rotary group which is connected to
Gext Brake release port - external the motor output splines which are positioned to the
M1 Gauge port control pressure transmission input.
PW200-7 10-23
10-24 PW200-7
12
OPERATION OF TRAVEL MOTOR
1.During normal travel

2
5 4 6 1
1. Travel motor
2. Transmission and clutch
3. Drive shafts 140
Max Angle
4. Main control valve
Displacement
5. Main pump
6. Swivel joint
(cc/rev)
• Oil is supplied to the travel motor from the control

valve by the travel spool. When the spool is
opened the machine accelerates from the sta-
tionary the pressure at the travel motor rises to 42 Min Angle
maximum. This high pressure is used to set the
displacement of the travel motor to maximum to
give maximum torque. 275 308 380
• As the machine speed increases, so pressure Pressure (kg/cm²)
required to move the machine will reduce. This
reducing pressure is used to reduce the dis-
placement of the travel motor to allow increasing
speed. The travel motor changes from maximum
displacement to preset minimum. Displacement
changes according to the diagram.
PW200-7 10-25
12 2.Control of speed downhill valve.This allows the counterbalance valve

At high speed when the machine is travelling- springs to centralise the spool. The travel motor
downhill, machine speed must be limited to pre- will rotate because it is driven from the wheels
vent overspeed of travel motor, transmission and and so oil in the travel motor is circulated at high
axles. In the downhill condition the machine pressure through the brake valves. This oil circu-
weight is driving the machine and pressure at the lated at high pressure through the brake valves
travel motor inlet becomes low. This low pres- slows the machine speed down.
sure is used to close the counterbalance
3 4
1. Counterbalance valve
2. Relief valve
3. Swivel joint
4. Main control valve
10-26 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLUTCH CONTROL CIRCUIT
12
CLUTCH CONTROL CIRCUIT
Gear pump
on Engine
Park brake switch Park brake solenoid valve
Controller Transmission clutch solenoid valve
Swivel joint
P Q
Powershift Transmission
Travel motor
Small clutch
Large clutch
PW200-7 10-27
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLUTCH CONTROL CIRCUIT
12
FUNCTION
The clutches maintain the drive between the travel

motor and the transmission low or high gear. The low
and high gear are combined within the same clutch
pack and gear selection is provided by the Hi/Lo gear
tranmission clutch solenoid.
A clutch is disengaged by applying pressure to that
particular clutch piston and the system does not
allow pressure to be applied to both clutch pistons at
the same time.
1.Pressure applied to transmission port ’P’ dis-
engages the high gear clutch pack meaning the
low gear clutch pack is engaged- low gear has
been selected.
2.Pressure applied to transmission port ’Q’ dis-
engages the low gear clutch pack meaning the
high gear clutch pack is engaged - high gear has
been selected.
3.When there is no pressure applied to port ’Q’
and port ’P’, both low gear and high gear
clutches are engaged meaning the parking brake
has been applied.
10-28 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AXLE
AXLE
OUTLINE
• A trunnion-type axle shaft with a king pin at the
• Each axle consists of an axle housing supporting final drive end is used to enable the direction of
the chassis weight, a differential set in the axle the machine to be changed.
housing, a final drive, and a brake provided at
each end.
FRONT AXLE
5 5
2 1 4 2
6 3 6
1. Steer cylinder 3. Axle housing 5. Brake line input

2. Track control arms 4. Drive shaft input 6. Wheel hub
PW200-7 10-29
3 5 6 7 9 23 25 27 28
2 4 8 10 11 24 26
1
29 30
12
13
14 38 37
15 36
35
22 21 16 34
20 17 33
18 32
19
31
1. Planetary holder 20. Screw

2. O-ring 21. Axle body long steering
3. Seal ring 22. Air valve
4. Screw 23. Screw
5. Pin 24. Shim ring
6. Disk/Washer 25. O-ring
7. Bushing 26. Roller bearing
8. Lip seal 27. Protection cap
9. Bushing 28. Nipple
10. Pressure pad 29. Beval gear
11. Axle body short steering 30. Shim ring
12. O-ring 31. Planetary holder
13. Disk/Washer 32. Flange
14. Bushing 33. Lip seal
15. Seal ring 34. Roller bearing
16. Ring 35. Shim ring
17. Parallel pin 36. Bushing
18. Pin 37. Shim ring
19. Security dowel 38. Roller bearing
10-30 PW200-7
12
REAR AXLE
3 3
4 2 4
1. Axle housing
2. Drive shaft input
3. Brake line input
4. Wheel hub
PW200-7 10-31
12
13 15 17 19 21 23
1 2 3 4 5 12 14 16 18 20 22 24
11
33 27 25
32 31 29
10 30 28 26
9
8 7 6
1. Screw 18. Hub

2. O-ring 19. O-ring
3. Roller Bearing 20. Plug
4. Beval Gear 21. Circlip
5. Roller Bearing 22. Hollow Wheel
6. Nut 23. Gear Pinion
7. Flange 24. Planetary Holder
8. Lip Seal 25. Screw Plug
9. Roller Bearing 26. Screw
10. Bushing 27. Disk/Washer
11. Roller Bearing 28. Brake
12. Shaft 29. Bushing
13. Adjusting Ring 30. Cylinder Head Screw
14. Tube Fitting 31. Circlip
15. Roller Bearing 32. Gasket
16. Sleeve 33. Seal Ring
17. Roller Bearing
10-32 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SUSPENSION LOCK CYLINDER
SUSPENSION LOCK CYLINDER
5
4
1
6
1. Plunger
2. Cylinder housing
3. Check valve cartridge
4. Switching cylinder
5. Control spool
6. Wiper
SPECIFICATIONS
Piston Diameter 100mm

Stroke 180mm
Pilot Pressure Min. 2.8 MPa
PW200-7 10-33
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SUSPENSION LOCK CYLINDER
12
CIRCUIT through pipelines to the suspension lock solenoid
valve (4).
Purpose When the excavator is being moved on the jobsite,
The undercarriage of wheeled hydraulic excavators the suspension lock solenoid valve should be enger-
has one of the two driven axles oscillating mounted. nised so that the hydraulic oil in the cylinder can be
This makes it possible to fully utilize the excavators returned to tank as the axle is oscillating up and
rimpull in rough terrain - all of the wheels being con- down. Before commencing excavating operations,
stantly in contract with the ground. A suspension cyl- the oscillation lock solenoid valve should be ener-
inder is fitted on each side of the undercarriage to gised to pressurise the oil in the cylinders. This will
block the axle during digging or lifting work. lock the axle in the position it is in.
Blocking the axle increases the excavators stability.
The oscillating axle (3) is mounted on axle mount pin
(2) in the middle of the excavator. The two cylinders
(1) which are full of hydraulic oil are connected
6
7
5
8
9
1. Cylinder
2. Axle mount pin
3. Oscillating axle
4. Oscillation lock solenoid valve
5. PPC pressure reducing valve
6. Hydraulic tank
7. Swivel joint
8. PPC operated check valve
9. Accumulator
AXLE OSCILLATION
Axle oscillation: = 10o

Minimum turning radius PW200 = 7.2m / PW220 =
7.4m
10-34 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BRAKING SYSTEM
BRAKING SYSTEM
PW200-7 10-35
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BRAKING SYSTEM
1. Hydraulic oil filter

2. Gear pump
3. Priority valve
4. Brake control valve
5. Accumulator - service brake (0.75 l.)
6. Accumulator - service brake (0.75 l.)
7. Accumulator - parking brake (0.75 l.)
8. Pressure switch - stop light (5 +/- 2 bar)
9. Pressure switch - accumulator (100 +/- 5 bar)
10. Two stage solenoid
11. Pressure switch (parking brake) - (40 +/- 1 bar) < less than activates
12. Brake pedal
13. Swivel joint
14. Service brake cylinder
15. Service brake cylinder
16. Small (high speed) clutch
17. Large (low speed) clutch
Structure and Function

The brake system is fully hydraulic. Hydraulic oil is
supplied at high pressure by gear pump to a priority
valve giving priority to the steering circuit first and
secondly to the braking circuit when the steering is
not being used.in the steering circuit. When braking
oil is sent to the brake valve which provides braking
pressure to two separate braking circuits (service
brakes). In the event of failure of the power supply,
the accumulators provide brake pressure to allow the
machine to be safely stopped.
A parking brake is provided which is operated by
selecting park brake switch in cab. This de-energises
both high and low gear signals and locks the trans-
mission gears.
If there is no pressure the parking brake will activate.
10-36 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BRAKE/STEER PUMP
BRAKE/STEER PUMP
3 4
5
1 2
1. Delivery port (outlet)

2. Suction port (inlet)
3. Washer
4. Nut
5. Pump assembly
FUNCTION
The brake/steer pumps function is to produce the

necessary oil flow/pressure to operate the brake,
steering and pilot pressure contol circuits.
The pump is directly driven off the engine ancilliary
P.T.O.
SPECIFICATIONS
Type gear pump

Rated speed 2500 RPM
Displacement 25cc/REV
Rated pressure 250 bar
PW200-7 10-37
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
LS
EF
CF
When the steering wheel is turned, the oil flow is dis-

P Pressure port (from pump) tributed in such a way that the oil flow necessary for
EF Output port to brake system steering is led to the steering unit through the CF
connection.
CF Output port to steering system
The remaining oil flow is available for the working
LS Load sensing port from steering valve hydraulics through the EF connection.
The distribution is controlled by the LS signal from
the steering unit; so that the oil flow to the steering
SPECIFICATION
unit is always determined by the actual steering rate.
Priority valve control 7 bar

spring pressure
FUNCTION
10-38 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER BRAKE VALVE
POWER BRAKE VALVE
A T1 T2
1 X
3 View A
2
5
6
7
R2 N
8 X1
R1 F R3
9 R
P B
4
T4
N1 T3
Brake system support pedal

1 9 Latch pin stirrup T4 Service brake
with hook
2 Brake module F Accumulator pressure switch X Parking brake
Accumulator (charging valve
3 Accumulator charging valve R X1 Parking brake pressure switch
stabiliser)
4 3 ways complete solenoid valve R1 Accumulator (service brake) N Tank (plugged)
5 Pedal rubber R2 Accumulator (service brake) B Return
6 Latch pedal T1 Service brake pressure switch N Tank (plugged)
Service brake pressure switch
7 Latch pedal fixing screw T2 N1 Tank (plugged)
(plugged)
Accumulator (park brake
8 Latch pin T3 Service brake R3 plugged)
SPECIFICATIONS applied to depress the pedal, the greater the deceler-

ation of the machine, until the machine is eventually
in a stationary position.
(cut in) = 120 +/- 5 bar An alternative function of the power brake valve is
Accumulator charge pressure
(cut out) = 155 +0/-2 bar the digging brake application, if the machine is to be
used for digging, the power brake valve should be
Service brake pressure 63 bar
fully depressed until the pedal is locked and the
Park brake pressure 58 +/- 7 bar latching hook is secured on its location pin. This will
FUNCTION prevent the machine from "Travelling" when it is
being used for digging
The main function of the power brake valve is gradu-
ally reduce the machines travelling speed when the
pedal is slowly depressed. The higher the force
PW200-7 10-39
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ACCUMULATOR FOR BRAKE SYSTEM
ACCUMULATOR FOR BRAKE SYSTEM
SPECIFICATIONS
1. Nominal capacity 0.75L

2. Max working pressure 210 bar
3. Max p dynamic 175 bar
4. Working temperature - 30 to 125o C
o
5. Diaphragm NBR
6. Fluid Mineral oil
7. Body Forged steel
8. Surface finish Rust preventative coating
10-40 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING TRAIN
STEERING TRAIN
5
2
1. Hydraulic filter 4. Steering valve

2. Brake/steer pump 5. Steering cylinder
3. Priority valve 6. Steering wheel
Structure and Function

• The steering is fully hydraulic. The oil sent by the
brake/steer pump (2) mounted on the PTO at the
front of the engine, flows via the priority valve (3)
to the steering valve (4). From here it is passed
through swivel joint to steering cylinder (5). the
steering cylinder then extends or retracts to
move the tie-rod and steer the machine
• In the event of a failure of the hydraulic system
the machine can be steered by emergency steer-
ing. The steering valve acts as a pump to send
oil to the steering cylinder.
PW200-7 10-41
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
1
7
1. Steering wheel
2. Steering column
3. Pedal
4. Hose connections
5. Orbitrol valve
6. Mounting bracket
7. Sunshine sensor
10-42 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ORBITROL VALVE
ORBITROL VALVE
P Pressure port (from priority valve)

T Tank port
L Left turn port
R Right turn port
LS Load sensing port (to priority valve)
SPECIFICATIONS
Type : OSPD 80/240 LS (DYN)

Nominal displacement (normal operation) 240cc/rev
Nominal displacement (emergency operation) 80cc/rev
Relief valve setting 190 +5 bar
PW200-7 10-43
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ORBITROL VALVE
12
10-44 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC EQUIPMENT LAYOUT DRAWINGS
12
HYDRAULIC EQUIPMENT LAYOUT DRAWINGS
1. L.H. PPC valve 8C. Swing brake solenoid 14. Hydraulic adjust boom pedal
2. Swing motor 8D. Suspension lock solenoid 15. HCU pedal
3. Control valve 8E. Merge flow solenoid 16. Suspension lock cylinders
4. Combination cooler 8F. Travel neutral solenoid 17. Front axle
5. Travel motor 8G. Travel creep solenoid 18. Rear axle
6. Transmission 9. Hydraulic pump 19. Hydraulic tank
7. PPC Accumulator 10. Hydraulic filter 20. Arm cylinder
8. Solenoid valve assembly 11. Swivel joint 21. 1st boom cylinder
8A. PPC hydraulic press lock solenoid 12. R.H PPC valve 22. 2nd boom adjust cylinder
8B. 2 stage relief solenoid 13. Safety lock lever 23. Bucket cylinder
8B 8D 8F 1 2 3 4
8A 8C 8E 8G
7
6 5
PW200-7 10-45
12
11 12 13
10
14
15
9
19
18
17
16 16
20
22
21
23
21
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC EQUIPMENT LAYOUT DRAWINGS
PW200-7 10-47
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
10-48 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
7
6
3
2
4
1
1. Sight gauge
SPECIFICATIONS
2. Oil filler cap
3. Hydraulic tank Tank 200 l
4. Suction strainer Y filter micron Amount of oil inside tank 143 l
5. Filter element Y filter micron Pressure valve
6. Strainer 16.7 +/-6.9 kPa
Relief cracking pressure
7. Bypass valve {0.17 +/-0.07 kg/cm2}
0 - 0.49 kPa
Suction cracking pressure
{0 - 0.005 kg/cm2}
150 +/- 30 kPa
Bypass valve set pressure
{1.5 +/- 0.3 kg/cm2}
PW200-7 10-49
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
HPV95 + 95 (PW200-7K)
PM PSIG REAR PEPC
PD1F PBF
1 PENF
PENR
PAR
PLSF 4
PLSFC PAF
PLSR FRONT
PLCRC
PRC
PFC 6 3R
5 3F
ISIG IM PS
Front load pressure detection

1 Front main pump PAF Front pump delivery port PLSFC point
Front pump delivery pressure
2 Rear main pump PFC PLSR Rear load pressure input port
detection port
Rear load pressure detection
3F LS valve front PAR Rear pump delivery port PLSRC point
Rear pump delivery pressure
3R LS valve rear PRC PS Pump suction port
detection port
LS set selector pressure
4 PC valve PBF Pump pressure input port PSIG detection port
PC set selector pressure
5 LS-EPC valve PD1F Case drain port PM detection port
Front pump control pressure
6 PC-EPC valve PENF PEPC PPC basic pressure input port
detection port
Rear pump control pressure
IM PC mode selector current PENR detection port
ISIG LS set selector current PLSF Front load pressure input port
10-50 PW200-7
12
Shaft (Front) Cylinder block

1. Cradle 6. Valve plate
2. Case (Front) 7. End cap
3. Rocker cam 8. Shaft (Rear)
4. Shoe 9. Case (Rear)
5. Piston 10. Servo piston
PW200-7 10-51
12
SWP
FUNCTION
• The rotation and torque transmitted to the pump

shaft are converted into hydraulic energy, and • Rocker cam (4) has flat surface A, and shoe (5)
pressurized oil is discharged according to the is always pressed against this surface while slid-
load. ing in a circular movement.
• It is possible to change the discharge amount by Rocker cam (4) brings high pressure oil at cylin-
changing the swash plate angle. der surface B with cradle (2), which is secured to
the case, and forms a static pressure bearing
STRUCTURE
when it slides.
• Cylinder block (7) is supported to shaft (1) by a • Piston (6) carries out relative movement in the
spline, and shaft (1) is supported by the front and axial direction inside each cylinder chamber of
rear bearings. cylinder block (7).
• The tip of piston (6) is a concave ball, and shoe • The cylinder block seals the pressure oil to valve
(5) is caulked to it to form one unit. Piston (6) and plate (8) and carries out relative rotation. This
shoe (5) form a spherical bearing. surface is designed so that the oil pressure bal-
ance is maintained at a suitable level. The oil
inside each cylinder chamber of cylinder block
(7) is sucked in and discharged through valve
plate (8).
10-52 PW200-7
12
OPERATION
1. Operation of pump
• Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle α
between centre line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle α is called the swash plate
angle.)
• Centre line X of rocker cam (4) maintains
swash plate angle α in relation to the axial
direction of cylinder block (7), and flat surface
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 vol-
umes E and F is created inside cylinder block
(7). The suction and discharge is carried 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 during that
stroke. On the other hand, the volume of
chamber F becomes larger, and as the volume
becomes bigger, the oil is sucked in.
• If centre line X of rocker cam (4) is in line with
the axial direction of cylinder block (7) (swash
plate angle = 0), the difference between vol-
umes E and F inside cylinder block (7)
becomes 0, so the pump does not carry out
any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
PW200-7 10-53
12 2. Control of discharge amount

• 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 servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement (↔) according to the signal pres-
sure 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 pressure (self pres-
sure) 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 the pres-
sure at the large diameter end. The relation-
ship in the size of pressure PP at the small
diameter piston end and pressure Pen at the
large diameter end, and the ratio between
the area receiving the pressure of the small
diameter piston and the large diameter pis-
ton controls the movement of servo piston
(12).
10-54 PW200-7
12
LS VALVE
1 Plug PP Pump port

2 Locknut PDP Drain port
3 Sleeve PLP LS control pressure output port
4 Spring PLS LS pressure input port
5 Seat PPL PC control pressure input port
6 Spool PSIG LS mode selection pilot port
7 Piston
8 Sleeve
PC VALVE
1 Servo piston assembly PP1 Pump port

2 Plug PP2 Pump pressure pilot
3 Pin PT Drain port
4 Spool PM PC mode selector pressure pilot port
5 Retainer PPL PC control pressure output port
6 Seat PLP LS control pressure output port
7 Cover
8 Wiring
PW200-7 10-55
12
FUNCTION
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 differential pressure] (the dif-
ference between main pump pressure PP and
control valve outlet port pressure PLS).
Main pump pressure PP, pressure PLS {called 09141
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 relationship between dis-
charge amount Q and differential pressure
∆PLS, (the difference between main pump pres-
sure 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 to this,
and the selector point for the pump discharge
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 (self-
pressure) and PP2 (other pump pressure) are
high, the PC valve controls the pump so that no
more oil than the constant flow (in accordance
with the discharge pressure) flows even if the
stroke of the control valve becomes larger. In this
way, it carries out equal horsepower control so
that the horsepower absorbed by the pump does
not exceed the engine horsepower. 09142
In other words, If the load during the operation
becomes larger and the pump discharge pres-
sure rises, it reduces the discharge amount from
the pump; and if the pump discharge pressure
drops, it increases the discharge amount from
the pump. The relationship between the average
of the front and rear pump discharge pressures
(average discharge amount of F, R pumps (PP1
+ PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to the
PC-EPC valve solenoid shown as a parameter.
The controller senses the actual speed of the
engine, and if the speed drops because of an
increase in the load, it reduces the pump dis-
charge amount to allow the speed to recover. In
other words, when the load increases and the
engine speed drops below the set value, the
command current to the PC-EPC valve solenoid
from the controller increases according to the
drop in the engine speed to reduce the pump
swash plate angle.
10-56 PW200-7
12
OPERATION
B
Control circuit
pressure setting
valve
SDP08884
LS valve
1. When control valve is at neutral position from port K and the same pump pressure PP
• The LS valve is a three-way selector valve, with also enters port J at the small diameter end of
pressure PLS (LS pressure) from the inlet port of the piston, so the swash plate is moved to the
the control valve brought to spring chamber B, minimum angle by the difference in the area of
and main pump discharge pressure PP brought the piston (12)
to port H of sleeve (8). The size of this LS pres- .
sure PLS + force Z of spring (4) and the main
pump pressure (self pressure) PP determines
the position of spool (6). However, the size of the
output pressure PSIG (the LS selection pres-
sure) of the EPC valve for the LS valve entering
port G also changes the position of spool (6).
(The set pressure of the spring changes).
• Before the engine is started, servo piston (12) is
pushed to the right. (See the diagram on the
right)
• When the engine is started and the control lever
is at the neutral position, LS pressure PLS is 0
MPa {0 kg/cm²}. (It is interconnected with the
drain circuit through the control valve spool.)
At this point, spool (6) is pushed to the left,and
port C and port D are connected. Pump pressure
PP enters the large diameter end of the piston
PW200-7 10-57
12
SDP08885
Control circuit
pressure setting
valve
2.Operation in increase direction for pump dis- piston (7) is pushed to the left, it acts to make the
charge amount set pressure of spring (4) weaker, and the differ-
• When the difference between the main pump ence between PLS and PP changes when ports
pressure PP and LS pressure PLS, in other D and E of spool (6) are connected.
words, LS differential pressure ∆PLS, becomes
smaller (for example, when the area of opening
of the control valve becomes larger and pump
PP drops), spool (6) is pushed to the right by the
combined force of LS pressure PLS and the
force of spring (4).
• When spool (6) moves, port D and port E are
joined and connected to the PC valve. When this
happens, the PC valve is connected to the drain
port, so circuit D - K becomes drain pressure PT.
(The operation of the PC valve is explained
later).
• For this reason, the pressure at the large diame-
ter end of servo piston (12) becomes drain pres-
sure PT, and pump pressure PP enters port J at
the small diameter end, so servo piston (12) is
pushed to the right. Therefore, the swash plate
moves in the direction to make the discharge
amount larger. If the output pressure of the EPC
valve for the LS valve enters port G, this pressure
creates a force to move piston (7) to the left. If
10-58 PW200-7
12
Control circuit
pressure setting
valve
SDP08886
3.Operation in decrease direction for pump dis-

charge amount
• The following explains the situation if the servo
piston (12) moves to the left (the discharge
amount becomes smaller). When LS differential
pressure ∆PLS becomes larger (for example,
when the area of opening of the control valve
becomes smaller and pump pressure PP rises),
pump pressure PP pushes spool (6) to the left.
• When spool (6) moves, main port pressure PP
flows from port C and port D and from port K, it
enters the large diameter end of the piston.
• Main pump pressure PP also enters port J at the
small diameter end of the piston, but because of
the difference in area between the large diameter
end and the small diameter end of servo piston
(12), servo piston (12) is pushed to the left.
• As a result, the swash plate moves in the direc-
tion to make angle smaller.
• If LS selection pressure PSIG enters port G, it
acts to make the set pressure of spring (4)
weaker.
PW200-7 10-59
12
SDP08887
AO
4.When servo piston is balanced ↔ 30 kg/cm²} of the EPC valve of the LS valve)
• Let us take the area receiving the pressure at the is applied to port G, the balance stop position will
large diameter end of the piston as A1, the area change in proportion to pressure PSIG between
receiving the pressure at the small diameter end PP - PLS = 2.2 ↔ 0.69 MPa {22 ↔ 7 kg/cm²}.
as A0, and the pressure flowing into the large
diameter end of the piston as Pen. If the main
pump pressure PP of the LS valve and the com-
bined force of force Z of spring (4) and LS pres-
sure PLS are balanced, and the relationship is
A0 x PP = A1 x Pen, servo piston (12) will stop in
that position, and the swash plate will be kept at
an intermediate position. (It will stop at a position
where the opening of the throttle from port D to
port E and from port C to port D of spool (6) is
approximately the same.)
• At this point, the relationship between the area
receiving the pressure at both ends of piston (12)
is A0: A1 = 3:5, so the pressure applied to both
ends of the piston when it is balanced becomes
PP: Pen = 3:5.
• The position where spool (6) is balanced and
stopped is the standard centre, and the force of
spring (4) is adjusted so that it is determined
when PP - PLS = 2.2 MPa {22 kg/cm²}. However,
if PSIG (the output pressure of 0 ↔ 2.9 MPa {0
10-60 PW200-7
12
09143
Control circuit
pressure setting
valve
PC Valve
1. When pump controller is normal • The size of command current X is deter-
A. When the load on the actuator is small and mined by the nature of the operation (lever
pump pressures PP1 and PP2 are low operation), the selection of the working
Movement of PC-EPC solenoid (1) mode, and the set value and actual value for
• The command current from the pump con- the engine speed.
troller flows to PC-EPC solenoid (1).This Other pump pressure
command current acts on the PC-EPC valve This is the pressure of the pump at the oppo-
and outputs the signal pressure. When this site end.
signal pressure is received, the force push- For the F pump, it is the R pump pressure
ing piston (2) is changed. For the R pump, it is the F pump pressure
• On the opposite side to the force pushing
this piston (2) is the spring set pressure of
springs (4) and (6) and pump pressure PP1
(self pressure) and PP2 (other pump pres-
sure) pushing spool (3). Piston (2) stops at a
position where the combined force pushing
spool (3) is balanced, and the pressure
(pressure of port C) output from the PC valve
changes according to this position.
PW200-7 10-61
12
09144
Control circuit
pressure setting
valve
ACTION OF SPRING (1) LS valve), the pressure entering the large

diameter end of the piston from port J becomes
• The spring load of springs (4) and (6) in the PC drain pressure PT, and servo piston (9) moves to
valve is determined by the swash plate position. the right. In this way, the pump discharge amount
• If piston (9) moves to the left, spring (6) is com- moves in the direction of increase.
pressed, and if it moves further to the left, spring • As servo piston (9) moves further, springs (4)
(6) contacts seat (5) and is fixed in position. In and (6) expand and the spring force becomes
other words, the spring load is changed by piston weaker. When the spring force becomes weaker,
(9) extending or compressing springs (4) and (6). spool (3) moves to the left, so the connection
• If the command circuit input to PC-EPC valve between port C and port D is cut, and the pump
solenoid (1) changes further, the force pushing discharge pressure ports B and C are con-
piston (2) changes, and the spring load of nected. As a result, the pressure at port C rises,
springs (4) and (6) also changes according to the and the pressure at the large diameter end of the
value of the PC-EPC valve solenoid command piston also rises, so the movement of piston (9)
current. to the right is stopped.
• Port C of the PC valve is connected to port E of • In other words, the stop position for piston (9) (=
the LS valve (see (1) LS valve). Self pressure pump discharge amount) is decided at the point
PP1 enters port B and the small diameter end of where the force of springs (4) and (6) and the
servo piston (9), and other pump pressure PP2 pushing force from the PC-EPC valve solenoid
enters port A. and the pushing force created by the pressures
• When pump pressures PP1 and PP2 are small, PP1 and PP2 acting on the spool (3) are in bal-
spool (3) is on the right. At this point, port C and ance.
D are connected, and the pressure entering the
LS valve becomes drain pressure PT. If port E
and port G of the LS valve are connected (see
10-62 PW200-7
12
09145
Control circuit
pressure setting
valve
B. When load on actuator is large and pump • If main pump pressure PP increases further
discharge pressure is high and spool (3) moves further to the left, main
• When the load is large and pump discharge pump pressure PP1 flows to port C and acts
pressures PP1 and PP2 are high, the force to make the discharge amount the minimum.
pushing spool (3) to the left becomes larger When piston (9) moves to the left, springs (4)
and spool (3) moves to the position in the and (6) are compressed and push back
diagram above. When this happens, as spool (3). When spool (3) moves to the left,
shown in the diagram above, part of the the opening of port C and port D becomes
pressurized oil from port B flows out through larger. As a result, the pressure at port C (=
port C where the LS valve is actuated to port J) drops, and piston (9) stops moving to the
D, and the pressurized oil flowing from port C left.
to the LS valve becomes approximately • The position in which piston (9) stops when
2:1 / 3:5 of main pump pressure PP. this happens is further to the left than the
• When port E and port G of the LS valve are position when pump pressures PP1 and PP2
connected (see (1) LS valve), the pressure are low.
from port J enters the large diameter end of
servo piston (9), and servo piston (9) stops.
PW200-7 10-63
12
• 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 average pump
pressure (PP1 + PP2)/2 and pump dis-
charge 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 pres-
sure (PP1 + PP2)/2, and pump discharge
amount Q is proportional to the pushing
force of the PC-EPC valve solenoid and
moves in parallel. In other words, the push-
ing force of PC-EPC solenoid (1) is added
to the force pushing to the left because of
the pump pressure applied to the spool (3),
so the relationship between the average
pump pressure (PP1 + PP2)/2 and Q
moves from (1) to (2) in accordance with
the increase in X.
10-64 PW200-7
12
09146
Control circuit
pressure setting
valve
2.When pump controller is abnormal and PC pro-

lix switch is ON
A. When load on main pump is light
• If there is a failure in the pump controller,
turn emergency pump drive switch ON to • At this point, port C is connected to the drain
switch to the resistor side. In this case, the pressure of port D, and the large diameter
power source is taken directly from the bat- end of the piston of servo piston (9) also
tery. But if the current is used as it is, it is too becomes the drain pressure PT through the
large, so use the resistor to control the cur- LS valve. When this happens, the pressure
rent flowing to PC-EPC valve solenoid (1). at the small diameter end of the piston is
large, so servo piston (9) moves in the direc-
• When this is done, the current becomes con-
tion to make the discharge amount larger.
stant, so the force pushing piston (2) is also
constant.
• If the main pump pressure PP1 and PP2 are
low, the combined force of the pump pres-
sure and the force of PC-EPC valve solenoid
(1) is weaker than the spring set force, so
spool (3) is balanced at a position to the left.
PW200-7 10-65
12
09147
Control circuit
pressure setting
valve
B. When main pump load is heavy

• In the same way as in the previous item,
when the emergency pump drive switch is
ON, the command current sent to PC-EPC
valve solenoid (1) becomes constant. For
this reason, the force of piston (2) pushing
spool (3) is constant.
• If main pump pressures PP1 and PP2
increase, spool (3) moves further to the left
than when the main pump load is light, and is
balanced at the position in the diagram
above.
• In this case, the pressure from port B flows • The curve when the PC prolix switch is ON is
to port C, so servo piston (9) moves to the curve (2), which is to the left of curve (1) for
left (to make the discharge amount smaller) when the pump controller is normal.
by the same mechanism as explained in item
2)-b, and stops at a position to the left of the
position when the load on the pump is light.
In other words, even when the emergency
pump drive switch is ON, the curve for the
pump pressure PP and discharge amount Q
is determined as shown in the diagram for
the valve of the current sent to the PC-EPC
valve solenoid through the resistor.
10-66 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PILOT PRESSURE CONTROL (PPC) SYSTEM
PILOT PRESSURE CONTROL (PPC) SYSTEM
36 Bar0
-3
Damper branch hose

To main
pump
EPC valve
From orbitrol
valve load 3
sensing signal
To orbitrol valve
To low gear/high gear

solenoid valve
1. Gear Pump
2. Steering/Braking priority valve
3. Power Brake Valve
4. Pressure Reducing Valve
Incorporated in Main Solenoid Valve Block
FUNCTION
• The PPC Pump less system discharges pres-

surised oil to operate the PPC circuit and sole-
noid valve assemblies.
PW200-7 10-67
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
PW200 -220-7K
OUTLINE .
1 6-spool valve
Control valve consists of an 6-spool valve (unit type),
2 Cover 1
with optional 3 service valves, pump merger divider
valve, back pressure valve. 3 Cover 2
• Since all valves are assembled together with 4 Pump merge divider valve
connecting bolts and their passages are con- 5 Back pressure valve
nected to each other inside the assembly, the 6 Service valve
assembly is small in size and easy to maintain.
7 Service valve
• Since one spool of the control valve is used for
one work equipment unit, its structure is simple. 8 Service valve
A1 To bucket cyl head P10 From travel PPC valve

A2 To stabilizer P11 From arm PPC valve
A3 To boom cyl bottom P12 From arm PPC valve
A4 To swing motor LH P-1 From 2p boom PPC valve
A5 To travel P-2 From 2p boom PPC valve
A6 To arm cyl head P-3 From service 1 PPC valve
A-1 To adjust cyl P-4 From service 1 PPC valve
A-2 To clamshell rotate P-5 From service 2 PPC valve
A-3 To 2nd HCU option P-6 From service 2 PPC valve
B1 To bucket cyl bottom BP1 Swing LS separation valve
B2 To stabilizer PLS1 To rear pump control
B3 To boom cyl head PLS2 To front pump control
B4 To swing motor RH PP1 From rear main pump
B5 To travel PP2 From front main pump
To sol valve, PPC valve, EPC
B6 To arm cyl bottom PR valve
From pump merge divider sol
B-1 To bucket cyl bottom PS valve
B-2 To bucket cyl bottom att PX1 From 2 stage solenoid valve
B-3 To bucket cyl bottom att PX2 From 2 stage solenoid valve
P1 From bucket PPC valve SA Pressure sensor fitting port
P2 From bucket PPC valve SB Pressure sensor fitting port
P3 From stabilizer PPC valve T To tank
P8 From swing PPC valve TS To tank
P9 From travel PPC valve TSW To swing motor
10-68 PW200-7
12
B-3 B-2 B-1 B1 B2 B3 B4 B5 B6 1

6 7 8
PLS1 Bp1
2
PLS2
LS
Bypass
P
3 Ts
A-3 A-2 A-1 A1 A2 A3 A4 A5 A6

SB
P-3 P1 P5 P9
P6 P10 PX P-5 P-1 P3 P7 P11
P-4 P2 PX1
P-6 P-2 P4 P8 P12
PX2
TSW2
PS TSW1
4
Regeneration Valve (Arm)
SA
PP1 PP2 5
PW200-7 10-69
11 12 13 14 15 16 17 18 19 20
10 9 8 7 6 5 4 3 2 1
1. Unload valve 11. Adj pressure compensation valve (Service)

2. Pressure compensation valve (Arm OUT) 12. Adj pressure compensation valve (Service)
3. Pressure compensation valve (Travel) 13. Pressure compensation valve (2P Boom)
4. Pressure compensation valve (Left swing) 14. Pressure compensation valve (Bucket CURL)
5. Pressure compensation valve (Boom RAISE) 15. Pressure compensation valve (Stabilizer)
6. Pressure compensation valve (Stabilizer) 16. Pressure compensation valve (Boom LOWER)
7. Pressure compensation valve (Bucket DUMP) 17. Pressure compensation valve (Right swing)
8. Pressure compensation valve (2P Boom) 18. Pressure compensation valve (Travel)
9. Adj pressure compensation valve (Service) 19. Pressure compensation valve (Arm IN)
10. Adj pressure compensation valve (Service) 20. Main relief valve
10-70 PW200-7
27.5~34.3Nm
(2.8~3.5kgm) 58.8~73.6Nm
(6.0~7.5kgm)
E D
A B
156.9~176.5Nm 156.9~176.5Nm
(16~18kgm) (16~18kgm)
C D E
PW200-7 10-71
11 12 12 12 15 13
15 15 15 14 15 15 15
10 15 15 15 15 12 13 15 15 15
9 8 7 6 5 4 3 2 1
1. Spool (Arm) 7. Spool (2P Boom)

2. Spool (Travel) 8. Spool (Service)
3. Spool (Swing) 9. Spool (Service)
4. Spool (Boom) 10. Unload valve
5. Spool (Stabilizer) 11. Main relief valve
6. Spool (Bucket) 12. Spool return spring
Unit:mm
No Check Item Criteria Remedy
13 Spool return spring side diameter length load length load
94.18Nm 75.3Nm If damaged or
54.2 X 34.8 53.5 9.6kgm 7.6kgm deformed, replace
spring
120.6Nm 96.5Nm
14 Spool return spring 54.5 X 34.8 53.5 12.3kgm 9.8kgm
120.6Nm 96.5Nm
15 Spool return spring 54.5 X 34.8 53.5 12.3kgm 9.8kgm
10-72 PW200-7
9 10 11 12
13 14 15 16
8 7 6 5 4 3 2 1
28
34~44Nm
19.6~27.5Nm (3.5~4.5kgm)
(2~2.8kgm)
26
27
25 24 23 22 21 20 19 18 17
1. Safety suction valve (Arm OUT) 10. Safety suction valve (Service) 19. LS select valve
2. Suction valve (Travel REVERSE) 11. Suction valve (Stabilizer DOWN) 20. LS shuttle valve (Boom)
3. Safety suction valve (Boom 12. Safety suction valve (Bucket 21. LS shuttle valve (Stabilizer)
RAISE) CURL)
4. Suction valve (Stabilizer UP) 13. Suction valve (Stabilizer DOWN) 22. LS shuttle valve (Bucket)
5. Safety suction valve (Bucket 14. Safety suction valve (Boom 23. LS shuttle valve (2P Boom)
DUMP) LOWER)
6. Safety suction valve (2P boom) 15. Suction valve (Travel FORWARD) 24. LS shuttle valve (Service)
7. Safety suction valve (Service) 16. Safety suction valve (Arm IN) 25. LS shuttle valve (Service)
8. Safety suction valve (Service) 17. LS shuttle valve (Arm) 26. LS check valve
9. Safety suction valve (Service) 18. LS shuttle valve (Travel) 27. Pressure relief plug

Free length x Out- Installed Installed Free Installed If damaged or
28 Check valve spring side diameter length load length load deformed, replace
spring
1.47Nm 1.2Nm
8.5 (0.15kgm) (0.12kgm)
PW200-7 10-73
49~58.8Nm
2 17 (5~6kgm)
18
Arm control valve Travel control valve

3
372.7~411.9Nm
(38~42kgm) 19
9
1 147.1~186.3Nm 372.7~411.9Nm
(15~19kgm) (38~42kgm)
15 16
8
137.2~156.8Nm 137.2~156.8Nm
(14~16kgm) (14~16kgm)
22
24
7
14
20
10
23
21
137.2~156.8Nm
(14~16kgm)
372.7~411.9Nm
(38~42kgm) 372.7~411.9Nm
6 (38~42kgm) 13
5 4
12 11 137.2~156.8Nm
(14~16kgm)
ARM CONTROL VALVE TRAVEL CONTROL VALVE

1. Unload valve 4. Safety suction valve 11. Suction valve
2. Main relief valve 5. Spool 12. Spool
Pressure compensation valve 13. Pressure compensation valve
3. Lift check valve 6. (OUT) (REVERSE)
7. LS shuttle valve 14. LS shuttle valve
8. (IN) (FORWARD)
9. Safety suction valve 16. Suction valve
10. Check valve for regeneration cir-

cuit
10-74 PW200-7

17 Relief spring side diameter length load length load
406.7Nm 325.6Nm
30.7 X 9.6 25.9 (41.5kgm) (33.2kgm)
69.6Nm 55.7Nm
18 Valve spring 24.3 X 8 19.5 (7.1kgm) (5.7kgm)
70.6Nm 56.4Nm If damaged or
19 Unload spring 31.5 X 10.2 26.9 (7.2kgm) (5.8kgm) deformed, replace
spring
6.2Nm 4.9Nm
20 Regeneration valve spring 31.5 X 10.3 19 (0.6kgm) (0.5kgm)
17.5Nm 14Nm
21 Piston return spring 48.1 X 10.8 28 (1.8kgm) (1.4kgm)
79.4Nm 63.5Nm
17.5Nm 14Nm
PW200-7 10-75
372.7~411.9Nm 12
(38~42kgm) 5 11 137.3~156.9Nm
14 6 (15~16kgm)
137.3~156.9Nm
(15~16kgm)
372.7~411.9Nm
(38~42kgm)
10
4
13
372.7~411.9Nm
(38~42kgm)
372.7~411.9Nm
(38~42kgm) 9
2 137.3~156.9Nm 8 137.3~156.9Nm
(14~16kgm)
(14~16kgm)
Bucket control valve 1 Service control valve 7
BUCKET CONTROL VALVE SERVICE VALVE

1. Safety suction valve 7. Safety suction valve
2. Spool 8. Spool
3. Pressure compensation valve (DUMP) 9. Adj pressure compensation valve
4. LS shuttle valve 10. LS shuttle valve
5. Pressure compensation valve (CURL) 11. Adj pressure compensation valve
6. Safety suction valve 12. Safety suction valve

13 Piston return spring side diameter length load length load If damaged or
17.5Nm 14Nm deformed, replace
48.1 X 10.8 28 (1.8kgm) (1.4kgm) spring
29.4Nm 23.5Nm
14 Piston return spring 36.9 X 11.1 28 (3kgm) (2.4kgm)
10-76 PW200-7
372.7~411.9Nm
(38~42kgm)
19 4 Swing control valve
107.9~147.1Nm
(11~15kgm)
21
22
19
Boom control valve Stabilizer control valve
2
372.7~411.9Nm
372.7~411.9Nm
(38~42kgm)
(38~42kgm) 1
10 372.7~411.9Nm
9 137.3~156.9Nm (38~42kgm)
20 (14~16kgm) 16 17 137.3~156.9Nm
20 (14~16kgm)
8
15
18
20
14
11
5
20 137.3~156.9Nm 137.3~156.9Nm
7 (14~16kgm) (14~16kgm)
6 372.7~411.9Nm 15
372.7~411.9Nm (38~42kgm)
(38~42kgm) 13
SWING CONTROL VALVE BOOM CONTROL VALVE STABILIZER VALVE

1. Spool 5. Suction valve 12. Suction valve
2. Pressure compensation valve (Left) 6. Spool 13. Spool
3. LS select valve 7. (Raise) (Reverse)
Pressure compensation valve
4. 8. LS shuttle valve 15. LS shuttle valve
(Right)
Pressure compensation valve 16. Pressure compensation valve (For-
9. (Lower) ward)
10. Safety suction valve 17. Suction valve
11. Check valve for regeneration circuit
PW200-7 10-77

18 Regeneration valve spring side diameter length load length load
6.2Nm 4.9Nm
31.5 X 10.3 19 (0.6kgm) (0.5kgm)
17.5Nm 14Nm If damaged or
19 Piston return spring 48.1 X 10.8 28 (1.8kgm) (1.4kgm) deformed, replace
spring
17.5Nm 14Nm
428.3Nm 343Nm
21 Load spring 30.4 X 16.7 27 (43.7kgm) (35kgm)
3Nm 2.4Nm
22 Check valve spring 13.6 X 5.5 10 (0.3kgm) (0.25kgm)
10-78 PW200-7
5 6
2P boom control valve
2
1
2P BOOM CONTROL VALVE

1. Safety suction valve
2. Spool
3. Pressure compensation valve (EXTEND)
4. LS shuttle valve
5. Pressure compensation valve (RETRACT)
6. Safety suction valve

7 Piston return spring side diameter length load length load If damaged or
29.4Nm 23.5Nm deformed, replace
28 (3kgm) (2.4kgm) spring
17.5Nm 14Nm
8 Piston return spring 28 (1.8kgm) (1.4kgm)
PW200-7 10-79
7 8
2
20 6
3
1 5
4
1. Unload valve 5. Pump merge divider valve (For LS)

2. Main relief valve 6. Return spring
3. Pump merge divider valve (Main) 7. Valve (Sequence valve)
4. Return spring 8. Spring (Sequence valve)
10-80 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
FEATURES STRUCTURE
• CLSS is an abreviation for Closed center Load • The CLSS consists of a main pump (2 pumps),
Sensing System, and has the following features. control valve, and actuators for the work equip-
ment.
1. Fine control not influenced by load • The main pump body consists of the pump itself,
the PC valve and LS valve.
2. Control enabling digging even with fine control
3. Ease of compound operation ensured by flow

divider function using area of opening of spool
during compound operations
4. Energy saving using variable pump control
PW200-7 10-81
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CENTRE SWIVEL JOINT
CENTRE SWIVEL JOINT
F 1 3 5 7 9 11 13 B
A
4 4
14
2
A 7
11
12
8
6 6
A-A D C
E 2 4 6 10 12
8 14
1. Steering left 11. Speed sensor signal

2. Drain 12. Transmissiom large clutch
3. Motor volume pilot 13. Suspension lock
4. Travel motor A 14. Transmission small clutch
5. Undercarriage attachment cylinder head A. Slip ring assembly
6. Travel motor B B. Cover
7. Undercarriage attachment cylinder bottom C. Housing
8. Service brake-1 D. Sealing ring
9. Service brake-2 E. O-ring/backup ring seal
10. Steering right F. Rotor
Unit: mm
Criteria
No. Check Item Remedy
Standard Size Standard clearance Repair limit
-0.02
1 Internal shaft 110-0.06 Max.=0.21 >=0.26 Replace
0.15
Min.=0.12
2 External rotor
110 0.10
10-82 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC PEDAL
TRAVEL PPC PEDAL
2
3
T
4
P
1. Pedal A. To forward-reverse solenoid

2. Bracket P. To travel neutral solenoid
3. Pin T. To tank
4. Valve
FORWARD PRESSURE SWITCH
PRESSURE SENSOR
TRAVEL
TRAVEL CONTROL VALVE
NEUTRAL F - R SOLENOID
PEDAL TRAVEL SPOOL
SOLENOID
THE PRESSURE SENSOR IS A

PROPORTIONAL DEVICE WHICH
FEEDS TRAVEL PPC PRESSURE
DATA TO THE CONTROLLER
REVERSE PRESSURE SWITCH
PW200-7 10-83
12
MONITOR
TRAVEL PPC TRAVEL
PRESSURE PPC
SENSOR
PARK HI F-N-R
BRAKE LO
SWITCH SWITCH
CREEP
F-R
SOL PUMP
PRESSURE
SENSOR
GOVERNOR TRAVEL N
MOTOR CONTROLLER SOL
STEERING
PUMP
MAIN
PUMP
TRAVEL
CONTROL
VALVE
CREEP
SOL
SPEED SENSING
MOTOR
SPEED PICKUP
PARK BRAKE
SOL
T/M CLUTCH
SOL UPPER
LOWER
TRAVEL SPEED
MOTOR SENSING
PUMP
2ND CLUTCH
1ST CLUTCH
POWERSHIFT
TRANSMISSION
FUNCTION
10-84 PW200-7
12
PW200-7 10-85
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
WORK EQUIPMENT • SWING PPC VALVE
P. From main pump

T. To tank
P1. Left: Arm OUT / Right: Boom LOWER

P2. Left: Arm IN / Right: Boom RAISE
P3. Left: Swing RIGHT / Right: Bucket CURL
P4. Left: SwingLEFT / Right: Bucket DUMP
10-86 PW200-7
12
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Disc
6. Nut (For connection of lever)
7. Joint
8. Plate
9. Retainer
10. Body
11. Filter
PW200-7 10-87
12
Unit: mm

Centering spring
12 side diameter length load length load
(For P3 and P4)
9.81 N 7.85 N If damaged or
38.7 x 15.5 34 —
{1.0 kg} {0.8 kg} deformed,
replace spring
Centering spring 17.7 N 14.1 N
13 42.5 x 15.5 34 —
(For P3 and P4) {1.8 kg} {1.44 kg}
16.7 N 13.3 N
14 Metering spring 26.5 x 8.2 24.9 —
{1.7 kg} {1.36 kg}
10-88 PW200-7
OPERATION
1) At neutral
Ports A and B of the control valve and ports
P1 and P2 of the PPC valve are connected to
drain chamber D through fine control hole f in
spool (1). (Fig. 1)
2) During fine control (neutral → fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (1) is also
pushed by metering spring (2), and moves
down.
When this happens, fine control hole f is shut
off from drain chamber D, and at almost the
same time, it is connected to pump pressure
chamber PP, so pilot pressure oil from the
main pump passes through fine control hole f
and goes from port P1 to port A.
When the pressure at port P1 becomes
higher, spool (1) is pushed back and fine con-
trol hole f is shut off from pump pressure
chamber PP. At almost the same time, it is
connected to drain chamber D to release the
pressure at port P1. When this happens, spool
(1) moves up or down so that the force of
metering spring (2) is balanced with the pres-
sure at port P1. The relationship in the posi-
tion of spool (1) and body (10) (fine control
hole f is at a point midway between drain hole
D and pump pressure chamber PP) does not
change until retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of
the control lever, so the pressure at port P1
also rises in proportion to the travel of the con-
trol lever. In this way, the control valve spool
moves to a position where the pressure in
chamber A (the same as the pressure at port
P1) and the force of the control valve spool
return spring are balanced. (Fig. 2)
PW200-7 10-89
WORK EQUIPMENT • SWING PPC VALVE
12
3) During fine control (when control lever is

returned)
• When disc (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure
oil at port P1 is released.
If the pressure at port P1 drops too far, spool
(1) is pushed down by metering spring (2),
and fine control hole f is shut off from drain
chamber D. At almost the same time, it is con-
nected to pump pressure chamber PP, and the
pump pressure is supplied until the pressure
at port P1 recovers to a pressure that corre-
sponds to the lever position.
When the spool of the control valve returns, oil
in drain chamber D flows in from fine control
hole f in the valve on the side that is not work-
ing. The oil passes through port P2 and enters
chamber B to fill the chamber with oil. (Fig. 3)
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP. Therefore, the pilot pressure oil from
the main pump passes through fine control
hole f and flows to chamber A from port P1,
and pushes the control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f and flows to
drain chamber D. (Fig. 4)
10-90 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
T. To tank
P. From main pump
P1. Port
P2. Port
PW200-7 10-91
Unit: mm

9 Centering spring side diameter length load length load If damaged or
124.5 N 100 N deformed,
33.9 x 15.3 28.4 — replace spring
{12.7 kg} {10.2 kg}
16.7 N 13.7 N
10 Metering spring 22.7 x 8.1 22 —
{1.7 kg} {1.4 kg}
OPERATION
At neutral
• The pressurized oil from the main pump
enters from port P and is blocked by spool (1).
• Ports A and B of the control valve and ports a
and b of the PPC valve are connected to
drain port T through fine control hole X of
spool (1).
10-92 PW200-7
WHEN OPERATED
• When lever (5) is moved, metering spring (2)

is pushed by piston (4) and retainer (7), and
spool (1) is pushed down by this.
• As a result, fine control portion Y is connected
with port a, and the pressurized oil from port P
flows from port a to port A of the control valve.
PW200-7 10-93
• When the pressure at port a becomes higher,

spool (1) is pushed back by the force acting
on the end of the spool, and fine control por-
tion Y closes.
• As a result, spool (1) moves up and down to
balance the force at port a and the force at
metering spring (2).
• Therefore, metering spring (2) is compressed
in proportion to the amount the control lever is
moved. The spring force becomes larger, so
the pressure at port a also increases in pro-
portion to the amount the control lever is
operated.
In this way, the control valve spool moves to a
position where the pressure of port A (the
same as the pressure at port a) is balanced
with the force of the return spring of the con-
trol valve spool.
10-94 PW200-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing brake,
merge-divider.
PS
SOLENOID
VALVE P0
V01
A1
A2
V02
T1
A3
V03
V04 A5
A6
V05
A8
V06
P2
V07
RELIEF P1
VALVE TO
TO. To tank
T1. To tank
A1. 2 stage relief
P1. From brake valve
A2. Swing brake
P2. To : main valve,
2 stage back pressure valve, A3. Suspension lock valve
EPC valve in main pump
A5. Merge/flow valve
PS. To : accumulator,
manifold valve block, A6. Travel neutral
2 stage back pressure lock A8. Travel creep (motor volume pilot)
P0. PPC hydraluic pressure lock
PW200-7 10-95
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS ................................................................. 20- 2

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS................................................................. 20- 4
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING ................................................................................................................................ 20-201
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
❋ When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
❋ When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
❋ When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
❋ Be careful not to get caught in the fan, fan belt or other rotating parts.
PW200/220-7K 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Applicable model PW200, 220-7K
Engine SAA6D102E-2
Standard value for

Item Measurement condition Unit Service limit value
new machine
High idling 2,200 ±70 2,200 ±70
Engine speed Low idling rpm 1,000 ±50 1,000 ±50
Rated speed 1,950 ±20 1,950 ±20
At sudden acceleration
Max. 4.0 Max. 6.0
Exhaust gas color LO idle - HI idle Bosch index
At high idling Max. 0.5 Max. 1.5
Valve clearance Intake valve 0.25 —

mm
(Normal temperature) Exhaust valve 0.51 —
Difference
Oil temperature: 40–60ºC MPa Min. 2.4 between cyinders
Compression pressure
Engine speed: 250rpm {kg/cm2} {Min. 24.6} Min. 1.0
{Min. 10.3}
(Water temperature: operating kPa Max. 1.2 5.1

Blow-by pressure
range) At rated output {mmH2O} {Max. 123} {520}
(Water temperature: operating

range) At high idling 0.39–0.64 0.25
Oil pressure MPa
{4.0–6.5} {2.6}
(SAE15W-40) {kg/cm2}
At low idling Min. 0.15 0.09
{Min. 1.5} {0.9}
Whole speed range (inside oil

Oil temperature ºC 80–110 120
pan)
Fuel injection timing Before Top Dead Center °(degree) 11 ±1 11 ±1
Fan belt tension mm 8 Min. 6, Max. 10
Air conditioner Deflection when pressed with fin-

compressor belt ten- ger force of approx. 58.8 N{6 kg} mm 5–8 5–8
sion
20-2 PW200/220-7K
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Category
Permissible
Item Measurement Condition Unit Standard value
value
• Engine water temperature: Within

operation range
2 pumps at relief • Hydraulic oil temperature: Within
1,940 ±100 1,940 ±100
A mode operation range
• Engine at high idling
• Arm in relief condition
• Engine water temperature: Within
Engine speed
operation range
At 2-pump relief + one • Hydraulic oil temperature: Within
rpm
touch power up operation range 1,900 ±100 1,900 ±100
A mode • Engine at high idling
• Arm relief + One-touch power
max. switch in ON condition
• Auto-deceleration switch in ON
Speed when auto-
condition 1,400 ±100 1,400 ±100
deceleration is operated
• All control levers in NEUTRAL
condition
Boom control valve
Arm control valve
Bucket control valve
Spool stroke
Swing control valve

mm 9.5 ±0.5 9.5 ±0.5
Travel control valve
Adjust control valve
(2PBoom only)
Stabiliser control valve
Boom control lever 60.5 ±3.5 60.5 ±3.5
Travel of control
Arm control lever • Engine stopped 60.5 ±3.5 60.5 ±3.5

Bucket control lever • At center of control lever grip 60.5 ±3.5 60.5 ±3.5
levers
• Max. reading up to stroke end mm

Swing control lever (excepting lever play in NEU- 60.5 ±3.5 60.5 ±3.5
Travel control pedal TRAL position) 9.2 ±0.2 9.2 ±0.2
Play of control lever Max. 3.0 Max. 3.0
• Hydraulic oil temperature: Within 17 ±3.9 Max. 24.5
Boom control lever
operation range {1.7 ±0.4} {Max. 2.5}
• Engine at high idling 17 ±3.9 Max. 24.5
Arm control lever • At center of control lever grip {1.6 ±0.4} {Max. 2.5}
• At tip in case of pedal
14 ±2.9 Max. 21.6
Bucket control lever • Max. reading up to stroke end
{1.4 ±0.3} {Max. 2.2}
of control levers
Operating force
14 ±2.9 Max. 21.6

Swing control lever
{1.4 ±0.3} {Max. 2.2}
N{kg}
55.4 ±5 Max. 65
Travel control pedal
{5.5 ±0.5} {Max. 6.5}
340 ±17 {35 Max. 510 {Max.

Brake pedal
±3.5} 52.5}
PW200/220-7K 20-3
Applicable model PW200,220-7K (Std) PW220-7K (Opt HD Cwt)

Category
Standard Permissible
Item Measurement Condition Unit
value value
• Hydraulic oil temperature: Within

operation range
Unload 3.9 ±1.0 3.9 ±1.0
• Working mode: A mode
pressure {40 ±10} {40 ±10}
• Hydraulic pump output pressure with
all control levers in NEUTRAL posi-
tion
Boom • Hydraulic oil temperature: Within 34.8 ±1.0 33.3–36.8
Arm operation range {335 ±10} {340–375}
37.3 ±1.0 36.3–39.2
Bucket • Working mode: A mode
{380 ±10} {370–400}
• Hydraulic pump output pressure with
all measurement circuits relieved 30.9 ±1.5 28.9–32.9
Swing
• Values inside parenthesis: Hydraulic {315 ±15} {295–335}
Travel oil pressure with one-touch power
38.2 ±1.0 37.3–40.2
max. switch in ON mode (reference
Stabiliser {390 ±10} {380–410}
only)
Control operation range
circuit • Engine running at high idling 3.6 +0 / - 0.3 3.0–3.6
source • Control circuit pressure setting valve {36.7 +0 / -3} {30.6–36.7}
Hydraulic pressure
pressure input (7 station solenoid valve block

port P1)
MPa
Front Pump {kg/cm2}
• Roadwheels
raised off
ground
• LO travel
speed
• Hydraulic oil tem- • Service brake
perature: Within disengaged
operation range travel pedal
• Engine at high fully depressed
idling
• Working mode: L Rear Pump
LS control • Roadwheels 2.2 ±0.1 2.2 ±0.1
mode
circuit on ground. {22 ±1} {22 ±1}
• Disconnect the LS
EPC solenoid CN • Raise boom
V22 slowly
• Hydraulic pump • Measure pres-
pressure - LS sures during
pressure period where
main pump
pressure is
stabilised.
(approx
12~14MPa)
20-4 PW200/220-7K
Applicable model PW200,220-7K (Std) PW220-7K (Opt HD Cwt)

Category
value value
Swing
deg. Max. 100 Max. 130 Max. 100 Max. 130
brake
(mm) (–) (–) (–) (–)
angle • Hydraulic oil temperature: Within oper-
ation range
• Engine running at high idling
• Swing circle misalignment amount
when stopping after one turn
Swing
90° 3.0 ±0.3 Max. 3.6 3.0 ±0.3 Max. 3.6

• Hydraulic oil tem-
Time perature: Within
taken to operation range
• Engine running at sec.
start
swing high idling
• Working mode: A
mode 180° 4.3 ±0.4 Max. 5.1 4.3 ±0.4 Max. 5.1
• Time required for
passing points 90
and 180 degrees
from starting point
PW200/220-7K 20-5

Category
Permissible
value
Time taken to
sec. 25.4 ±2.5 Max. 30
swing
• Hydraulic oil temperature: Within operation range
• Time required for 5 more turns after making initial
one turn
Swing
15o
Hydraulic drift
mm 0 0
of swing • Hydraulic oil temperature: Within operation range
• Engine stopped
• Keeping upper structure transverse on slope of 15
degrees
• Notching a mating mark on inner and outer races of
swing circle
• Mating mark misalignment amount during 5 minutes
Leakage from • Engine running at high idling
¶/min Max. 5 Max. 10
swing motor • Swing lock switch: ON
• Leakage amount for one minute during swing relief
20-6 PW200/220-7K

Category
Permissible
value
CR 89.3±9 89.3±9
LO 18.9 +2 / -0 18.9 +2 / -0
• Machine in road travel posture
Travel speed • Engine running at high idle sec.
(1) • Hydraulic oil temperature
45~55oC
20km/h 9 + 1/ -0 9 +1 / -0
• Run up for at least 200M or until
the max travel speed is stabi-
lised,then measure time taken to Hi
travel the next 50M on flat ground
35km/h 5.1 +0.5 / -0 5.1 +0.5 / -0
Travel
CR 222 ±22 222 ±22
LO 951 +0 / -95 951 +0 / -95

• Raise machine road wheels off
Travel speed ground using work equipment rpm
(2) and chassis attachments
• Engine running at high idle 20km/h 2368 +0/ -238 2368 +0/ -238
• Service brake and park brake
both disengaged
Hi
• Fully depress travel pedal and
measure propshaft rotations.
• Hydraulic oil temperature 35km/h 3400 +0 / -340 3400 +0 / -340
45~55oC. Within operation range
PW200/220-7K 20-7

Leakage of travel motor Category
Item Measurement Condition Unit Standard value Permissible value
• Engine running at high idle

• Hydraulic oil temperature 45~55oC.
Leakage of travel Within operation range.
/min 5 ±1 Max. 10
motor • Apply service brake and relieve
travel circuit.
• Disconnect transmission drain line.
Whole work
equipment (tooth Max. 600 Max. 900
tip fall amount)
Boom cylinder
Hydraulic drift of work equipment
(cylinder retrac- Max. 18 Max. 27

tion amount) * PW200/220 = 2150kg (including
bucket mass)
Work equipment

Arm cylinder (cyl-
operation range
inder extension mm Max. 160 Max. 240
• Flat and level ground
amount)
• Work equipment in measurement
posture as illustrated above
Bucket cylinder • Engine stopped
(cylinder retrac- • Work equipment control lever in Max. 40 Max. 58
tion amount) NEUTRAL position
• Fall amount for 15 minutes as meas-
Second Boom ured every 5 minutes starting imme-
adjust cylinder diately after initial setting
Max. 20 Max. 30
(Cyl retraction
amount)
20-8 PW200/220-7K
Applicable model PW200-7K PW220-7K

Category
Standard Permissible Standard Permissible

value value value value
RAISE
3.8 ±0.4 Max. 4.6 3.8 ±0.4 Max. 4.6
Mono
boom
boom • Hydraulic oil temperature: Within
lift operation range
LOWER
2.9 ±0.5 Max. 3.5 2.9 ±0.5 Max. 3.5
• Working mode: A
• Time required from raise stroke
end till bucket touches ground
RAISE
4.2 ±0.4 Max. 5.0 4.2 ±0.4 Max. 5.0

Two
Work equipment speed
piece
Work equipment

1st operation range
boom sec.
LOWER
lift • Working mode: A

3.3 ±0.3 Max. 3.9 3.3 ±0.3 Max. 3.9
end till bucket touches ground
RAISE
5.0 ±0.5 Max. 6.0 5.0 ±0.5 Max. 6.0

Two
piece
boom
2nd
LOWER
adjust operation range

5.0 ±0.5 Max. 6.0 5.0 ±0.5 Max. 6.0
• Working mode: A
end till lower stroke end
PW200/220-7K 20-9

Category

RAISE
• Hydraulic oil temperature: Within 3.5 ±0.5 Max. 4.5 3.5 ±0.5 Max. 4.5
operation range
Outrig-
• Working mode: A
ger
• Time required for 1 outrigger
raise stroke end to lower stroke
LOWER
end. 3.9 ±0.4 Max. 4.7 3.9 ±0.4 Max. 4.7
RAISE
2.1 ±0.3 Max. 2.7 2.1 ±0.3 Max. 2.7

operation range
Dozer • Engine running at high idle
Blade • Working mode: A
end to lower sroke end.
LOWER
2.1 ±0.3 Max. 2.7 2.1 ±0.3 Max. 2.7
20-10 PW200/220-7K

Category

3.8 ±0.4 Max. 4.6 3.8 ±0.4 Max. 4.6
IN
Arm
operation range
OUT
Work equipment speed
• Engine running at high idling 3.0 ±0.3 Max. 3.6 3.0 ±0.3 Max. 3.6
• Time required from dumping
stroke end to digging stroke end
CURL
2.5 ±0.3 Max. 3.1 2.5 ±0.3 Max. 3.1
Work equipment
Bucket
operation range
DUMP
• Engine running at high idling 2.4 ±0.3 Max. 3.0 2.4 ±0.3 Max. 3.0
• Time required from dumping
stroke end to digging stroke end
Mono-
Time lag
boom
• Hydraulic oil temperature: Within opera- sec. Max. 1.0 Max. 1.2
boom
lift tion range
• Engine running at low idling
• Operate full boom down from stroke end
till bucket touches ground. Measure delay
from bucket touching ground to bucket
starting to push the machine up.
PW200/220-7K 20-11

Cate-gory
value value
Arm Max. 1.0 Max. 1.2

• Operate full arm curl from dumping stroke end to full
retraction. Measure delay when arm pauses midway
Time lag
through operation sec.
Bucket Max. 1.0 Max. 1.2

Work equipment

• Operate full bucket curl from dumping stroke end to
full retraction. Measure delay when bucket pauses
midway through operation
Internal leakage
Cylinders • Hydraulic oil temperature: Within operation range 5 20

leackage

cc/min
• Leakage amount for one minute with cylinder or travel
Center swivel
to be measured in relief condition 10 50
joint

Two piece • Engine running at low idle
Time lag
boom 1st • Operate full boom down from stroke end till bucket sec. Max. 1.0 Max. 1.2
boom lift touches ground. Measure delay from bucket touching
ground to bucket starting to push the machine up.
20-12 PW200/220-7K

Cate-gory
value value

Two piece • Engine running at low idle
boom 2nd • Operate full boom adjust down from stroke end till Max. 1.0 Max. 1.2
boom adjust bucket touches ground. Measure delay from bucket
touching ground to bucket starting to push the
machine up.
Work equipment
Time lag
sec.

• Engine running at low idle
Outrigger • Raise outrigger off ground then operate full lower Max. 1.0 Max. 1.2
• Measure delay from when outrigger touches ground
to outrigger starting to lift machine up

• Engine running at low idle
Blade • Raise blade off ground then operate full lower Max. 1.0 Max. 1.2
• ‘Measure delay from when blade touches ground to
blade starting to lift machine up
Performance of
hydraulic pump
Hydraulic pump
See next page ¶/min See next page
delivery
PW200/220-7K 20-13

Cate-
gory
Discharge amount of hydraulic pump (A mode)
Performance of hydraulic pump
• Pump speed: At 1,950 rpm, PC current 310 mA
Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point
pressure other pump amount Q limit Q
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) (¶/min) (¶/min)
As desired P1 P2 P1+P2 See graph See graph

2
★ As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
★ When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the spec-
ified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of
measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
20-14 PW200/220-7K
Applicable model tbc

Cate-
gory
Discharge amount of hydraulic pump (A mode)
Performance of hydraulic pump
• Pump speed: At 2,050 rpm, PC current 310 mA
Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point
pressure other pump amount Q limit Q
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) (¶/min) (¶/min)
As desired P1 P2 P1+P2 See graph See graph

2
★ As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
★ When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the spec-
ified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of
measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PW200/220-7K 20-15
Flow control characteristic of PC valve (STD)

★ The values in this table are used as reference values when carrying out troubleshooting.
PW200, 220-7K
Applicable model
(Std)
Category Item Measurement Condition Unit Reference Value
Mono boom
Time required for turn-
Characteristics of 4.4 ±0.4
ing from 0 to 90 • Hydraulic oil temperature: Within operation
PC flow control sec. Two piece boom
degrees with boom range
valve 4.1 ±0.4
raised • Engine at high idling
• Rated load applied to bucket
• Solid and flat ground
• Time required till passing spot of 90 degrees
starting from illustrated posture and with boom
raised
PW220-7K
Applicable model
(Opt HD Cwt)
Category Item Measurement Condition Unit Reference Value
Mono boom
Time required for turn-
Characteristics of 4.6 ±0.4
ing from 0 to 90 • Hydraulic oil temperature: Within operation
PC flow control sec. Two piece boom
degrees with boom range
valve 4.3 ±0.4
raised • Engine at high idling
• Rated load applied to bucket
• Solid and flat ground
• Time required till passing spot of 90 degrees
starting from illustrated posture and with boom
raised
20-16 PW200/220-7K
( PW200-7, PW220-7 )
PW200 PW220
20-17 PW200/220-7K
20-18
TESTING AND ADJUSTING
Rear pump output pressure checking port

3a PC-EPC valve outlet pressure checking port PM
Front pump outlet pressure checking port PFC 3b Front servo piston inlet pressure PENF
Front pump load pressure input port PRC 4a LS-EPC valve outlet pressure checking port PSIG
Rear pump load pressure input port PLSF 4b Rear servo piston inlet pressure PENR
PW200/220-7K
20-19
Model Serial No. Service meter reading Client user's name Implemented on: Inspected by:
1 Engine (PW200 / 220-7)
Condition setting Standard value
No Fuel Dial Working Auto One-touch Work equipment operation Measurement item Unit New machine Failure judgement Measured value Judgement
mode decelerator power max switch
1 Engine rotation rpm 2000 ~ 2200 2000 ~ 2200 Good / No good

Full 2
2 All control levers Engine oil pressure Mpa(kg/cm ) 0.39 ~ 0.64 (4.0 ~ 6.5) 0.25 (2.6) Good / No good
OFF
3 in NEUTRAL Engine rotation rpm 950 ~ 1050 950 ~ 1050 Good / No good
Low OFF
4 A Engine oil pressure Mpa(kg/cm 2) Min 0.15 (Min 1.5) Min 0.09 (Min 0.9) Good / No good
5 Travel relief Engine rotation rpm 1850 ~ 2050 1850 ~ 2050 Good / No good
OFF
6 Full (Apply service brake) Blow-by pressure kPa(mmH 2O) Max 1.2 (Max 123) 5.1 (520) Max Good / No good
7 ON OFF All control levers in NEUTRAL Engine rotation rpm 1300 ~ 1500 1300 ~ 1500 Good / No good
2 Work Equipment speed (PW200 / 220-7)

Hydraulic oil temperature (45 ~ 55° C)
Condition Setting Standard Value
PW200-7 PW220-7 Measured value Judgement

No
Fuel Dial Working Work equipment posture Measurement item Unit PW200 / PW220 *
mode Monoboom Two Piece Boom Monoboom Two Piece Boom Monoboom / Two Piece Boom *
Nom Value Tolerance Nom Value Tolerance Nom Value Tolerance Nom Value Tolerance
No load, fully extended 1st Boom RAISE 3,8 3.4 ~ 4.2 4,2 3.8 ~ 4.6 3,8 3.4 ~ 4.2 4,2 3.8 ~ 4.6 Good/No good
1
No load, 1st Boom max extend 2nd Boom RAISE 5 4.5 ~ 5.5 5 4.5 ~ 5.5 Good/No good
2 A Arm DUMP 3,0 2.7 ~ 3.3 3,0 2.7 ~ 3.3 3,0 2.7 ~ 3.3 3,0 2.7 ~ 3.3 Good/No good
3 Boom held level Arm DIG 3,8 3.4 ~ 4.2 3,8 3.4 ~ 4.2 3,8 3.4 ~ 4.2 3,8 3.4 ~ 4.2 Good/No good
4 E s 3,9 3.5 ~ 4.3 3,9 3.5 ~ 4.3 3,9 3.5 ~ 4.3 3,9 3.5 ~ 4.3 Good/No good
5 (L) 6,2 5.6 ~ 6.8 6,2 5.6 ~ 6.8 6,2 5.6 ~ 6.8 6,2 5.6 ~ 6.8 Good/No good
6 Boom & Arm held level Bucket DIG 2,5 2.2 ~ 2.8 2,5 2.2 ~ 2.8 2,5 2.2 ~ 2.8 2,5 2.2 ~ 2.8 Good/No good
Swing (5 turns) right 25,4 22.9 ~ 27.9 25,4 22.9 ~ 27.9 25,4 22.9 ~ 27.9 25,4 22.9 ~ 27.9 Good/No good
7
Full Fully extended left 25,4 22.9 ~ 27.9 25,4 22.9 ~ 27.9 25,4 22.9 ~ 27.9 25,4 22.9 ~ 27.9 Good/No good
Time to start swing 90° 3,0 2.7 ~ 3.3 3,0 2.7 ~ 3.3 3,0 2.7 ~ 3.3 3,0 2.7 ~ 3.3 Good/No good
8
(empty bucket) 180° 4,6 4.1 ~ 5.0 4,6 4.1 ~ 5.0 4,6 4.1 ~ 5.0 4,6 4.1 ~ 5.0 Good/No good
Hi (35km/h spec) road speed km/h 35 31.5 ~ 35.0 35 31.5 ~ 35.0 35 31.5 ~ 35.0 35 31.5 ~ 35.0 Good/No good
9
prop speed rpm 3400 3060 ~ 3400 3400 3060 ~ 3400 3400 3060 ~ 3400 3400 3060 ~ 3400 Good/No good
Hi (20km/h spec) road speed km/h 20 18 ~ 20 20 18 ~ 20 20 18 ~ 20 20 18 ~ 20 Good/No good
10
Travel prop speed rpm 2368 2130 ~ 2368 2368 2130 ~ 2368 2368 2130 ~ 2368 2368 2130 ~ 2368 Good/No good
A Lo road speed km/h 9,5 8.6 ~ 9.5 9,5 8.6 ~ 9.5 9,5 8.6 ~ 9.5 9,5 8.6 ~ 9.5 Good/No good
11
Creep road speed km/h 2,0 1.8 ~ 2.2 2,0 1.8 ~ 2.2 2,0 1.8 ~ 2.2 2,0 1.8 ~ 2.2 Good/No good
12
Single Outrigger lower 3,9 3.5 ~ 4.3 3,9 3.5 ~ 4.3 3,9 3.5 ~ 4.3 3,9 3.5 ~ 4.3 Good/No good
13
Chassis attachments up raise s 3,5 3.2 ~ 3.9 3,5 3.2 ~ 3.9 3,5 3.2 ~ 3.9 3,5 3.2 ~ 3.9 Good/No good
Dozer Blade lower 2,1 1.9 ~ 2.3 2,1 1.9 ~ 2.3 2,1 1.9 ~ 2.3 2,1 1.9 ~ 2.3 Good/No good
14
raise 2,1 1.9 ~ 2.3 2,1 1.9 ~ 2.3 2,1 1.9 ~ 2.3 2,1 1.9 ~ 2.3 Good/No good
* delete as applicable to machine under inspection
3 Work Equipment hydraulic drift amount (PW200 / 220-7)

Hydraulic oil temperature (45 ~ 55° C)
Condition Setting Standard Value
No Fuel Dial Working Work equipment posture Measurement item Unit Mono Boom Two Piece Boom Measured value Judgement
mode
New model Failure judgement New model Failure judgement
Hydraulic drift amount at
1 Engine stop Boom and Arm held level, Bucket loaded mm Max 600 Max 900 Max 600 Max 900 Good/No good
bucket tooth tip (15min)
PW200/220-7K
20-20
4 Inspection of hydraulic circuit (PW200 / 220-7
c d e f g
Condition Setting kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2
No Part to be checked Fuel Dial Working Auto One-touch F main pump R main pump F main pump LS R main pump LS Control circuit Remarks
Work equipment operation
mode decelerator power max switch pressure
1 PPC circuit Circuit pressure 3.6 +/- 0.2MPa (36.7 +/- 2.0kg/cm2)
OFF
2 Main relief valve Arm dumping relief 34.8 +/- 0.5MPa (355 +/- 5kg/cm2)
3 (When power increased) A ON 37.2 +/- 0.5MPa (380 +/- 5kg/cm2)
Main - LS = 3.9 +/- 1.0MPa (40 +/- 10kg/cm2)
Neutral
LS differential pressure = Unload pressure
Raise road wheels clear of ground using work equipment &
chassis attachments.
LS valve Disconnect V22 (LS EPC solenoid)
(LS differential L Select LO travel speed.
4
pressure valve) Full mode OFF Fully depress travel pedal.
Main - LS = 2.2 +/- 0.1 MPa (22 +/- 1kg/cm2)
Lower machine with roadwheels on ground
OFF
Disconnect V22 (LS EPC solenoid)
Raise boom very slowly by operating wrist levers.
During the portion where main pump pressure is stable
at approx 12~14 MPa measure data P.
Right relief
5 Swing safety valve Swing lock switch ON 30.9 +/- 1.5MPa (315 +/- 15kg/cm2)
Left relief
A
Main relief valve, Travel relief Forward
6 38.2 +/- 1.0MPa (390 +/- 10kg/cm2)
Travel safety valve, Reverse
Connection to be changed at hosese and f
c d e f g
Condition Setting kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2
No Part to be checked Fuel Dial Working Auto One-touch F main pump R main pump F main pump servo R main pump servo Control circuit Remarks
mode decelerator power max switch pressure
Main servo balance pressure balance

7 Servo Full A OFF OFF Arm dumping relief
e/c= f/d = 3/5
Connection to be changed at hosese and f, and guage to be replaced with one

with K capacity
c d e f
Condition Setting kg/cm2 kg/cm2
No Part to be checked Fuel Dial Working Auto One-touch F main pump R main pump PC LS Remarks < Reference value : kg/cm2 >
mode decelerator power max switch EPC EPC
Low < 3.2MPa (36.7kg/cm2) Delivery variance by switching mode>

A
< 0.6MPa > Q
8 PC - EPC valve E OFF OFF Neutral < 1.2MPa >
Full
L < 1.8MPa >
B < 1.4MPa > P
Neutral At neutral : 3.6MPa (36kg/cm2)
A
9 LS - EPC valve Full OFF OFF When two pumps relieved : 0MPa (0kg/cm2)
Arm dumping relief
L When one pump relieved : 1.6MPa (16kg/cm2)
P-M Tune Up Data2.xls 23/04/2003
PW200/220-7K
OTHERS HYDRAULIC CIRCUIT DIAGRAM (1/2)
HYDRAULIC CIRCUIT DIAGRAM (1/2)

PW200-7K, PW220-7K
PW200/220-7K 90-3
THIS PAGE LEFT INTENTIONALLY BLANK
90-4 PW200/220-7K
HYDRAULIC CIRCUIT DIAGRAM (2/2)

PW200-7K, PW220-7K
PW200/220-7K 90-5
90-6 PW200/220-7K
OTHERS ELECTRICAL CIRCUIT DIAGRAM (1/3)
ELECTRICAL CIRCUIT DIAGRAM (1/3)
PW200-7K, PW220-7K
PW200/220-7K 90-7
90-8 PW200/220-7K
PW200-7K, PW220-7K
PW200/220-7K 90-9
90-10 PW200/220-7K
PW200-7K, PW220-7K
PW200/220-7K 90-11
90-12 PW200/220-7K

(SM) pw200 - pw220 - Preliminary - Version2

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(SM) pw200 - pw220 - Preliminary - Version2

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What equipment does this manual cover?

What equipment does this manual cover?

What information is included in the specifications section?

What information is included in the specifications section?

UEBM00190X

MACHINE MODEL SERIAL NUMBER

PW220-7K 00 K40001 AND UP 00

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . 10-1

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . Will Be Issued Later

Specification Dimension Drawings

Arm length mm (Tt/In) 1800 2400 2900 3500

Arm length mm (Tt/In) 1800 2400 2900 3500

Swing speed rpm 12.4

Flywheel horsepower kW/rpm {HP/rpm} 106.7/1,950 {143/1,950}

Max. torque Nm/rpm {kgm/rpm} 610.0/1,500 {62.2/1,500}

Starting motor 24V, 4.5 kW

Type x No. HPV95+95, variable displacement

Delivery l/min Piston type: 214 x 2

Type x No. 1 Piece Boom 6-spool + 1 service spool type x 1 Hydraulic

Travel motor A6VM140 HAXT/63W-V2B380A-SK, Piston type

(with counter balance valve): x 1

Type Boom Arm Bucket

Double act- Double acting Double acting

ing piston piston piston

Inside diameter of cylinder mm 120 135 115

Max. distance between pins mm 3,204.5 3,565 2,800

Double act- piston piston

Inside diameter of cylinder 185 135 135 115

KIND AMBIENT TEMPERATURE CAPACITY (l)

Diesel ASTM D975 No. 2

Cooling system Water Add antifreeze 23 —

Front Fuchs titan hydra 20W-40 2.85 —

ENGINE RELATED PARTS

1. Drive plate 5. Damper assembly

RADIATOR • OIL COOLER • CHARGE AIR COOLER

Oil Coolant Air

1. Centre swivel joint 10. Accumulators

1 Swing circle inner race (No. of teeth: 92)

Amount of grease: 15.8l (G2 - LI)

No Check item Criteria Remedy

SWING MACHINERY & MOTOR

1 Swing pinion (No. of teeth: 12)

No. Check item Criteria Remedy

B From swing lock solenoid valve PW200-7 PW220-7

1. Brake spring 11. Valve plate

No. Check item Criteria Remedy

Standard size Repair limit

Operation of swing lock

together, and the brake is applied.

2.When swing lock solenoid valve is excited

RELIEF VALVE PORTION

1. Undercarriage 8. Double Wheel Assy

Type Single motor two speed automatic powershift

Pressure applied in port P will disengage the small

Park brake switch Park brake solenoid valve

Controller Transmission clutch solenoid valve

Hi sun + planet locked together, planetary drive = 1:1

1. Sleeve 8. Roller Bearing