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COMPONENT CODE 6A

INSTALLATION REF NO. BT06019


DATE March 31, 2006
MANUAL Page 1 of 48

SUBJECT: PC200 Series machines -8


PURPOSE: To inform field personnel
APPLICATION: PC200-8 Excavator Serial Number 300001 to 399999
PC200LC-8 Excavator Serial Number 300001 to 399999
PC210-8 Excavator Serial Number 60001 to 69999
PC210LC-8 Excavator Serial Number 60001 to 69999
PC220-8 Excavator Serial Number 70001 to 79999
PC220LC-8 Excavator Serial Number 70001 to79999
PC230-8 Excavator Serial Number ---
PC230LC-8 Excavator Serial Number ---
FAILURE CODE: 6A00Z9
DESCRIPTION:

1. Introduction
When you install an additional circuit for installing attachment to PC200 Series machines -8 in the
field, perform the procedure in accordance with service news.

2. List of parts
PART No. 1-189: Sales Code 7PB38A-W,X(Main body side piping)
PART No. 190-206: Sales Code 7PB38-J(Service valve)
PART No. 207-268: Sales Code 7PB26-U,W,X,Y(Arm & Boom piping)
PART No. 269-284: Consumable parts (Please arrange if necessary)
Part No. Part Name Q’ty Remarks
20Y-62-51580 BLOCK 1
() () (0)
01010-81240 BOLT 2
() () (0)
01643-31232 WASHER 2
() () (0)
20Y-62-43222 BRACKET 1
() () (0)
07371-31049 FLANGE 2
() () (0)
07372-21035 BOLT 4
() () (0)

BT06019
Page 2 of 48
Part No. Part Name Q’ty Remarks
01643-51032 WASHER 4
() () (0)
07371-31049 FLANGE 2
() () (0)
07372-21035 BOLT 4
() () (0)
01643-51032 WASHER 4
() () (0)
07040-12412 PLUG 1
() () (0)
07002-12434 O-RING 1
() () (0)
01010-81240 BOLT 4
() () (0)
01643-31232 WASHER 4
() () (0)
20y-62-51760 BRACKET 1
() () (0)
01010-81285 BOLT 4
() () (0)
01643-31232 WASHER 4
() () (0)
07098-01007 HOSE 1
() () (0)
07000-13032 O-RING 2
() () (0)
07371-31049 FLANGE 2
() () (0)
07372-21035 BOLT 4
() () (0)
01643-51032 WASHER 4
() () (0)
07097-21016 1 FOR PC200,
HOSE
() (0) 210
07097-21017 HOSE 1 FOR PC220,
() () (0) 230

BT06019
Page 3 of 48
Part No. Part Name Q’ty Remarks
07000-13032 O-RING 2
() () (0)
07371-31049 FLANGE 2
() () (0)
07372-21035 BOLT 4
() () (0)
01643-51032 WASHER 4
() () (0)
20y-62-51181 FRAME 1
() () (0)
07049-01215 PLUG 2
() () (0)
01010-81250 BOLT 2
() () (0)
175-54-34170 WASHER 2
() () (0)
01010-81250 BOLT 2
() () (0)
01643-31232 WASHER 2
() () (0)
702-21-01910 VALVEA. 1
() () (0)
01010-81040 BOLT 3
() () (0)
01643-31032 WASHER 3
() () (0)
20y-62-51771 BRACKET 1
() () (0)
07049-01215 PLUG 2
() () (0)
07371-31049 FLANGE 2
() () (0)
07372-21035 BOLT 4
() () (0)
01643-51032 WASHER 4
() () (0)

BT06019
Page 4 of 48
Part No. Part Name Q’ty Remarks
07371-51260 FLANGE 2
() () (0)
01010-81245 BOLT 4
() () (0)
01643-31232 WASHER 4
() () (0)
20Y-62-43460 NIPPLE 1
() () (0)
02896-11008 O-RING 1
() () (0)
07002-12034 O-RING 1
() () (0)
11Y-62-12160 ELBOW 1
() () (0)
02896-11008 O-RING 1
() () (0)
07002-11423 O-RING 1
() () (0)
ACCUMU-
20Y-970-6450 1
LATORA
() (0)
()
20Y-62-43290 ELBOW 1
() () (0)
07002-12434 O-RING 1
() () (0)
20y-62-43280 BRACKET 1
() () (0)
01010-81295 BOLT 2
() () (0)
01643-31232 WASHER 2
() () (0)
175-61-51750 PLATE 1
() () (0)
01010-81225 BOLT 2
() () (0)
01643-31232 WASHER 2
() () (0)

BT06019
Page 5 of 48
Part No. Part Name Q’ty Remarks
01010-81285 BOLT 4
() () (0)
01643-31232 WASHER 4
() () (0)
07097-01005 HOSE 1
() () (0)
07000-13032 O-RING
2(0)
() ()
07371-31049 FLANGE 2
() () (0)
07372-21035 BOLT 4
() () (0)
01643-51032 WASHER 4
() () (0)
07097-21217 HOSE 1 FOR PC200,
() () (0) 210
07097-21218 HOSE 1 FOR PC220,
() () (0) 230
07000-13038 O-RING 2
() () (0)
07371-51260 FLANGE 2
() () (0)
01010-81245 BOLT 4
() () (0)
01643-31232 WASHER 4
() () (0)
20y-970-2700 FILLTER 1
() () (0)
20Y-62-43351 FLANGE 1
() () (0)
07002-14234 O-RING 1
() () (0)
20Y-62-43361 ELBOW 1
() () (0)
07002-14234 O-RING 1
() () (0)

BT06019
Page 6 of 48
Part No. Part Name Q’ty Remarks
01010-81230 BOLT 4
() () (0)
01643-31232 WASHER 4
() () (0)
20Y-62-51280 FRAME 1
() () (0)
01010-81225 BOLT 2
() () (0)
01643-31232 WASHER 2
() () (0)
01010-81230 BOLT 4
() () (0)
01643-31232 WASHER 4
() () (0)
20Y-62-43311 HOSE 1
() () (0)
07000-13038 O-RING 2
() () (0)
01010-81035 BOLT 2
() () (0)
01643-31032 WASHER 2
() () (0)
01010-81035 BOLT 2
() () (0)
01643-31032 WASHER 2
() () (0)
07094-11024 CLAMP 2
() () (0)
07095-01038 CUSHION 1
() () (0)
01010-81280 BOLT 2
() () (0)
01643-31232 WASHER 2
() () (0)
20Y-62-43320 BRACKET 1
() () (0)

BT06019
Page 7 of 48
Part No. Part Name Q’ty Remarks
01010-81225 BOLT 2
() () (0)
01643-31232 WASHER 2
() () (0)
20Y-62-51321 HOSE 1
() () (0)
07000-13038 O-RING 2
() () (0)
01010-81035 BOLT 2
() () (0)
01643-31032 WASHER 2
() () (0)
01010-81040 BOLT 2
() () (0)
01643-31032 WASHER 2
() () (0)
07095-01241 CUSHION 1
() () (0)
21K-62-72810 CLAMP 1
() () (0)
01010-81225 BOLT 2
() () (0)
01643-31232 WASHER 2
() () (0)
20Y-62-51681 FILTERA. 1
() () (0)
20Y-62-51781 BRACKET 1
() () (0)
01010-81075 BOLT 2
() () (0)
01643-31032 WASHER 2
() () (0)
02782-10214 ELBOW 2
() () (0)
07002-12034 O-RING 2
() () (0)

BT06019
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Part No. Part Name Q’ty Remarks
02896-11008 O-RING 2
() () (0)
01010-81225 BOLT 2
() () (0)
01643-31232 WASHER 2
() () (0)
20y-62-45690 TEE 1
() () (0)
02896-11009 O-RING 1
() () (0)
02896-11008 O-RING 1
() () (0)
07002-12034 O-RING 1
() () (0)
11Y-62-12130 NIPPLE 1
() () (0)
02896-11008 O-RING 1
() () (0)
07002-11423 O-RING 1
() () (0)
11Y-62-12330 ELBOW 1
() () (0)
02896-11008 O-RING 2
() () (0)
07002-11423 O-RING 1
() () (0)
20y-62-51450 BRACKET 1
() () (0)
SOLENOI-
20Y-60-41611 1
DASS’Y
() (0)
()
22B-26-11320 UNION 1
() () (0)
02896-11008 O-RING 1
() () (0)
07002-11423 O-RING 1
() () (0)

BT06019
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Part No. Part Name Q’ty Remarks
20Y-62-52121 HOSE 1
() () (0)
208-62-72480 HOSE 1
() () (0)
08034-20536 BAND 9
() () (0)
20Y-62-52142 HOSEASS’Y 1
() () (0)
20Y-62-51930 HOSE 1
() () (0)
04434-51212 CLIP 1
() () (0)
01010-81225 BOLT 1
() () (0)
01643-31232 WASHER 1
() () (0)
04434-52212 CLIP 1
() () (0)
04434-51012 CLIP 1
() () (0)
20Y-62-51922 HOSEASS’Y 1
() () (0)
PILOT-
702-16-04290 VALVE,PC20 1
() 0-8ATT (0)
()
22U-54-25660 SEAL 1
() () (0)
20Y-43-41760 SEAT 1
() () (0)
01010-81025 BOLT 2
() () (0)
01643-31032 WASHER 2
() () (0)
01643-31032 WASHER 2
() () (0)

BT06019
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Part No. Part Name Q’ty Remarks
20Y-62-25360 BRACKET 1
() () (0)
01010-D1035 BOLT 2
() () (0)
01643-71032 WASHER 2
() (0) (0)
207-43-81250 PEDAL 1
() () (0)
01010-D1045 BOLT 2
() () (0)
01643-71032 WASHER 2
() () (0)
22U-54-25541 PLATE 1
() () (0)
01010-81025 BOLT 3
() () (0)
01643-31032 WASHER 3
() () (0)
207-43-81220 PLATE 1
() () (0)
01240-00816 BOLT 4
() () (0)
207-43-81240 CAP 1
() () (0)
20T-910-8660 NIPPLE 1
() () (0)
07000-12011 O-RING 1
() () (0)
20Y-62-52160 ELBOW 2
() () (0)
02896-11008 O-RING 2
() () (0)
07000-12011 O-RING 2
() () (0)
20Y-62-43470 NIPPLE 1
() () (0)

BT06019
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Part No. Part Name Q’ty Remarks
02896-11008 O-RING 1
() () (0)
11Y-62-12140 NIPPLE 1
() () (0)
02896-11008 O-RING 1
() () (0)
07000-12011 O-RING 2
() () (0)
20Y-62-51751 HOSEA 1
() () (0)
04435-51210 CLIP 1
() () (0)
01583-11408 NUT 1
() () (0)
206-06-61130 SWITCH 2
() () (0)
08193-21012 CLIP 1
() () (0)
08053-01510 CLIP 1
() () (0)
01580-01008 NUT 2
() () (0)
08034-20536 BAND 1
() () (0)
04434-50610 CLIP 1
() () (0)
01580-01008 NUT 1
() () (0)
11Y-62-12330 ELBOW 2
() () (0)
02896-11008 O-RING 4
() () (0)
07002-11423 O-RING 2
() () (0)
WIRING-
20Y-06-41251 1
HARNESS
() (0)
()

BT06019
Page 12 of 48
Part No. Part Name Q’ty Remarks
09659-A057A PLATE 1
JAPANESE
() () (0)
09659-A057B PLATE 1 WITHOUT
() () (0) LETTER
09659-53000 PLATE 1
ENGLISH
() () (0)
PLATE,
09659-51000 1
SAFETY SPANISH
() (0)
()
VALVE
723-41-08800 SUBA.(KIT) 1
() FULL (0)
()
01011-61455 BOLT 4
() () (0)
01643-31445 WASHER 4
() () (0)
07000-13032 O-RING 2
() () (0)
723-46-17510 O-RING 2
() () (0)
723-11-19130 O-RING 2
() () (0)
723-46-17520 O-RING 2
() () (0)
723-46-17530 O-RING 2
() () (0)
11Y-62-12130 NIPPLE 1
() () (0)
02896-11008 O-RING 1
() () (0)
07002-11423 O-RING 1
() () (0)
11Y-62-12160 ELBOW 1
() () (0)
02896-11008 O-RING 1
() () (0)

BT06019
Page 13 of 48
Part No. Part Name Q’ty Remarks
07002-11423 O-RING 1
() () (0)
11Y-62-12330 ELBOW 1
() () (0)
02896-11008 O-RING 2
() () (0)
07002-11423 O-RING 1
() () (0)
20Y-62-52751 TUBE 1 FOR PC200,
() () (0) 210
206-62-21350 TUBE 1 FOR PC220,
() () (0) 230
20Y-62-52761 TUBE 1 FOR PC200,
() () (0) 210
206-62-21360 TUBE 1 FOR PC220,
() () (0) 230
07000-13035 O-RING 2
() () (0)
07372-21040 BOLT 8
() () (0)
01643-51032 WASHER 8
() () (0)
20Y-62-52730 BRACKET 2
() () (0)
BOLT 4
01010-81645-()
() (0)
01643-31645 WASHER 4
() () (0)
20Y-62-52670 CLAMP 4
() () (0)
01010-81275 BOLT 4
() () (0)
01643-31232 WASHER 4
() () (0)
20Y-62-52770 TUBE 1
() () (0)

BT06019
Page 14 of 48
Part No. Part Name Q’ty Remarks
20Y-62-52780 TUBE 1
() () (0)
20Y-62-52740 BRACKET 6
() () (0)
01010-81665 BOLT 12
() () (0)
01643-31645 WASHER 12
() () (0)
20Y-62-52680 CLAMP 12
() () (0)
205-62-73431 SEAT 6
(0) () (0)
01010-81230 BOLT 12
() () (0)
20Y-62-13450 PLATE 6
() () (0)
20Y-62-45382 BRACKET 2 FOR PC200,
() () (0) 210
206-62-73592 BRACKET 2 FOR PC220,
() () (0) 230
01010-81235 BOLT 4
() () (0)
20Y-62-13450 PLATE 2
() () (0)
20Y-62-52670 CLAMP 4
() () (0)
01010-81275 BOLT 4
() () (0)
01643-31232 WASHER 4
() () (0)
07097-21015 HOSE 1 FOR PC200,
() () (0) 210
07097-21016 HOSE 1 FOR PC220,
() () (0) 230
21T-09-11460 O-RING 2
() () (0)

BT06019
Page 15 of 48
Part No. Part Name Q’ty Remarks
07371-31049 FLANGE 4
() () (0)
07372-21035 BOLT 8
() () (0)
01643-51032 WASHER 8
() () (0)
07097-21218 HOSE 1 FOR PC200,
() () (0) 210
07097-21217 HOSE 1 FOR PC220,
() () (0) 230
07000-13038 O-RING 2
() () (0)
07371-51260 FLANGE 4
() () (0)
01010-81245 BOLT 8
() () (0)
01643-31232 WASHER 8
() () (0)
20Y-970-5320 BRACKET 2
() () (0)
01010-81230 BOLT 8
() () (0)
01643-31232 WASHER 8
() () (0)
20Y-970-5300 VALVE ASSY 2
() () (0)
207-970-2110 NIPPLE 2
() () (0)
07000-13038 O-RING 2
() () (0)
01010-81245 BOLT 8
() () (0)
01643-31232 WASHER 8
() () (0)
07371-51260 FLANGE 4
() () (0)

BT06019
Page 16 of 48
Part No. Part Name Q’ty Remarks
01010-81230 BOLT 4
() () (0)
01643-31232 WASHER 4
() () (0)
205-970-5770 CAP 2
() () (0)
20Y-62-55340 TUBE 1
() () (0)
20Y-62-55350 TUBE 1 FOR PC200,
() () (0) 210
206-62-23190 TUBE 1 FOR PC220,
() () (0) 230
207-62-31330 CLAMP 4
() () (0)
01010-81230 BOLT 4
() () (0)
20Y-62-13450 PLATE 2
() () (0)
07000-13038 O-RING 2
() () (0)
01010-81245 BOLT 8
() () (0)
01643-31232 WASHER 8
() () (0)
07002-12034 O-RING 1
() () (0)
07002-12034 O-RING 1
() () (0)
07002-11423 O-RING 1
() () (0)
02896-11008 O-RING 1
() () (0)
07002-12034 O-RING 1
() () (0)
02896-11009 O-RING 1
() () (0)

BT06019
Page 17 of 48
Part No. Part Name Q’ty Remarks
07002-11423 O-RING 1
() () (0)
07002-11423 O-RING 1
() () (0)
02896-11008 O-RING 2
() () (0)
07002-11423 O-RING 3
() () (0)
02896-11008 O-RING 3
() () (0)
723-11-19130 O-RING 2
() () (0)
723-46-17520 O-RING 2
() () (0)
07000-13032 O-RING 2
() () (0)
723-46-17510 O-RING 2
() () (0)
723-46-17530 O-RING 3
() () (0)

BT06019
Service News BT06019 Page 17 of 48

Installing Procedures of Additional Circuit for Installing Attachment to PC200


Series machines: -8

Note 1) Additional arm piping mounting seat will be separately required.


Note 2) Work equipment needs to be reinforced for PC200-8, PC200LC-8, PC220-8, and
PC220LC-8.
Note 3) When installing a breaker, special parts must be installed depending on the type.
Note 4) A crusher may be installed only to PC210-8, PC210LC-8, PC230-8 and PC230LC-8.
Note 5) When installing a crusher, install an arm, link and bucket cylinder dedicated for
demolition work.
At the same time, install a pressure reducing valve to the arm digging PPC circuit.

1. Description of Installation
1-1 Selection of Additional Circuit
Table 1
Attachment piping Control piping Safety valve set pressure
Working Maximum flow rate
installation installation (kg/cm2)
actuator
1st 2nd 1st 2nd 1st 2nd 1st 2nd
2-stage safety valve
1A 2P - AT - Right - -
305·210/305
2-stage safety valve
2A 2P 1P AT BF Right Left 305
305·210/305

Note (1) MAX flow rate


2P: Merged flow rates of maximum 2 units of pump
1P: Merged flow rate of a maximum 1 unit of pump
(2) ATT piping installation
AT: Factory-installed up to the arm top at shipment
BF: Factory-installed down to the boom foot at shipment
(3) See Table 3 for sales code of shipment by unit.

1-2 General List of Required Parts


Table 2
Return Low-
Working Service circuit Solenoid Additional pressure Control Pressure
Pilot filter EPC valve
actuator valve selector valve filter accumu- pedal switch
valve lator
1A X1 X1 X1 X1 X1 X1 X1 X1 X2
2A X2 X1 X1 X1 X1 X1 X2 X1 X4

As introduced by
Remarks this Service News
(1) As to the additional circuit, connect additional parts indicated in Table 2 with piping
and/or wiring.
(2) See Fig. 4 for the schematic diagram of the piping and wiring.
(3) See Fig. 5 for the hydraulic circuit diagram.
(4) Service valve is not installed to the Japan standard machines.
(5) A safety valve is provided to the service valve on a machine shipped to an order for
shipment by unit under a by-unit shipment sales code. If desired to use other safety
valve of different set pressure, make a separate selection out of Table 3.
(1 unit of safety valve is available per each sales code.)
BT06019
Service News BT06019 Page 19 of 48

1-3 Introduction of Sales Codes for Shipment by Unit

Table 3
Sales code Applicable machine model/Specifications Remarks
Piping on the 7PB38A-W PC200, PC210 Main piping, control piping (pedal included),
machine body selector valve, solenoid valve, additional return
(for a single 7PB38A-X PC220, PC230 filter, pilot filter, EPC valve, pressure switch and
attachment) low-pressure accumulator
Service valve 7PB35-J PC200 - PC230 For 2-pump flow rate (with safety valve)
Mounting bolts (for 7 valves) and O-ring
Elbow for pilot port
7PB36-H PC200 - PC230 For 2-pump flow rate + 1 pump flow rate (both
with safety valve)
Mounting bolts (for 8 valves) and O-ring
Elbow for pilot port
Safety valve 4PJ34B-A PC200 - PC230 For set pressure of 305/210 kg/cm 2
(Service
4PJ34C-A PC200 - PC230 For set pressure of 305/250 kg/cm 2
valve)
4PJ34A-A PC200 - PC230 For set pressure of 305/170 kg/cm 2
4PJ31-D PC200 - PC230 For set pressure of 170 kg/cm 2
4PJ32-F PC200 - PC230 For set pressure of 210 kg/cm 2
4PJ33-D PC200 - PC230 For set pressure of 250 kg/cm 2
4PJ34-D PC200 - PC230 For set pressure of 305 kg/cm 2
Piping on the 7PB25-F PC200STD boom (for breaker work with a frequency Boom piping, piping mounting seat and
work of over 50%) reinforcing board
equipment 7PB25-G PC200STD boom (for breaker work with a frequency Boom piping, and piping mounting seat
(for a single of under 50%)
attachment) PC200 and PC210 reinforced booms
7PB26-U PC200STD boom (for breaker work with a frequency Boom, arm piping, piping mounting seat and
of over 50%) + STD arm reinforcing board
7PB26-W PC200STD boom (for breaker work with a frequency Boom, arm piping and piping mounting seat
of over 50%) + reinforced arm
PC200 and PC210 reinforced boom + reinforced
arm
7PB25-H PC220, PC230 Boom piping, and piping mounting seat

7PB26-X PC220STD arm Boom, arm piping, piping mounting seat and
reinforcing board
7PB26-Y PC200 and PC230 reinforced arm Boom, arm piping and piping mounting seat

BT06019
Service News BT06019 Page 20 of 48

1-4 Service Valve and Service Valve-related Parts


Table 4
Parts Part No. Quantity Remarks
Valve for 723-41-08800 1 For 2-pump flow rate with safety valve and variable
single pressure compensating valve
attachment 01011-61455 4 Mounting bolt
01643-31445 4 Mounting washer
07000-13032 2 O-ring for the mounting surface
723-46-17510 2 O-ring for the mounting surface
723-11-19130 2 O-ring for the mounting surface
723-46-17520 2 O-ring for the mounting surface
723-46-17530 2 O-ring for the mounting surface
Valve for 2 723-41-08800 1 For 2-pump flow rate with safety valve and variable
attachments pressure compensating valve
723-41-08900 1 For 1-pump flow rate with safety valve and variable
pressure compensating valve
723-46-15220 4 Mounting bolt
01643-31445 4 Mounting washer
07000-13032 4 O-ring for the mounting surface
723-46-17510 4 O-ring for the mounting surface
723-11-19130 4 O-ring for the mounting surface
723-46-17520 4 O-ring for the mounting surface
723-46-17530 4 O-ring for the mounting surface
Safety valve 723-90-76100 1 Normally Set pressure 305 kg/cm 2 at 190 l/min
Crack pressure 250 kg/cm 2 at 5 l/min
When leading-in Set pressure 210 kg/cm 2 at 190 l/min
the pilot pressure Crack pressure 155 kg/cm 2 at 5 l/min
723-90-76300 1 Normally Set pressure 305 kg/cm 2 at 190 l/min
Crack pressure 250 kg/cm 2 at 5 l/min
When leading-in Set pressure 250 kg/cm 2 at 190 l/min
the pilot pressure Crack pressure 205 kg/cm 2 at 5 l/min
723-90-76400 1 Normally Set pressure 305 kg/cm 2 at 190 l/min
Crack pressure 250 kg/cm 2 at 5 l/min
When leading-in Set pressure 170 kg/cm 2 at 190 l/min
the pilot pressure Crack pressure 115 kg/cm 2 at 5 l/min
723-90-61400 2 Set pressure 305 kg/cm 2 at 190 l/min
Crack pressure 250 kg/cm 2 at 5 l/min
723-90-61200 2 Set pressure 210 kg/cm 2 at 190 l/min
Crack pressure 155 kg/cm 2 at 5 l/min
723-90-61300 2 Set pressure 250 kg/cm 2 at 190 l/min
Crack pressure 205 kg/cm 2 at 5 l/min
723-90-61100 2 Set pressure 170 kg/cm 2 at 190 l/min
Crack pressure 115 kg/cm 2 at 5 l/min
Note (1) Service valve on a machine body shipped from the factory is installed with a 2-
2
stage safety valve for high set pressure of 305 kg/cm and for low set
2 2
pressure of 210 kg/cm and a safety valve for a set pressure of 305 kg/cm .
(2) Service valve on a machine body shipped by unit under a by-unit shipment
sales code is installed with a 2-stage safety valve for high set pressure of 305
2 2
kg/cm and for low set pressure of 210 kg/cm and a safety valve for a set
2
pressure of 305 kg/cm .
BT06019
Service News BT06019 Page 21 of 48

1-5 Introduction of Related Service News

Table 5
Service News No. Title
BT06005 Repair procedures of work equipment for installing additional piping for
attachment on PC200-8 and PC210-8
BT06014 Repair procedures of work equipment for installing additional piping for
attachment on PC220-8 and PC230-8

BT06019
Service News BT06019 Page 22 of 48

1-6 Schematic Diagrams


(1) Machine body layout Low-pressure accumulator Selector valve Hydraulic tank Pilot filter

Fig. 1

Main valve

#12

For service
2-stage safety valve
(Low-pressure set for
mode B)

Solenoid valve
CN-V06
Front view of the main valve
(when viewed from the front of the machine body)

#10 Oil cooler

Relaying block Return filter

PPC valve
Pressure switch CN-P13
with EPC valve
(CN-P14, CN-P15)
CN-V30 Under floor (When viewed from under the machine body)

BT06019
Service News BT06019 Page 23 of 48

(2) Work equipment layout

Fig. 2

Additional piping #12 for the boom

Additional piping #10 for the boom

Additional piping
#12 for the boom

Additional piping
#10 for the boom

Stop valve

P P

BT06019
Service News BT06019 Page 24 of 48

(3) Schematic illustration

Fig. 3

To hydraulic
tank

Accumulator
Pilot filter

From the self-pressure


reducing valve
Selector valve

Breaker
2-stage Pump
safety
valve

Controller

Main valve

Solenoid valve
Control pedal

From the
self-pressure
To hydraulic
PPC valve with reducing valve
tank
EPC valve for
ATT

Pressure Additional
switch return filter
Oil cooler

BT06019
Service News BT06019 Page 25 of 48

(4) About the additional control


(a) Additional function
<1> Attachment circuit selector: Upon selecting mode B, the piping on the breaker return side changes to the return filter from the main valve, simultaneously switching the 2-stage safety valve set of
the service valve to the low-pressure side.
A selector valve, 2-stage safety valve, solenoid valve, associated pilot piping and wiring, and pressure switch wiring are required.

<2> Attachment flow rate adjustment: In response to an increase/decrease of the scale on the monitor screen, flow rate at full stroke of the control pedal can be adjusted (ATT & mode B).
Flow rate distribution may be adjusted when performing a compound operation with boom raise (ATT mode only).
EPC valve and associated pilot piping and wiring, pressure switch wiring and monitor setting are required.

(b) System configuration

Fig. 4
Hydraulic circuit Electric circuit

Connected as introduced
ON/OFF CN-V06 by this Service News
Main valve
SOL output
Screen for setting with or
ATT 2-stage without attachment
safety valve ATT circuit
selector valve

Service ATT circuit selector


solenoid valve
Bucket Connected as
Self-pressure introduced by this ATT and boom raise
L.H. travel reducing valve CN-V30 Flow rate adjust screen
(F pump pressure) Service News
Boom EPC output

Swing
Pilot
R.H. travel filter R.H. service valve
Flow rate adjust
Arm screen
Pressure
sensor
Pressure sensor

Additional filter
for the breaker

To P-2 To P-1 ATT reducing and


adjusting EPC valve
Controller
Boom raise PPC

Monitor

Boom raise signal

R pump pressure

(c) Troubleshooting
<1> Attachment circuit selector relay, disconnection/short-circuit
<2> Attachment flow rate adjust EPC valve, disconnection/short-circuit

BT06019
Service News BT06019 Page 26 of 48

(5) Hydraulic circuit diagram

Fig. 5

BT06019
Service News BT06019 Page 27 of 48

2. Installation procedure
2-1 General items
(1) For the disassembly/assembly procedures not described in this Service News, refer to
the Shop Manual and/or instruction manual.
(2) Remove the parts that are not specified in this Service News and cumbersome to work
for each disassembly. Reinstall them after installing the parts for additional circuit.

Remarks 1. Replace removed O-rings with new parts since they are consumables.
2. Replace removed cotter pins with new parts since they are safety-critical
parts.
3. Refer to the details of the modification on page 30 for general cautions.
4. The work can be done without removing the cab.

Contents
No. Item Page
1 Preparation 11
2 Removal of the parts (unnecessary parts and reusable parts)
(1) Removing the floor mat and foot rest. 12
Reworking the floor mat 13
(2) Removing the piping-related parts under the floor 14
(3) Removing the piping-related parts of machine body 15
(4) Removing and installing solenoid valve-related parts 16
(5) Removing the main valve end block 17
(6) Removing the boom piping-related parts 18
3 Installing the parts for additional circuit
(1) Installing service valve and end block to the main valve 20
(2) Installing related parts to the main valve, pump and hydraulic tank 21
(3) Installing the control pedal (R.H.), related parts and floor mat 22
(4) Installing the piping, brackets and related parts between the main valve and 23
work equipment
(5) Installing the piping, brackets and related parts between the main valve and 24
work equipment (to the R.H. side of the machine)
(6) Installing the return piping, additional return filter and the related parts 25
(7) Installing PPC piping and related parts 26
(8) Installing the boom piping 27
(9) Installing the arm piping 28
4 Monitor setting and adjusting 29
5 General cautions 30
6 Post work 31

BT06019
Service News BT06019 Page 28 of 48

2-2 Parts Classification


(1) Parts in the Service News are separated and indicated according to the following
classification:

Parts marked with are to be reinstalled after removal.

Parts marked with are to be dumped.

Parts marked with are consumable parts.

(Replace with new parts when reinstalling)

Parts marked with are consumable parts and to be replaced with new ones.

Parts marked with are to be replaced with additional parts or modified parts.

No.

(2) in this Service News coincide with Parts Nos. in the Parts List.

2-3 Procedure
2-3-1 Preparation
(1) Check the quantity of parts that require modification according to the list of repair
parts.
(2) Move the machine body to a flat ground protected from the rain and dusts and install
the work equipment.
(3) After stopping the engine, tilt the work equipment lever quickly to the full stroke in
each direction and bleed residual pressure from the main and pilot circuits.
(4) Loosen the hydraulic tank cap and bleed the air from the tank.
(Beware of a hazard of sudden loosening. Loosen the cap slowly.)
(5) If the temperature of hydraulic oil is high, wait until it comes down before proceeding
to the next work.

BT06019
Service News BT06019 Page 29 of 48

2-3-2 Removal of unnecessary parts and reusable parts


(1) Remove the floor mat and footrest according to Fig. 6.

Fig. 6
20Y-53 Remove and cut out to repair

14712 See Fig. 7 for the repair content.

22U-54
25120

01643 01010
31032 81025
(2) (2)
Floor frame

01643 01010
31032 81020

22U-54
25531

BT06019
Service News BT06019 Page 30 of 48

Fig. 7

Turn the removed floor mat over and repair section P as indicated below:

Slit

Remove the hatched area along the notch line.


Radius for the corner and angle shall be "3".

BT06019
Service News BT06019 Page 31 of 48

(2) Remove the nipples, etc. from the block under the floor according to Fig. 8.
Also remove taped connectors

Fig. 8

02781 02896 07002


0021D 11008 11423

Floor frame
Toward T
front of
the
machine

01010 01643 02781 02896 07002

31032 0021D 11008 11423


81016
(2) (2)
Remove only one side of each.

Remove the tape and


disconnect the connector
at the end.

CN-V30 CN-P13

BT06019
Service News BT06019 Page 32 of 48

(3) Remove the nipples, elbows, solenoid valves, hoses, brackets, etc. from the machine body according to Fig. 9.
Also disconnect the taped connectors.

Fig. 9

01010 01643 01010 01643


Hydraulic tank 11Y-62 02896 07002 Main valve
81225 31232 81225 31232
12130 11008 11423
Pump

Main valve
Pump

02782 02896 07002


20Y-62 07000 01010 01643
10315 11009 12034 11Y-62 02896 07002
53160 13040 81035 31032
12330 11008 11423
(2) (2)
(2)
Main valve

01010 01643
Main valve
81225 31232
(2) (2)

04434
51512
20Y-60
208-62 41621

22U-62 72610
01010 01643
21551 81085 31032
(2) (2)
Main valve
01010 01643
01010 01643 20Y-62 81225 31232
81225 31232 51461
Remove the tape and disconnect
(2) (2)
the connector at the end.
CN-V06

BT06019
Service News BT06019 Page 33 of 48

(4) Remove the nipples and elbows from the 5-spool solenoid valve and install to the 6-spool solenoid valve according to Fig. 10.

Fig. 10
274 273

279 278 02783 02896 07002

11Y-62 02896 07002 10315 11009 12034


12130 11008 11423 272 271
(3) (3) (3)
11Y-62 02896 07002
12130 11008 11423

5-spool solenoid valve


270

20Y-62 07002
21940 12034

269

22U-60 07002
21330 12034

277 276 275 129

20Y-62 02896 07002 20Y-62 07002 20Y-60 20Y-60


41960 11008 11423 16630 41621 41611
11423
(2)

130 131 132

22B-26 02896 07002


11320 11008 11423

6-spool solenoid valve

BT06019
Service News BT06019 Page 34 of 48

(5) Remove the main valve end block according to Fig. 11.

01643 01010 281


End cap 283 Fig. 11
31445 61490 723-46
(4) (4) 723-46
17520
282 17510
(2)
(2)
07000
13032
(2)
284

723-46
17530
(3)

280

723-11
19130
(2) Toward front of the machine
Disassembly procedure

<1> Preparations
· When disassembling the main valve, loosen the hydraulic tank cap to bleed the air from the tank to prevent an oil flow out of the channel inside the main valve.
(Beware of a hazard of sudden loosening. Loosen the cap slowly.)

Note: If oil flow from the path of main valve does not stop during disassembly, it is necessary to drain the oil out of the hydraulic tank beforehand.

· Thoroughly clean the joint area of the main valve cover and machine body using Drysol, and then dry.
(If it takes a long time to dry, wipe off with a rag.)

<2> Disassembly of main cover


Loosen and remove the mounting bolts and remove the cover assembly
To prevent hazards, apply a lifting bolt to the cover and lift with a crane, etc.

Fig. 12

4 cover mounting bolts


Toward front of the machine

Tapped hole for a lifting bolt (10 x 1.5)


Lifting bolt is equivalent to KES04530-01018.

View from the top of the machine

BT06019
Service News BT06019 Page 35 of 48

(6) Remove the plug from the boom according to Fig. 13.

Fig. 13

07049
01215
(4)
07049
01620
(8)

07049
01620
(8)

BT06019
Service News BT06019 Page 36 of 48

2-3-3 Installing the parts for additional circuit


Fig. 14 shows the mounting positions for the main parts.

Fig. 14

Mounting seats for the


return filter brackets

Mounting seats for the selector


valve and piping brackets

Mounting seat for


PPC hose clamp

Mounting seat for the


pilot filter brackets

Floor frame

Mounting seat for PPC


valve with EPC valve
View from the bottom of the machine
Mounting seat for the Mounting seat for the
Mounting seat for
EPC valve wiring clamp pressure switch wiring
the EPC valve
connector
wiring connector

BT06019
Service News BT06019 Page 37 of 48

(1) Install the service valve and end block according to Fig. 15.
191 192
Select the safety valve as may be required from Table 4 on page 3 for replacement. 194 193
01011 01643
Detailed assembly procedures 723-46 07000
61455 31445
(a) Body (main body) (4) (4) 17510 13032
Service valve (2)
· Remove O-ring on the contacting face of the body. Apply oil stone (fine) to (2)
remove the attached sealing agent and rust.
However, the following precautions should be taken:
(i) Don't damage the O-ring when removing.
197
(ii) Do not damage the contacting face.
(iii) Keep the removed dusts from entering the path of the body. 723-46
17530
· Wipe the body contacting face with a clean Drysol-soaked cloth or the like to remove oil and (2)
grease. 195
(Wipe until the grease is removed.)
You may apply a spray type Drysol. 723-11
19130
Remarks: If it is difficult to remove grease from the contacting face because of oil (2)
accumulated in the path of the body, remove oil with a dropper or the like
196
beforehand. 190
723-46
· Install the removed O-ring to the body.
17520 723-41
(If any scratch or wear is found, replace the O-rings with new ones.)
(2) 08800 Upper side
(b) Service valve side
of machine
· Wipe the body contacting face with a clean Drysol-soaked cloth or the like to remove oil and With the safety valve
grease.
(Wipe until the grease is removed.) Contacting face Fig. 15
(hatching)
You may apply a spray type Drysol.
Tapped hole for
· After checking that O-rings are installed on the block contacting face, check that the O-rings mounting bolt (c) Installing service valve
do not fall off when the mating surface is turned downward in the air. M14 x 2.0 · Install the service valve and end cover by aligning
If they should fall off, apply thin layer of grease and install them again. O-rings the body end faces.
Such grease must be in trace quantity and clean without contamination.
· Tighten the mounting bolts following the arrows on
· Apply sealant to the cover and the body contacting face. diagonal lines as the diagram shown below:
End cover contacting face
(hatching)
· Apply the tightening torque to the bolts as follows:
Remarks: · For the sealant, use Sealend No.242 of Sealend Co. or equivalent. 1st time: 10 - 12 kgm
· Apply Sealend No.242 mixed with methanol of approx 20%. 2nd time: 16 - 18 kgm
(Will be hardened if shelved.) 3rd time: 16 - 18 kgm (for checking purpose)
· Better apply Sealend after taking a portion to a polyester container (oiler will do) O-rings
having the tapered end.

Sealant

Body contacting face


(hatching)

BT06019
Service News BT06019 Page 38 of 48

(2) Install related parts to the 6-spool solenoid valve, main valve, pump and hydraulic tank according to Fig. 16.

Fig. 16
125 126 127
Main valve
Hydraulic tank 11Y-62 02896 07002
12330 11008 11423
(2)

Pump

122 123 124

11Y-62 02896 07002


12130 11008 11423

118 119 120 121

20Y-62 02896 02896 07002


45690 11009 11008 12034

201 202 203 Main valve


204 205 206

11Y-62 02896 07002 11Y-62 02896 07002


12160 11008 11423 12330 11008 11423 01010 01643
(2) 81085 31032
(2) (2)

198 199 200 129


Main valve
11Y-62 02896 07002 20Y-60 04434 01010 01643 V6
12130 11008 11423 41611 51512 81225 31232 V5

V4
V3

V2

Main valve

V1

BT06019
Service News BT06019 Page 39 of 48

(3) Install the related parts to under the floor frame and lay the repaired floor mat according to Fig. 17. 172
Fig. 17 20Y-62 20Y-62 20Y-62 Hose assembly
152 151 153 159 161 160 146 154 155 Yellow
52340 22810 51751 Composed of the
01010 207-43 207-43 01240 20Y-43 01010 01643 8 points marked
01643 207-43
L = 4100 mm (2) with
71032 D1035 81250 81220 81240 00816 41760 D1045 71032
(2) (2) (4) (2) (2)
150 20Y-62
52350
20Y-62
25360 L = 3350 mm

Yellow
158 157
08034
01643 01010 145
20519
31032 81025 22U-54 (2)
(3) (3) 25660 174
156
20Y-62 20Y-62 Red
01583 No color
22U-54 52330 22790
Floor frame 11408 (2)
25541
176 L = 900 mm
Tightening torque
08193 8.5 - 10.6 kg·m
Main valve 208-62 20Y-62 Blue
21012
144 Primary pressure 72480 22820
177 block (2)
702-16 167 168 171 L = 1080 mm
08053 Z 04290 20Y-62 02896 07000
01510 Red
173
43470 11008 12011
178 04435
Red Tightening torque
3 - 4 kg·m 51210
01580
Return block
01008 PPC valve
with EPC Blue 182 183 184
(2) Blue
185 valve
CN-P14 11Y-62 02896 07002
20Y-06 12330 11008 11423
No color
41251
(2) (4) (2)
179
175
CN-P15
08034
206-06 Yellow
Tightening Tightening torque 20536
61130
torque 3 - 4kg·m
(2) 3 - 4 kg·m
Tightening torque 3 - 4 kg·m
149 147 148 162 163 169 170 171 181 180
164 165 166
01643 01010 01643 20T-910 07000 11Y-62 02896 07000 01580 04434
20Y-62 02896 07000
31032 81025 31032 8660 12011 12140 11008 12011 01008 50610 CN-V30 CN-P13
52160 11008 12011
(2) (2)
(2) (2) (2) (2) Z
BT06019
Service News BT06019 Page 40 of 48

(4) Install the piping and brackets according to Fig.18.

Fig. 18
20

34 33 12 11 18 19 21 22 07371
31049
01643 01010 07002 07040 07098 07000 07372 01643
(2)
31232 81250 12434 12412 01007 13032 21035 51032
(2) (2) (2) (4) (4)
L = 700 mm Main valve
29

20Y-62
51181

07371
31049
(2) 30
7 6
07049
01643 07372
01215
51032 21035 (2)
(4) (4)
9 10

07372 01643
21035 51032
(4) (4)
To the boom 8

07371

For PC200 and 210 31049


(2)
L = 1600 mm 1
25 23
20Y-62
07000 07097
51580
13032 21016 31 32

(2) 01010 175-54 2 3


24
81250 34170 01010 01643
07097
(2) (2) 81240 31232
21017 (2) (2)

26 27 28 16 17 15 4 13 14
For PC220 and 230
L = 1700 mm 07371 07372 01643 01010 01643 20Y-62 20Y-62 01010 01643
31049 21035 51032 81285 31232 51760 43222 81240 31232
(2) (4) (4) (4) (4) (4) (4)
BT06019
Service News BT06019 Page 41 of 48

(5) Install the piping and brackets according to Fig. 19.

Fig. 19
59 60

35 49 50 51 40 41 42 66 67 65 52 01010 01643
702-21 11Y-62 02896 07002 07371 07372 01643 07372 01643 07371 20Y-970 81225 31232

01910 12160 11008 11423 31049 21035 51032 21035 51032 31049 6450 (2) (2)
(2) (4) (4) (4) (4) (2)
Main valve 186
73 72 Degrease the
09659 contacting face.
01643 01010 A057A
31232 81245
(4) (4)
71 Z
07371
51260
(2) Selector valve
Accumu-
lator

To the boom
58
Z
175-61
51750
For PC200 and 210 63 64
L = 1700 mm 55
07097 07000
70 68 20Y-62
01005 13032
07000 07097 43280
(2)
L = 500 mm
13038 21217
56 57
(2) 69
01010 01643
07097 81295 31232
21218 (2) (2)
53 54
For PC220 and 230
20Y-62 07002
L = 1800 mm
43290 12434
44 45 43 46 47 48 36 37 39
61 62 38
01010 01643 07371 20Y-62 02896 07002 01010 01643 20Y-62 01010 01643 07049
81245 31232 51260 43460 11008 12034 51771 81040 31032 01215
81285 31232
(4) (4) (2) (4) (4) (2)
(3) (3)

BT06019
Service News BT06019 Page 42 of 48

(6) Install the return piping according to Fig. 20. 103 104
Fig. 20
111 112 113 114 115 01010 01643
Assemble the pilot
117 116 109 81040 31032
filter so that the arrow
01010 01643 02782 07002 02896
points to the R.H. side (2) (2)
95 94 01643 01010 20Y-62 of the machine body. 81075 31032 10214 12034 11008 99 100
01643 01010 31232 81225 51681 (2) (2) (2) (2) (2)
(2) (2) 20Y-62 07000
31232 81280 Pump
(2) 51321 13038
(2) (2)
92 L = 1850 mm
07094 107 108
11024
01010 01643
(2)
81225 31232
91 90 Pilot
(2) (2)
filter
01643 01010
31032 81035 01010 01643
(2) (2) 110 81225 31232
20Y-62 (2) (2)
105
51781
07095
Main valve 01241
Selector valve 106
128
21K-62 101 102
20Y-62
87 86 72810
51450 01010 01643
07000 20Y-62 To oil 81035 31032
cooler
13038 43311 (2) (2)
(2)
L = 1450 mm
22U-62
98 97 21551

01643 01010
01010 01643
31232 81225
81225 31232
(2) (2) (2) (2)
96 Return
82 83
filter
20Y-62
01010 01643
43320 Tightening torque: 20 - 30 kg·m
Tightening torque: 20 - 30 kg·m 81225 31232
Assemble the return filter (2) (2)
93 88 89 76 75 74 77 78 81 79 80 84 85
so that the arrow points to
the L.H. side of the
07095 01010 01643 07002 20Y-62 20Y-970 machine body. 20Y-62 07002 20Y-62 01010 01643 01010 01643
01038 81035 31032 14234 43351 2700 43361 14234 51280 81230 31232 81230 31232

(2) (2) (4) (4) (4) (4)

BT06019
Service News BT06019 Page 43 of 48

(7) Install the piping according to Fig. 21.


Fig. 21

01010 01643 04434 04434


136
81225 31232 53212 51312
20Y-62 Hose assembly 137 Hydraulic
52142 Composed of the tank
3 points marked with
20Y-62

Blue 51930 133


02760 02760 20Y-62 Install the mouthpiece on the side
L = 650 mm 20Y-62 of the spiral to the solenoid valve. Main valve
00219 00218 22820
52121
(2) 01643
L = 1900 mm L = 1800 mm 01010
L = 1800 mm 81225 31232

To hydraulic
142
pump
Pilot
Yellow
filter 04434
51012 Pilot
filter
Blue
Selector valve 01010 01643
81225 31232
Yellow
141
Clamp with the hose (yellow) between the PPC
Hydraulic Blue valve for ATT and the R.H. spring box on the 143
tank 04434 main valve.
6-spool
solenoid valve 52212 20Y-62 01010 01643
Main valve 51922 81255 31232

L = 1250 mm

134 135 Places 138 139 140


marked
Swing motor
208-62 08034 with . 04434 01010 01643
72480 20536 51212 81225 31232
To swivel (9)
L = 1080 mm

BT06019
Service News BT06019 Page 44 of 48

(8) Install the piping to the boom according to Fig. 22.

Fig. 22

229
For PC200 and 232 233 234 235 226 225 228 227 221 211 212 213
210 20Y-62
20Y-62 20Y-62 01010 01643 205-62 20Y-62 20Y-62 01010 20Y-62 07000 07372 01643
45382
13450 52670 81275 31232 73431 52680 13450 81230 52780 13035 21040 51032
(2)
230 (2) (4) (4) (4) (6) (12) (6) (12) (2) (8) (8)
For PC220 and
230 206-62

73592
(2)
231

01010
81235
(4)
224 223 209
For PC200 and
01643 01010 20Y-62 210
31645 81665 52761
(12) (12)
210
For PC220 and
206-62 230
222
21360
20Y-62

52740 215 216


(6) 01010 01643
81645 31645
(4) (4)
220
218 219
20Y-62
01010 01643
52770
81275 31232
(4) (4)
207
For PC200 and 217
210 20Y-62
20Y-62
52751
52670
208 (4)
For PC220 and 214
230 206-62

21350 20Y-62
52730
(2)
BT06019
Service News BT06019 Page 45 of 48

(9) Install the piping to the arm according to Fig. 23. 240 241 239
Fig. 23
245 07372 01643 07371
247 246 244 21035 51032 31049
07371
01643 01010 51260 07000 (8) (8) (4)
238
31232 81245 (4) 13038
(2) 21T-09
(8) (8)
242 11460
(2)
For PC200 and 210 07097
236
L = 1800 mm 21218
07097 For PC200 and 210
243 21015 L = 1500 mm
07097 264
For PC220 and 230
237
L = 1700 mm 21217 01010
07097 For PC220 and 230
81230
261 21016 L = 1600 mm
(4)

For PC200 and 210 20Y-62 263


265
55350 207-62
20Y-62
262 31330
13450 (4)
For PC220 and 230 206-62 (2) 260
23190 20Y-62
55340
(2)
267 268

01010 01643
81245 31232
(8) (8)
266

07000
13038
(2)
257 258

01010 01643
81230 31232
(4) (4)
253 256 255 254 252 259 251 248 249 250

07000 07371 01643 01010 20Y-970 20Y-970 20Y-970 20Y-970 01010 01643
13038 51260 31232 81245 2110 5770 5300 5320 81230 31232
(2) (4) (8) (8) (2) (2) (2) (2) (8) (8)

BT06019
Service News BT06019 Page 46 of 48

2-3-4 Monitor setting


(1) Setting for with or without attachment
· If installed with an attachment piping, make the setting for the service menu with or without attachment according to the following procedures.
· This setting enables to troubleshoot the adjust function of the attachment flow rate and/or related parts to the attachment piping.

<1> Check that abnormality is not displayed.

<2> Make the following switching operation on the normal display screen and shift to the
"Service Menu" initial screen.
[4]+[1] -> [2] -> [3]. (While holding down the [4] switch, enter the numerals
sequentially).

<3> Select and run [06] by switch operation on the "Service Menu" initial screen and shift to
the "Default" screen.

<4> Select and run [03] by switch operation on the "Default" screen and shift to the screen
"With/Without Service Cir."

<5> Select and run [With] by switching operation on the "With/Without Service Cir." select
screen and set to "With Service Circuit."

<6> Select and run [Return] menu, and return to the normal screen.

(2) Flow rate adjust function


· Operability will be enhanced if the following adjust functions are used according to the flow rate and weight of the attachment to be installed.
· For the setting method, refer to the "Special Functions of Machine Monitor" in the Shop Manual or the instruction manual.

<1> Attachment flow rate adjust performance (Operator's menu)


· Flow rate at the time the control pedal is actuated to the full stroke can be matched to the attachment to be used. (ATT and mode B)

<2> ATT flow rate adjust function (service menu) at compound time
· Flow rate distribution may be adjusted when simultaneously operating both the attachment and the boom. (ATT mode only)

BT06019
Service News BT06019 Page 47 of 48

2-3-5 General cautions


(1) Work indoor safe from the influence of wind, rain or sand or, when working outdoor, select a fair weather day and obtain a place that provides the ease of work.

(2) Pay attention to safety measures during work. Secure appropriate-sized area and flat land without obstructions to the work.
Ensure crane work safety during transportation, assembly, and disassembly.

(3) When transporting, disassembling or assembling, take great care not to cause damages to small parts, etc.

(4) Check the number of parts and damages if any before starting work.

(5) Apply grease to O-rings before installation.


(Apply thin layer of grease to ensure non-falling of O-ring when installing.)

(6) Be sure to check the tube for contaminant before piping.

(7) Be careful not to pry or twist the hose to install. Apply specified torque for installation.

(8) Tightening torques for the face seal type hose are as indicated in the following table:

Thread diameter (mm) 9/16-18UNF 11/16-16UN 13/16-16UN 1-14UNS 19/16-12UN


(Nominal No.) 02 03 04 05 06
Tightening torque 3.5 - 5.5 5.5 - 9.5 8.5 - 13.5 13 - 19 18 - 25
kg·m (N·m) (34 - 54) (54 - 93) (84 - 132) (128 - 186) (177 - 245)

(9) Tightening torques for the nipples and elbows are as indicated in the following table:
Unit: kg·m (N·m)
Thread diameter (mm) Range Target Nominal No.
14 3.5 - 6.5 (35 - 63) 4.5 (44) 02
20 8.5 - 13.5 (84 - 132) 10.5 (103) 03, 04
24 13.0 - 19.0 (128 - 186) 16.0 (157) 05, 06
33 37.0 - 49.0 (363 - 480) 43.0 (422) 10, 12
42 76.0 - 103 (746 - 1010) 90 (883) 14

(10) Tightening torques for the bolts and nuts having no torque specifications are as indicated in the following table.
Unit: kg·m (N·m)
When using a torque wrench When using an impact wrench
Thread diameter (mm)
Range Target Range Target
6 1.2 - 1.5 (11.8 - 14.7) 1.35 (13.2) 0.9 - 1.5 (8.8 - 14.7) 1.2 (12)
8 2.8 - 3.5 (27 - 34) 3.2 (31) 1.5 - 3.5 (14.7 - 34) 2.5 (25)
10 6.0 - 7.5 (59 - 74) 6.7 (66) 3.5 - 7.5 (34 - 74) 5.5 (54)
12 10 - 12.5 (98 - 123) 11.5 (113) 5.5 - 12.5 (54 - 123) 9.0 (89)
14 15.5 - 19.5 (153 - 190) 17.5 (172) 8.5 - 20.0 (84 - 196) 14.0 (137)
16 23.5 - 29.5 (235 - 285) 26.5 (260) 15.0 - 31.5 (147 - 309) 23.5 (230)
18 33 - 41 (320 - 400) 37 (363) 20.5 - 43.5 (201 - 427) 32.0 (315)
20 46.5 - 58 (455 - 565) 52.2 (512) 32.5 - 62.0 (319 - 608) 47.0 (460)
22 62.5 - 78 (610 - 765) 70.2 (688) 48.0 - 84.5 (471 - 829) 66.5 (650)
24 80 - 100 (785 - 980) 90 (882) 60.0 - 105 (588 - 1030) 82.5 (810)

BT06019
Service News BT06019 Page 48 of 48

2-3-6 Post work


After completing modification, carry out function tests and inspections according to the following check points:

(1) Wipe off oil from sections leaking as the results of modification work.

(2) Start the engine at a low speed, and check whether oil is leaking. Then, raise the speed gradually and make sure that no oil leaks.

(3) Bleed the air from the cylinder circuit according to the following instructions:

(a) Have the cylinder extended or contracted by running the engine at low speed.
Stop the cylinder about 100 mm short of the stroke end for the initial 4 to 5 strokes.

Remarks: If cylinder is moved fast to the stroke end and then relieved, rubber and resins inside the cylinder may be burnt.

(b) Then gradually raise the engine speed and conduct oil leak check and function check of the pilot circuit.

(4) Check the hydraulic oil level by holding the work equipment in an oil check attitude.
If it is not high enough, fill up the genuine oil described in the Operation and Maintenance Manual up to the specified level.

(5) For the handling of this additional circuit, give guidance to the user and operator to refer to the "Handling of Machines Attachable with the Attachment" in the instruction manual.

BT06019