PC200-8

HYDRAULIC EXCAVATOR
13 April 2006
AT
PC200-8
KAP TRAINING CENTRE
KI Page 1 / 54
Course Program

0900~0905 Opening Speech

0905~1030 Major Improvement -7 to -8
1030~1045 Tea Break
1045~1200 Engine 107 & Fuel system.
1200~1300 Lunch.
1300~1500 Monitor Practice & Field Test
Procedures.
1500~ 1545 Discussion.

PC200-8 Page 2 / 54
 PC200-8
Major Improvement From dash 7 to
dash 8

PC200-8
Overall Layout
Pilot filter (for ATT specification-based machines alone)
Single action/double action Fuel pre-filter
selector valve Control (with water separator)
Engine oil filter
(For ATT specification-based Battery Fuel tank valve Hydraulic oil tank
machines alone)
Main pump
Low-pressure
accumulator
(For ATT specification-
based machines
alone)

Swing motor/
swing machinery Fuel main filter

Swivel joint
Engine
(Tier 3 supported)
Multi pattern selector valve
(OPT)
Radiator
CAB
Oil cooler

After cooler

Fuel cooler

Condenser of air conditioner

(Receiver dryer contained)

Extended return filter

(For ATT specification-based machines alone) Air cleaner
Washer tank Reserve tank Tool box Grease gun holder

PC200-8 Page 4 / 54
Major Improvement

(A) Engine

PC200-8 Page 5 / 54
Engine
SAA6D102E (145PS) to SAA6D107 (150PS),
PC200-8 PC200-7
Fuel main filter Fuel filter
2m to be replaced at every 1000h 25m to be replaced at every 500h
Engine oil filter
Engine oil filter

Governor motor
Engine controller

Fuel pre-filter Fuel spill hose

To be abolished from Model 8 Water separator
10m to be replaced at every 500h
Equipped with built-in water separator (To be returned to the return pipe inside the engine)
Equipped with priming pump (manual)
KI PC200-8 Pulley Ratio -!.03
Change of fan - pulley ratio PC200: 0.87 0.96 Noise reduction
PC220: 0.96 1.03
PC200-8 Page 6 / 54
Engine
Fuel pre-filter Anti-noise muffler

Priming pump
Employment of
(manual)
two internal pipes

30 to 60 times

Pre-filter (10m)

Glass wool
Muffler cover
Water separator

For water separator

Water-in-fuel sensor

(Inspection before starting

operation is available from
the monitor panel) Provided to reduce engine exhaust noise

PC200-8 Page 7 / 54
Action against POOR FUEL for Common Rail system

For Poor Fuel Quality area like a South East Asia, China, Africa and
etc
Set up a NEW Filtering system for POOR FUEL.
Main Filter : Two 2 Filter (same as current Filter but add One
more)-Join in series
Additional Water Separator (same as current, used in Tier 1 /Tier2
107& 114 Eng = add 1 unit, 125 and bigger Eng = add 2 units
(parallel)

1. For 3 Region = USA, Europe, Japan and etc

10pre-filter + 2 main filter as STD

2. For non Tier3 Region = S.E.Asia, China, Africa and etc -> Add +
10pre-filter + 2main filter + (2main filter + Water separator)

PC200-8 Page 8 / 54
Layout of additional fuel main filter2 + water
separator
Standard spec For poor fuel quality country

Main fuel filter (2) x 1pc

Pre-fuel filter (10) w/ water Additional water separator One additional Main
separator x 1pc Mounted frame outer cover of fuel filter (2) series
the machine body (Centrifugal type-)series
Mounted frame outer cover of Mounted frame outer cover Mounted frame outer
the machine body Every 1000h cover of the machine
of the machine body
Every 500h
body
PC200-8 Page 9 / 54

History of fuel filter system development for CRI engine Fuel acceptable level

Tier2
Tier 2 Before C/M At the (Tier2
first time of CRI engine (Tier2) introduction, injector worn were appeared. NASWater contents
NAS

Std 55
Main


(before C/M) 8
grade 0.1%

For poor fuel arrangement 10
Pre- 10
55
Main 11 grade
+
0.6%
W/S
W/separator (before C/M)
()
(current)

Tier2
Tier2 After C/M (
By this measure, the problem was solved considerably.
Tier3Current
Tier3 for USA, etc NAS
NASWater contents

10
Pre- 10

Global standard 2 2
Main
+
)
(current) 13 grade
0.6%
W/S
W/separator
(current)
()

Tier3 New poor fuel However, the further measure is required to aim at market introduction
( NAS Water
NAS contents
New
for SEFiltering System
Asia, China, of PC200-8 in comfort to fuel with much water of Indonesia,
etc
and fuel with much dust of China.
Tier2,Tier3
10
Pre- 10 2 2
Main
Std + )
(current) 13 grade
0.6%
W/S
W/separator
()
(current)

For poor fuel arrangement

10
Pre- 10 22
Main Main
22

W/S
Water +
15 grade 0.6%
() )
(current) )
(current)
separator W/S
W/separator ( 2% )
(Centrifugal) (current)
()
PC200-8 Page 10 / 54
NAS Standard
NAS (National Aerospace Standard) 1638
No
of
pie
1,2 ces i Graf shows the particle size 5-15 micron
0 n
1,0 0,000 100 C
00, ...
800 00 0 Tier 3
,
600 000
,
400 000 Required
, for fuel
200 000 system
,00
0
0
class

Particle
size(m 6 7 8 9 10 11 12
515 16,000 32,000 64,000 128,000 256,000 512,000 1,024,000
1525 2,850 5,700 11,400 22,800 45,600 91,200 182,400
2550 506 1,012 2,025 4,050 8,100 16,200 32,400
50100 90 180 360 720 1,440 2,880 5,760
>100 16 32 64 128 256 512 1,024
Unit: pieces in 100 cc oil

Note: Tier 3 is possible to use max. NAS 13 class fuel, however we request fuel contamination control

PC200-8 Page 11 / 54
 Counter-measure for Indonesia Market

Wear of the injector has been caused by the excessive

Contamination and Water within the fuel.
In order to allow 2% water in the fuel, additional Water
Separator (other than the current Water Separator) is
necessary to prevent the failure of the injector.
Even though installing additional Water Separator, water
must be drained periodically because there is a limit in
capturing water in a Water Separator.
Therefore, allowable water in the fuel is Max 0.6%.

PC200-8 Page 12 / 54
WATER SEPARATOR EFFICIENCY

CURRENT COUNTERMEASURE

Water Content in Fuel % 0.6 2 2

Water Remove Efficiency by Water

% 95
Additional Separator (centrifugal)

Water Remove Efficiency by Water

% 95 95 95
Separator by Pre-Fuel Filter

Water Content of Output PPM 300 1000 50

Acceptable Range : 500 ppm and below

The fuel circuit is installed with two water separator in series connection of which its filtering
efficiency is upto 95%.
When 2% of water is mixed with fuel, the output of the filtering effect is acceptable.

PC200-8
Changes done around Engine
Change in engine mount structure
PC200-8 PC200-7

Change in stopper
structure

Change in lock

The same structure as PC400-7

PC200-8 Page 14 / 54
Changes done around Engine
Change in air cleaner and intake port

PC200-8 PC200-7

Intake port

Change in the size (PC200-8 alone): 11 inches 10 inches. PC220-7 is 11 inches.

PC200-8 Page 15 / 54
Cooling
Change in Cooling

PC200-8 PC200-7
Radiator
After cooler
Oil cooler
Oil cooler
Radiator

After cooler
Fuel cooler
Condenser of air conditione
Condenser of air conditioner

Side-by-side type Face-to-face type

PC200-8 Page 16 / 54
Cooling
Change in Cooling

PC200-8 PC200-7
Radiator
Oil cooler
After cooler
Radiator
Fuel cooler Oil cooler

After cooler
Condenser of
air conditioner

Condenser of air conditioner

Oil cooler is 3- Receiver dryer has a combined Pilot check valve:

piece assembly type structure To be contained in the control valve
(The same structure as PC228US- from Model 8
3)
PC200-8 Page 17 / 54
Major Improvement

(B) Electrical Parts

PC200-8 Page 18 / 54
Electrical equipment on Machine Body
Change in harness
PC200-8 PC200-7
All connectors were abolished Divided by connectors
and replaced with harnesses
To controller and To sensors on the
monitor machine body
To controller and To sensors on the
monitor machine body

Outside the CAB Inside the CAB Outside the CAB

Inside the CAB

Change in clip
PC200-8 PC200-7

Colgate clip (resin)

PC200-8 Page 19 / 54
 Electrical equipment on Machine Body
Change in travel alarm
Reduction in size of travel alarm

Model 7
Model 8

PC200 107dB
PC200 97dB
PC220 107dB
PC220 107dB

Improved safety of power supply circuit

Signal and power supply Ordinary conduit and tape are used
Employment of independent Heat-resistant conduit circuit (united)
power supply circuit (Single line) and tape are used

Model 8 Model 7 Alternator

Alternator

vinyl tape has been increased from 95C to 125C.

PC200-8 Page 20 / 54
Electrical equipment on Machine Body
Pressure sensor

Change in high-pressure sensor Change in connector

AMP EJ II (3-pole) DT (3 pole)

Six low-pressure sensors have been employed for PPC circuit

Current: Pressure switch
Connector: AMP EJ II (3-pole)

PC200-8 Page 21 / 54
Major Improvement

(C) Hydraulic Components

PC200-8 Page 22 / 54
Hydraulic Equipment and Pipe related Changes
New junction valve
Overview of Hydraulic Equipment EPC valve has been employed for the control of converging
and Pipe related Changes and dividing of main and LS (currently the control is done by
ON or OFF of the solenoid valve)

PPC circuit: Pressure sensor Pressure switch Employment of control valve-contained cooler check valve

PC200-8 Page 23 / 54
Hydraulic Equipment and Pipe related Changes
Overview of Hydraulic Equipment and Pipe related Changes
Reduction of hydraulic oil tank capacity 190L 200L

Changes in the main relief valve structure

The arm dump side safety valve has been replaced

with the centralized safety valve

Employment of the arm quick return valve

An EPC valve for PC control has been added to

support independent control of F and R pumps

Changes in the control valve mounting method (employment of bottom tightening) Changes in the discharge port (drawn out sideways)

PC200-8 Page 24 / 54
Hydraulic Equipment and Pipe related Changes
Changes in Control Valve Mounting Method

PC200-8 PC200-7

Tightening at bottom Tightening in sideways

PC200-8 Page 25 / 54
Hydraulic Equipment and Pipe related Changes
Employment of Control Valve-contained Cooler Check Valve
PC200-8 PC200-7

Cooler check valve

From oil cooler

Cooler check valve

To oil cooler To tank

Return Return

PC200-8 Page 26 / 54
Hydraulic Equipment and Pipe related Changes

Changes in Main Relief Valve Structure

PC200-7

PC200-8

The same structure as PC220-7

to PC400-7 has been employed

PC200-8 Page 27 / 54
Hydraulic Equipment and Pipe related Changes
Employment of Arm Quick Return Valve
B

From cylinder To tank

From cylinder

To control valve To tank Pilot signal for arm dump

(From internal passage
A-A B-B of control valve)

PC200-8 Page 28 / 54
Hydraulic Equipment and Pipe related Changes
To boom cylinder bottom
Replacement of Arm Dump Side Safety
Valve with Centralized Safety Valve
Boom valve
Pump circuit

Centralized
safety valve

To arm cylinder head

Arm valve

Tank circuit
Pump circuit

PC200-8 Page 29 / 54
Hydraulic Equipment and Pipe related Changes
Improvement in Oil Pressure Loss through
Employment of new Converging and Dividing Control
When flows from pumps are converged When pumps are divided

Converging and
dividing of the pumps
are executed
corresponding to the
pump pressures and
work patterns.

150 kg/cm2 50 kg/cm2 150 kg/cm2 50 kg/cm2

50 kg/cm2
Converged 150 kg/cm2 150 kg/cm2
150 kg/cm2
100 L/min
100 L/min 100 L/min 100 L/min

Press loss Divided

100 kg/cm2 100 L/min

Pumps R and F are

Division loss
independently controlled

PC200-8 Page 30 / 54
Hydraulic Equipment and Pipe related Changes
Improvement in Oil Pressure Loss through Employment of new Converging and Dividing Control
PC200-8 PC200-7

F control valve R control valve F control valve R control valve

Converging and Converging
dividing valve and dividing valve

Pressure
LS line SW
LS line Pressure
Pump sensor
Main line Main line
Pressure
sensor Pump
Pump Pump F Pump
F R Pressure
Pump sensor
R
LS valve LS valve LS valve LS valve

PC valve PC valve PC valve PC valve

LS_EPC LS_EPC

Controller
PC_EPC_R PC_EPC
ON/OFF solenoid
Controller

PC_EPC_F
valve for converging
Converging/ and dividing
dividing LS selector
proportional solenoid

Converging/
dividing main selector
proportional solenoid

PC200-8 Page 31 / 54
Hydraulic Equipment and Pipe related Changes
Changes conducted on main Pump

1) Improvement of pump efficiency HPV95+95, the same as Model 7.

2) Employment of two EPC valves

PC200-8 PC200-7
R pump discharge pressure F pump discharge pressure LS-EPC valve PC-EPC valve for F pump
pick-up port pick-up port

R pump LS pressure pick-up port F pump discharge pressure pick-up port

Changes conducted on pump discharge port
PC-EPC valve for R pump

PC200-8 Page 32 / 54
Major Improvement

(D) Frame and Cabin

PC200-8 Page 33 / 54
Revolving frame
Enlargement of Opening below Engine

PC200-8 PC200-7
Engine controller Supply pump
Injection pump

604 500

300

562.5

PC200-8 Page 34 / 54
Operator Cab and inside Cab
Employment of Operator Protective Cab Structure in Tipping Over

PC200-8 Page 35 / 54
Operator Cab and inside Cab
Employment of Operator Protective Cab Structure in Tipping Over

M12 bolt tightening torque: 98 to 123 Nm

Cab

Revolving frame
Details of stopper

M30 bolt tightening torque: 245 to 309 Nm

PC200-8 Page 36 / 54
Operator Cab and inside Cab
Cab Equipment One-touch storage of the
front window's lower glass
Grade up of monitor panel

7-inch color LCD

A large ashtray is newly prepared

Armrest

PC200-8 Page 37 / 54
Operator Cab and inside Cab
Electrical Equipment in rear side of CabPump controller
KOMTRAX

Air-con. controller

Change of relay

PC200-8 Page 38 / 54
Operator Cab and inside Cab
Pump Controller
PC200-8 PC200-7

Locked state Freed state

New type connector
Press the pawl

Raise the lever to remove

PC200-8 Page 39 / 54
Operator Cab and inside Cab
Monitor light switch

RH console

Light switch
(3-position type)

Position for nighttime

Light off position

Position for daytime

PC200-8 Page 40 / 54
Operator Cab and inside Cab
Monitor Panel
Functional integration
PC200-8 PC200-7
Monitor panel Monitor panel KOMTRAX controller

Communication terminal
Display unit Display unit (Dopa)
Control unit
Control unit GPS terminal
and storage
Switch unit
KOMTRAX Switch unit Control unit
(including air
communication terminal
conditioner switch)
Communication terminal
GPS function (Dopa) CAN

Controller for air conditioner Panel for air conditioner (Controller)

CAN Control unit

Display unit Air conditioner body

Air conditioner body Control unit

Switch unit

PC200-8 Page 41 / 54
Machine Cab
Overview of Changes conducted on Machine Cab

PC200-8 PC200-7

gas dumper

Complied with the new ISO standard

PC200-8 Page 42 / 54
Machine Cab
New Employment of PC200-8 PC200-7 (Existing machine)
Protrusion Type Slip-proof
Abrasive paper type

Protrusion type slip-proof

PC200-8 Page 43 / 54
Machine Cab
Field of Vision complied with New ISO Standard
PC200-8 PC200-7
Size: W200 H280 Size: 250 Size: W130 H280
Curvature: 1000 Curvature: 400 Curvature: 620

Size: W200 H280 Size: 250 Size: W135 H285

Curvature: 1000 Curvature: 400 Curvature: 620

PC200-8 Page 44 / 54
Machine Cab
Employment of Press Type Frame
Sounds of wind suctioned from the fan
PC200-8 PC200-7 is absorbed in the fan
PC200-8

Acoustic Sound absorption is done here

Pressed into
Welding
a single body

PC200-8 Page 45 / 54
Machine Cab
Employment of Gas Dumper for Opening and Closing of Engine Hood
PC200-8 PC200-7
Allows easy opening with a single hand Gas dumper Torsion bar

PC200-8 Page 46 / 54
Major Improvement

(E) Swing and Travel Motor

PC200-8 Page 47 / 54
Swing Machinery
Remote Draining of Swing Machinery
Remote draining of swing machinery has been made easier

PC200-8 PC200-7

Drain plug

PC200-8 Page 48 / 54
Swing Machinery
Swing motor
Shape of the motor case has been modified
PC200-8 PC200-7

KMF125ABE-6.

Reverse
prevention
valve

PC200-8 Page 49 / 54
Travel Machinery
Travel motor
PC200-8 PC200-7

floating seal with smaller diameter

tapered roller bearing

PC200-8 Page 50 / 54
Undercarriage-related Changes
Travel Motor
PC200-8 PC200-7

Changes in upper track roller holding approach

Step of track frame
Employment of additional improved riding step
for wide shoe (for shoes 800m or above only)

PC200-8 Page 51 / 54
Work Equipment
Current bushing at the arm tip has been replaced with CRHF
Bushing at Arm Tip bushing excelling in seizure resistance and wear resistance.

CRHF
CRHF
Bucket side end face:
IQT Sprayed with WC (tungsten)
(Hardening and tempering)

Bushing end face:

CRHF Sprayed with WC (tungsten)

(Carbide Reinforced Hardfacing Ferrous alloy)

PC200-8 Page 52 / 54
Engine/Pump Matching Control
Control of Model 8 Thus, two engine curbs are used on this Model 8.
Matching points are selectively used depending
Common rail type engine has been newly installed on the operation pattern.
Model 8.
Control of the engine is done with the engine controller. It (When the fuel dial is full in P mode)
is capable of controlling fuel injection.

Matching point 1 in P mode (P1)

When the operation pattern
requires full horsepower

Constant horsepower line

Torque

This difference in horsepower

represents the improvement Matching point 2 in P mode (P2)
done in pressure loss When the operation pattern
with and improved pressure
loss is used
Engine revolution
Oil pressure loss has been improved as
described in the section of the hydraulic
equipment. Improvement in fuel costs
When given the same work, you can reduce
the horsepower by the improvement done
on the oil pressure loss.

PC200-8 Page 53 / 54
Major Improvement

(G) Parts interchangeability

PC200-8 Page 54 / 54
Compatibility Information by Device

Designation PC200-7
Compatibility
Reasons why compatibility
Advice when there is no compatibility
Remarks

with PC200-7 was judged absent
Ass'y
Engine assembly X Tier3,UP(1110inch)
Tier3-complied common rail engine, Increase in air cleaner size (1110inch)
Unit

M/C Now Change in pulley ratio (0.870.96), Increase in engine output (150PS145PS)
X (0.870.96),UP(150PS145PS)
Ass'y
Main pump assembly X ,PCFR,LS
Changes in discharge port position, Independent control of F and R, Change in
M/C Now LS set
X
Ass'y
Control valve assembly X (),,
Installation method (tightening at bottom), Addition of arm quick return, Employment of built-in cooler check valve
M/C Now
X LS,Ass'y
Spool stroke has been modified due to change in LS set. Not identical with the converging and dividing assembly.
Ass'y
Swing motor assembly X
Reduction in weight ()
Compatibility will be generated if the machinery oil
M/C Now
X
refill tube (including bracket) is modified.
Ass'y
Travel motor assembly X ASS'Y
There is compatibility for final assembly and
M/C Now
X motor assembly

Boom cylinder 0
M/C Now
0

Arm cylinder X
Direction of pipes is not identical
Compatible including hose
M/C Now
X

Bucket cylinder X
Direction of pipes is not identical
Compatible including hose
M/C Now
X

Center swivel 0
M/C Now
0

Swing circle M/C X Now
Number of teeth is not identical
X

Swing machinery M/C X Now
Number of pinion teeth is not identical
X

Idler 0
M/C Now
0

Idler cushion 0
M/C Now
0

Track roller 0
M/C Now
0

Carrier roller X
Installation method is not identical
M/C Now
X

Track shoe 0
M/C Now
0

PC200-8 Page 55 / 54
Compatibility Information by Device
PC200-7
Designation Compatibility Reasons why compatibility Advice when there is no compatibility Remarks

with PC200-7 was judged absent
Ass'y X
Cooling assembly M/C Now Employment of side-by-side
X
arrangement
X
Operator cab M/C Now Structure is not identical
X
M/C X Now
Operator's seat X Move of armrest to console
X ,
Hydraulic oil tank M/C Now Reduction in capacity, Change on
X
return port
X
Fuel tank M/C Now Pipe mouthpiece is not identical
X
Ass'y 0
Boom assembly M/C Now Including pipe
0
Ass'y 0
Arm assembly M/C Now Including pipe
0
Ass'y X
Bucket assembly M/C Now End face processing is not identical
0
X ,
Revolving frame M/C Now Change of engine position, Change in installation method resulted from
X
employment of side-by-side arrangement
X
Track frame M/C Now Carrier roller installation method is not identical
X
X ASS'Y
Final M/C Now There is compatibility for final assembly
X
and motor assembly
0
Sprocket M/C Now
0
X ,,,
Machine cab M/C Now Hood, door, frame and partition are not
X
identical
X ,
Controller M/C Now Change in contents of control, Change
X
of connector
X 7,,KOMTRAX
Monitor M/C Now
X Provided with 7-LCD, air conditioner switch and KOMTRAX function
X
Engine control M/C Now Supports common rail engine
X
0
Work equipment PPC valve M/C Now
0
0
Travel PPC valve M/C Now
0

PC200-8 Page 56 / 54
Compatibility Information by Device

Designation PC200-7
Compatibility
Reasons why compatibility
Advice when there is no compatibility
Remarks

with PC200-7 was judged absent

Dumper 0
M/C Now
0

Solenoid valve 0 Ass'y
Not identical among
M/C Now
0 assemblies

Air conditioner X
Switch function has been moved to
M/C Now monitor panel
X

Counterweight X UP(,)
Increase in capacity (weight remains the same
M/C Now and specific gravity has been increased)
X

Consumable parts

Engine oil filter

M/C 0
Now
0

Fuel filter X (2m
Supports common rail engine 25m)
M/C Now (2m m 25m m)
X

Fuel pre-filter (10m)
Newly added (10m m)
M/C Now
X

Hydraulic oil filter 0
M/C Now
0

Air cleaner element X 11inch10inch
M/C Now
X

Fan belt X
Length is not identical
M/C Now
X

Hydraulic hose X
Length is not identical
M/C Now
X

Bucket tooth 0
M/C Now
0

Bucket adapter 0
M/C Now
0

Side cutter 0
M/C Now
0

PC200-8 Page 57 / 54