Service News Installing Procedures of Additional Ci Series machines: -8 BT06019A Page 1 of 31 uit for Installing Attachment to PC200 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 PC2201C-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 Tamm Toutaa | Prachmen pine | Conlppre | Saal vave sot presure Working instalation instalation kglem?) scuator Gq] and | tet | ond | tt [nd 7a Ind Tiago slay ave we | - SSS Zslage safety vale Right Left 305:210/305 305 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 ‘Solenoid | Additional “ave. | titer | Plotfiter 1A xt Xt xt xt xt xt xt xt 2 x2 xi xt xt xt xi x2 —1 = 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 Eig. 4 for the schematic diagram of the piping and wiring. (3) See Fig. 5 for the hydraulic ciroutt diagram. (4) Service valve is not installed to the Japan standard machines. (6) A safely 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.) BTO6019A,13 Introduction of Sales Codes for Shipment by Unit Table 3 Page 2 of 31 “Applicable machine modal Specifications Remarks jPe200, POZO Main Piping, contol piping (peda incudes), solctor valve, colonold valve, adelona return jeC220, POZO JPC200- PC230 iter, pilot iter, EPC valve, pressure switch and low-pressure accumulator |For 2-pump few rato (with safoy val) Mounting bats (for 7 valves) and O-ring Elbow for plot port For 2-pump Row rala >? pump Row rate Gath jth safer vaive) Mounting bolts (for 8 valves) and O-ring Elbow for plot por PBA \Pc200- P0230 For sot pressuro of 305/210 kglem = aPusAc-a |Po200-Po2s0 For st pressuro of 305/250 kem™ APSA [Po200 -Po230 For st pressure of 305/170 kglem = laeus1-D _[Po200- P0290 For sat pressure of 170 kg/em * lara IPo200-Po230 For set pressure of 210 kg/om * [4Ps99.0 Jpo200-Po2so For sot pressure of 250 kg/om * laruseD lpc200-Pc230 For sat pressure of 305 kalem * I7PBaSF |PC2005TD boom (or breaker work wilh a haquercy lorover 50%) [Boom piping, piping mounting seat and reinforsing board TPES [PC2008TO boom (or Breaker work with a Fequency Jet under 50%) le200 and PC210 reinforced booms [Beem piping, and piping mounting seat PERU |PC2005TD boom (or Breaker work witha frequency lot over 50%) + STD arm [Boom arm piping, piping mounting seat and reinforcing board PRIENT |PC2008TD boom (or breaker work wii a Frequency lorover 5%) + reinforced arm [P0200 and PC210 reinforced boom + reinforced [Beom, arm piping end piping mounting seat [PC230, POZ30 [Boom piping, and pling mounting seat |PC220STO arm [Boom, arm piping, sping mounting seat and ranforcing board [PC200 and P0230 reinforced arm Boom, arm piping and piping mounting seat BTO6O19ABT06019A Page 3 of 31 1-4 Service Valve and Service Valve-related Parts Table 4 Parts Part No. ‘Quantity Remarks Waive for | 72-41-0800 1 For 2-pump flow rate with safety valve and variable single pressure compensating valve fattachment | 01017-61465 Mounting bolt 01643-37445 [Mounting washer [07000-13082 [O-ring for the mounting surface 728-46-17610 [O-ring for the mounting surface 723-11-19700 [O-ring for the mounting surface 723-46-17520 [O-ring for the mounting surface 723-46-17530. [O-ring for the mounting surface Waive for2 | 723-41-08800 For 2-pump flow rate with safety valve and variable attachments pressure compensating valve 723-41-08900 For +-pump flow rate with safety valve and variable pressure compensating valve 72546-16220 Mounting bott (01643-31445 [Mounting washer ‘07000-43082 [ [O-ring for the mounting surface: 723-46-17510 [O-ring for the mounting surface 72811-19730 [O-ring for the mounting surface 723-46-17820 [O-ring for the mounting surface 723-46-17630. [O-ring for the mounting surface [Safety valve [723-90-76100 | 1 [Normally [Set pressure 305 kg/om” at 190 g/min Crack pressure 250 kg/om? at 5 g/min [When leading-in [Set pressure 210 kg/om? at 190 ¢/min the pilot pressure|Crack pressure 155 kg/om? at 5 g/min 723-90-76300 Normally |Set pressure 305 kg/cm? at 190 g/min |Crack pressure 250 ko/om? at § e/min When leading-in [Set pressure 250 kg/cm? at 190 ¢/min the pilot pressure |Crack pressure 205 ka/em? at § e/min 723-90-76400 | 7 |Normally [Set pressure 305 kg/em® at 190 g/min |Crack pressure 250 kg/m? at § ¢/min. |When leading-in [Set pressure 170 kg/cm? at 190 é/min ithe pilot pressure|Crack pressure 115 kg/cm? at § e/min 723-90-61400 2 Set pressure 305 kg/em® at 190 gimin [Crack pressure _ 250 kg/cm? at 6 g/min. 723-90-61200 [Set pressure 210 kg/em* at 190 gimin |Crack pressure 155 kg/om? at § é/min 723-80-61300 [Set pressure 250 kg/cm? at 190 g/min Crack pressure 205 kg/em® at § g/min 723-90-61100 ‘Set pressure 470 kg/cm? at 190 a/min Crack pressure 115 kg/cm? at 5 g/min Note (1) Service valve on a machine body shipped from the factory is installed with a 2- stage safely valve for high set pressure of 305 kg/cm? and for low set pressure of 210 kg/cm? and a safety valve for a set pressure of 305 kg/er. (2) Service valve on @ 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 kg/cm? and for low set pressure of 210 kg/cm” and a safety valve for a set pressure of 305 kg/cm” BTO6019ABTO6019A Page 4 of 31 4-5 Introduction of Related Service News Table 5 Service News No. Title Repair procedures of work equipment for installing additional piping for attachment on PC200-8 and PC210-8 Repair procedures of work equipment for installing additional piping for attachment on PC220-8 and PC230-8 BTO60194,[“Sexce Nee ———}_sro50108 Page Sof31 {mac by yeu fatPage 6 of 31 (2) Work equipment layout Fig. 2 Additional piping #12 for the boom Additional piping #12 for the boom ‘Additional piping #10 for the boom Stop valve BTO6019A[Seite ee 1 stosoren. Page 7 of 31Page 8of31 stay vavestet[Senza 1 soso rea. Page 96631BTO6019A Page 10 of 34 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 2. Preparation Replace removed O-rings with new parts since they are consumables. Replace removed cotter pins with new paris since they are safety-critical parts. Refer to the details of the modification on page 30 for general cautions. The work can be done without removing the cab. [Removal of the parts (unnecessary parts and reusable parts) [Removing the floor mat and foot rest. Reworking the floor mat Removing the piping-related parts under the floor Removing the piping-related parts of machine body Removing and installing solenoid valve-related parts Removing the main valve end block [Removing the boom piping-related parts Installing the parts for additional circuit Installing service valve and end block to the main valve Installing related parts to the main valve, pump and hydraulic tank installing the control pedal (R.H.), related parts and floor mat Installing the piping, brackets and related parts between the main valve and lwork equipment Installing the piping, brackets and related parts between the main valve and lwork equipment (to the R.H. side of the machine) Installing the return piping, additional retum filter and the related parts Installing PPC piping and related parts Installing the boom piping Installing the arm piping Monitor setting and adjusting |General cautions Post work BTO6019APage 11 of 31 (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. in this Service News coincide with Parts Nos. in the Parts List. 23 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.) (6) If the temperature of hydraulic oil is high, wait until it comes down before proceeding to the next work. BTO60194BTO6019A Page 12 of 31 2-3-2 Removal of unnecessary parts and reusable parts (1) Remove the floor mat and footrest according to Fig. 6. Fig. 6 2 Remove and cut out to repai 14712 ,/ See Eig. 7 for the repair content. \ 31032 ,", 81020 BTOGO19APage 13 of 31 Fig. 7 ‘Turn the removed floor mat over and repair section P as indicated below: Remove the hatched area along the notch line. Radius for the comer and angle shall be "3". BT06019ABTOSO19A Page 14 of 31 (2) Remove the nipples, etc. from the block under the floor according to Fig. 8. Also remove taped connectors Fig. 8 Remove the tape and disconnect the connector at the end. CN-P13 BTO6019A[“Seniee Were ———]aosoron, Page 150f 31 9 Remove ne gis enous sclera aes Roses Bach Homme macre ay ce ‘as acme ep cares ras cro owas yh roe ne[Sevice News] srosor0n Page 160131 fa[Sexes nexs 1] sros0188 Page 17 of 31 Tova tom ibe macine ens pense <> Preeons ‘iran erszantng he mi eo nyse (Gwe claranae soacenesanng. 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