Atachment Installation Guide zx210

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SERVICE BULLETIN CODE

DESCRIPTION
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SUBJECT
INSTALLATION PROCEDURE OF THE PIPING FOR AUXILIARY OPERATION OF ZX200-6
SERIES ATTACHMENT
OUTLINE
This Service Bulletin provides you with instructions on how to install the piping (assist piping,
additional pump system) for the auxiliary operation of attachment to ZX200-6 machine.
Undertake the work according to the table of contents on page 2.
Refer to the next page onward.
＊ Thoroughly read the safety section in the service manual before starting the work to ensure safe operation.
Welding work, if any, should only be done by qualified welders.
＊ After replacing the main hydraulic equipment or engine or after post-assembling the aforementioned as an
option, be sure to change and register the post-assembled device serial number on Global e-Service (MMR,
HR, MME, G-Claim).
APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Model(s): ZX210-6
Machine Serial Nos.: ZX200-6, ZX210-6

Verify details of the applicable models and serial numbers on Global e-Service
S/B (Service Bulletin).
STD. LABOR HOURS

12 Hours / two persons
EXPENSES AND THE TIME TO BE CHARGED

Charge to the customer.
PARTS
―
DESCRIPTION
Refer to the following page(s).
CHKD
SA/GI: ― APPD
TM
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DESCRIPTION
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Applicable models
Europe Specification Model Name Model Code
ZX210-6 DC450
ZX210LC-6 DC451
ZX210-6 DC45Z
Installation procedure of the piping (assist piping) for auxiliary operation

of attachment
This explanation is a summary of how to install the piping (assist piping, additional pump system) that is
used for the auxiliary operation of a ZX200-6 attachment.
Note that the parts kit lists and assembly drawings that are found in this Service Bulletin are prone to partial
revisions in the event of modification for quality improvement, etc.
CONTENTS
1 Usage objective of the parts kit …………………………………………………………… 3
2 Supply-state of the parts kit ………………………………………………………………… 3
3 Contents of the parts kit and cautionary remarks ……………………………………… 4
4 Hydraulic circuit diagram …………………………………………………………………… 5
5 Electric circuit diagram for electric operation parts …………………………………… 7
6 Parts kit numbers and assembly drawings ……………………………………………… 8

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DESCRIPTION
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1 Usage objective of the parts kit

The kit contains parts that are used for the auxiliary operation of an attachment, including swing devices
of full swing fork, full swing crusher, etc., chuck cylinder, etc. of hydraulic vibro. The additional pump parts
can be used on some models to increase the flow rate in the attachment piping (basic piping).
(In this case, you have to obtain additional parts separately.)
2 Supply-state of the parts kit

The following kits are available to suit the individual hydraulic source, front piping and operation formula.
Put the parts together according to usage objectives, user requests and such.
(1) Additional pump parts kit (hydraulic source)
Kit No. ※ Part Name Remarks
YA60056495 Additional pump
YA60033599 Valve, assist (cylinder) Center closed type (CYL)
YA60033600 Pump, gear
YA60056495 Additional pump
YA60034236 Valve, assist (motor) Center open type (ROTETING)
YA60033600 Pump, gear
(2) Assist front piping parts kit (front piping)

YA60056496 Piping, boom
YA60033591 Seat, screw (boom)
YA60033593 Seat, screw (arm)
(3) Hydraulic operation parts kit (operation system)

YA60034257 Pedal (L)
YA60056498 Piping, pilot
YA60034259 Mat, floor
(4) Electric operation parts kit

YA60033613 Front lever Cab side
YA60033614 Electric operation parts (cab) Cab side
YA60033615 Piping, pilot
YA60054342 Electric operation parts Base machine side
YA60033617 Cover (8)
YA60014765 Guard
YA60025944 Bracket Inside the cab
※ Kit numbers cannot be used to place orders.

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DESCRIPTION
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3 Contents of the parts kit and cautionary remarks

(1) Additional pump parts kit
① As hydraulic source, it uses the additional pump.
② The kit consists of a gear pump, additional valve (24.5MPa, ABT open circuit) and piping parts.
③ The discharge flow is about 30 l/min. To adjust, a slow return valve is required separately.
④ The additional valve comes with a main relief valve. At the time of factory shipment, the pressure is
set to 24.5MPa. Adjust according to attachment specification
⑤ A high pressure sensor is installed to the M port of the additional valve to allow the monitoring of the
additional pump discharge pressure.
(2) Assist front piping parts kit

① A 3/8 inch front piping, there are two for the left side and one for the right side. Install to the sides of
the boom and arm. (The arm piping will be below the main piping.)
② The pipe included in the kit is that to the plug at the arm end. However, the kit does not contain the
attachment connection hose. Obtain the hose suitable for the attachment.
③ The kit contains parts for the standard arm. For assembly with long arm and short arm, you will
need a pipe, hose and protector suitable for each. Place an order for them at the HCM regional
parts depot while referring to the parts kit list.
④ The pipe on the upper left side is used on the return circuit to the hydraulic oil tank. If it is used on
the cylinder circuit of the hydraulic vibro chuck, etc., the pipe on the lower left side can be used as
drain.
As a marker, attach a nameplate (YA00065064) to the arm side of the drain piping connection port.
Left side of the arm Attachment piping/high pressure
・Hydraulic operation … left pedal, front
Assist piping/drain (DR)
Assist piping/high pressure (A)

・Hydraulic operation … left pedal, front
・Electric operation … left lever, left button
(3) Hydraulic operation parts kit

① These parts control the auxiliary operation of the attachment by using the left-hand pedal.
② The kit consists of an operational pedal, pilot valve and piping parts.

① These parts control the auxiliary operation of the attachment by using the electric switch that is
installed in the control lever grip.
② The kit consists of grips (left and right), harness, solenoid valve and piping parts.
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DESCRIPTION
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4 Hydraulic circuit diagram

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DESCRIPTION
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DESCRIPTION
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5 Electric circuit diagram for electric operation parts

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DESCRIPTION
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6 Parts kit numbers and assembly drawings

(1) Additional pump parts kit (hydraulic source)
Kit No. ※ Part Name Assembly Drawing Remarks
YA60056495 Additional pump YA60042635
YA60033599 Valve, assist (cylinder) ―
Center closed type (CYL)
YA60033600 Pump, gear ―

YA60034236 Valve, assist (motor) ― Center open type (ROTETING)
(2) Assist front piping kit

Kit No. ※ Part Name Assembly Drawing/Additional Work Drawing Remarks
YA60056496 Piping, boom 9313383
YA60033591 Seat, screw (boom) 8121433 Additional work drawing for boom
YA60056497 Piping, arm YA60041397 2.91m, domestic specification ( ※ 2)
8120466 Additional work drawing for 2.91m arm
YA60033593 Seat, screw (arm)
YA40006493 Additional work drawing for 2.42m arm
YA60057783 Nameplate YA00065065 Nameplate affixation drawing
(For arms other than standard arm (2.91m) (domestic specification) ( ※ 2), refer to the separate list.)
(3) Hydraulic operation parts kit (operation system)

YA60034257 Pedal (L) YA60000356
YA60056498 Piping, pilot YA60048629
YA60034259 Mat, floor ―

YA60033613 Front lever YA60006944 Cab side
YA60033614 Electric operation parts (cab) YA60019493 Cab side
YA60033615 Pilot piping (AFL) YA60001820
YA60054342 Electric operation parts YA60026958 Base machine side
YA60033617 Cover (8) ―
YA60014765 Guard YA60018720
YA60025944 Bracket YA60001478 Inside the cab
※ For non-STD arm specification, order an assist pipe that is suitable for the specification while referring
to the list below (not contained in the arm piping kit).
Specification Reference Kit No. ※ Part Name Remarks
Short arm (2.42m) (Europe) 9259471 Piping, assist No need to order YA60056497
Short arm (2.91m) (Europe) YA60003640 Piping, assist No need to order YA60056497
※ Kit numbers cannot be used to place orders.
Note: To additionally arrange for standard arm-use assist piping kit YA60056497, the following parts are
required separately. Place an order for them at the HCM regional parts depot.
Reference Kit No. ※ Part No. Q’ty Part Name Remarks
9760615 1 Pipe Upper left
9259471 9760616 2 Pipe Lower left and right
(Short arm, 2,42m) (Europe) 4489201 3 Hose L=1500
A885003 3 Plug
YA40003352 1 Pipe Upper left
YA60003640
YA40003353 2 Pipe Lower left and right
(Arm, 2.91m) (Europe)
A885003 3 Plug
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DESCRIPTION
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(1) Additional pump parts kit

Kit no. YA60056495 (additional pump)
Item No. Part No. Q’ty Part Name Finish Weight Remarks New Parts
000 YA40026379 1 Bracket 2.02
002 4411001 2 Valve, shuttle 0.45
003 A885002 2 Plug 0.03
004 4436271 1 Sensor, pressure 0.13
005 4269537 1 Reducer 0.13
006 YA00003616 1 Harness, wire 0.17
007 YA60023487 1 Assembly, hose 2.09
008 4457107 2 Hose 0.22
010 YA40024777 1 Bracket 1.11
011 YA40024778 1 Bracket 0.88
012 YA40029458 1 Bracket 0.75
013 9764485 1 Bracket 0.20
014 4668866 1 Hose 0.76
015 9314066 1 Hose assembly 1.20
016 4600690 1 Hose 0.27
017 4351100 1 Hose 1.13
019 XV00003094 1 Hose 1.11
020 YA60042600 1 Assembly, hose 2.92
021 YA60042599 1 Assembly, hose 4.03
022 4193816 7 Clip 0.06
023 4190264 1 Clip 0.03
024 4190282 1 Clip 0.03
025 4276940 1 Adapter, S 0.19
026 A852123 3 Adapter, S 0.04
027 A852143 2 Adapter, S 0.10
028 A853166 1 Adapter, S 0.18
029 4303003 1 Tee, S 0.19
030 A852423 2 Tee, S 0.11
031 A853466 1 Tee, S 0.43
032 A852323 3 Elbow, S 0.09
034 A852343 1 Elbow, S 0.20
035 A853244 1 Elbow, S 0.16
036 A853266 1 Elbow, S 0.29
037 A853344 1 Elbow, S 0.22
038 A853366 1 Elbow, S 0.43
039 4138938 2 O-ring 0.01
040 4187308 6 O-ring 0.01
041 J781035 3 Bolt, socket 0.03
042 J281050 2 Bolt, sems 0.06
045 J271035 2 Bolt, sems 0.04
046 J271030 5 Bolt, sems 0.03
047 J271020 7 Bolt, sems 0.03
048 J260845 4 Bolt, sems 0.02
049 4121859 15 Clip, band 0.01
050 4055312 2 Clip, band 0.01
051 4055311 7 Clip, band 0.01
052 J281035 3 Bolt, sems 0.04
053 4449250 1 Clip 0.01
Kit no. YA60033599 (vale, assist (cylinder))

000 4676769 1 Valve, control 6.0 AB-T BLOCK TYPE
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DESCRIPTION
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Kit no. YA60033600 (pump, gear)

000 9218031 1 Pump, gear 4.20
001 4153543 1 O-ring 0.01 For the TX pump
Kit no. YA60034236 (valve, assist (motor))

000 4676782 1 Valve, control 6.0
(2) Assist front piping parts kit

Kit no. YA60056496 (piping, boom)
000 YA40028218 1 Pipe 3.09 Boom, upper left rear
001 YA40028219 1 Pipe 2.95 Boom, lower left rear
002 8121425 2 Pipe 2.79 Boom, left front
003 YA40028220 1 Pipe 3.09 Boom, right rear
004 8121426 1 Pipe 2.79 Boom, right front
005 94-2023 2 Plug 0.03
008 4189858 6 Clamp, pipe 0.17 Boom, left
009 4190124 6 Clamp, pipe 0.16 Boom, right
010 4665706 12 Bolt, sems 0.06 (Note 1)
Kit no. YA60033591 (seat, screw (boom))

000 9763817 2 Seat, screw 0.42 For 135US/225US/USR
001 9764929 2 Seat, screw 0.43 120/160LC/330 not required
002 9765301 10 Seat, screw 0.33
003 9770597 1 Seat, screw 0.53 For 135US
※ In this service bulletin, only 2 screw seats (01) 9764929 and 10 screw seats (02) 9765301 are to be used.
Kit no. YA60056497 (piping, arm)

000 YA40003350 2 Pipe 1.15 Arm, upper left and right
001 YA40003351 1 Pipe 1.08 Arm, lower left
002 4189858 2 Clamp, pipe 0.17 Arm, left
003 4190124 2 Clamp, pipe 0.16 Arm, right
004 4665706 4 Bolt, sems 0.06
005 4462707 3 Hose 3.05
006 4121859 2 Clip, band 0.005
007 94-2023 3 Plug 0.03
Kit no. YA60033593 (seat, screw (arm))

000 9765301 4 Seat, screw 0.33
Note 1: P/Nos. 4666091・4665706 can be installed using the substitute parts listed below.
Substitute for 4666091 (Mec bolt) Substitute for 4665706 (Mec bolt)
Bolt J901260 Bolt J901250
Washer J222012 Washer J222012
※ When you use the substitute parts, apply Loctite No. 262 (red) to the bolt thread.
Kit no. YA60057783 (nameplate)

000 YA00065064 1 Nameplate 0.001 ○
001 YA00065065 1 Procedure, nameplate 0.001
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DESCRIPTION
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(3) Hydraulic operation parts kit

Kit no. YA60034257 (pedal, L)
000 YB60000024 1 Valve, pilot 1.25
001 J901040 2 Bolt 0.03 For 00
002 A590110 2 Washer, plain 0.01 For 00
003 A590910 2 Washer, spring 0.01 For 00
004 8104230 1 Bracket 1.04
005 J271035 3 Bolt, sems 0.04 For 04
006 4317640 1 Bolt 0.02
007 M500807 1 Nutt 0.01
010 9766876 1 Bracket 0.31 Lock
011 J271025 2 Bolt, sems 0.03 For 10
012 9766167 1 Stopper 0.16
013 4279604 1 Spring 0.01
014 4287795 1 Pin 0.01
015 A763016 1 Pin, split 0.01
016 A590110 1 Washer, plain 0.01
019 9765823 1 Bracket 0.23
020 J260816 2 Bolt, sems 0.01 For 19
021 1033219 1 Pedal 0.4
022 4660756 1 Plate 0.15
023 J260835 2 Bolt, sems 0.02 For 22
026 3107562 1 Pedal, L 0.49 Travel, left (without lug)
Kit no. YA60056498 (piping, pilot)

000 YA60052330 1 Assembly, hose 1.26 1
001 YA60048628 1 Assembly, hose 1.26 2
002 4645592 1 Hose 0.29 T6
003 4696390 1 Hose 0.33 P3
004 A852123 3 Adapter, S 0.04
005 A852433 2 Tee, S 0.15
006 4190282 3 Clip 0.03
007 J271020 3 Bolt, sems 0.03
008 A852333 1 Elbow, S 0.13
Kit no. YA60034259 (mat, floor)

000 3120707 1 Mat, floor 5.4
Kit no. YA60033613 (front lever)

000 4708461 1 Grip 0.30 Thick grip 3SW (horn)
001 YA00025174 1 Grip 0.30 Thick grip 3SW (power DIG)
002 4705608 2 Shaft 0.07 To install the grip
003 J950012 4 Nut 0.02 To install the shaft and grip
004 4055311 2 Clip, band 0.01 To fix the grip harness (P/V side)
005 4300351 2 Clip, band 0.01 To fix the grip harness (console side)
006 2058780 2 Boots 0.17 Outer boots
008 J780820 8 Bolt, socket 0.01 To install the P/V
009 J222008 8 Washer 0.01 To install the P/V
011 YB40000006 2 Boots 0.05 Inner boots
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Kit no. YA60033614 (electric operation parts (cab))

000 4651295 1 Switch 0.05 Installation location: R2, L6
001 4651278 1 Harness, wire 0.01 Switch sub harness
002 2058776 1 Case 0.02 To install the switch
003 3121182 3 Cap 0.01 Cap for space in case
004 4121859 1 Clip, band 0.01
006 YA00016262 1 Harness, wire 1.00
007 4436534 2 Relay 0.03 B (B)
008 4055312 8 Clip, band 0.01
009 4692542 1 Clip, band 0.01
Kit no. YA60033615 (pilot piping)

000 YA00002786 1 Hose 0.90
001 YA00002787 1 Hose 0.87
003 A852433 2 Tee, S 0.15
005 4190282 3 Clip 0.03
006 J271020 3 Bolt, sems 0.03
010 4726439 1 Hose 0.23
011 YA00002788 1 Hose 0.37
012 A852133 1 Adapter, S 0.06
013 A852123 1 Adapter, S 0.04
Kit no. YA60033616 (electric operation parts)

000 4463199 1 Valve, solenoid 3.00
001 A852323 2 Elbow, S 0.09
002 A852333 2 Elbow, S 0.13
003 J271020 4 Bolt, sems 0.03
004 YA40015105 1 Bracket 1.17
005 J271030 3 Bolt, sems 0.03
006 4602634 1 Bracket 0.01
007 YA00024051 1 Harness, wire 0.07
008 4677580 1 Hose 0.76
009 4670534 1 Hose 0.76
010 4193848 1 Clip 0.05
011 4254600 3 Clip, band 0.01
012 4055312 8 Clip, band 0.01
Kit no. YA60033617 (cover (8))

001 YA40019592 1 Cover 3.45 Partition cover with holes
002 J271030 6 Bolt, sems 0.03 To install 01
Kit no. YA60014765 (guard)

000 4645331 1 Cover 2.07
001 J271030 3 Bolt, sems 0.03
Kit no. YA60025944 (bracket)

000 YA00031006 1 Bracket 0.28 To install the relay
001 J260816 2 Bolt, sems 0.01 To install 00
002 4254600 1 Clip, band 0.01 To band the harnesses
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Kit no. YA60056495 (additional pump)

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(08) YA00003669 ∼ 1/2 (08) YA00003669 ∼ 1/2

( HOSE ) ( HOSE )
[EG-07-09-040S] [EG-07-09-040S]
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(16) 4366863 ∼ 1
(HOSE)
[EE-07-09-082N]
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NOTES
1. No kink (or break) of hoses when assembling.
2. Avoid interference of hoses, covers and frame when assembling.
3. The mark suggested at parts number shows the initial of the mark
labeled on the hose.
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Kit no. YA60056496 (piping, boom)
B; High pressure
Drain
A; High pressure
If the guarantee term (five

months from the delivery date)
of the bolt for which TB2446
(blue) has been applied
expires, apply Loctite262 (red)
to the bolt before installing it.
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Kit no. YA60033591 (seat, screw (boom))

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Kit no. YA60056497 (piping, arm)

Kit no. YA60057783 (nameplate)
Put a nameplate on the

arm side of drain piping.
A; High pressure
Drain
B; High pressure
If the guarantee term (five months from the

delivery date) of the bolt for which TB2446
(blue) has been applied expires, apply
Loctite262 (red) to the bolt before installing it.
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Kit no. YA60033593 (seat, screw (arm))
Additional work drawing for 2.91m arm

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Additional work drawing for 2.42m arm

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Kit no. YA60034257 (pedal, L)

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NOTES
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Kit no. YA60033613 (front lever)

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Kit no. YA60033614 (electric operation parts (cab))

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Electrical operation
NOTES
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Electrical operation Electrical operation

and pedal (R)
Electrical operation Electrical operation

and pedal (R)
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and pedal (R)
and pedal (R)
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and pedal (L)
and pedal (L)
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and pedal (L)
and pedal (L)
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and pedal (L), (R)
and pedal (L), (R)
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and pedal (L), (R)
and pedal (L), (R)
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Kit no. YA60033616 (electric operation parts)
NOTES
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Kit no. YA60033617 (cover (8))

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Kit no. YA60014765 (guard)
Kit no. YA60025944 (bracket)

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Page 1 of 53

SERVICE BULLETIN CODE

Refer to the next page onward.

APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Serial Nos.: ZX200-6, ZX210-6

STD. LABOR HOURS

EXPENSES AND THE TIME TO BE CHARGED

Installation procedure of the piping (assist piping) for auxiliary operation

1 Usage objective of the parts kit …………………………………………………………… 3

2 Supply-state of the parts kit ………………………………………………………………… 3

3 Contents of the parts kit and cautionary remarks ……………………………………… 4

4 Hydraulic circuit diagram …………………………………………………………………… 5

5 Electric circuit diagram for electric operation parts …………………………………… 7

6 Parts kit numbers and assembly drawings ……………………………………………… 8

1 Usage objective of the parts kit

2 Supply-state of the parts kit

(2) Assist front piping parts kit (front piping)

(3) Hydraulic operation parts kit (operation system)

(4) Electric operation parts kit

※ Kit numbers cannot be used to place orders.

3 Contents of the parts kit and cautionary remarks

(2) Assist front piping parts kit

Assist piping/drain (DR)

Assist piping/high pressure (A)

(3) Hydraulic operation parts kit

(4) Electric operation parts kit

4 Hydraulic circuit diagram

5 Electric circuit diagram for electric operation parts

6 Parts kit numbers and assembly drawings

YA60033600 Pump, gear ―

(2) Assist front piping kit

(3) Hydraulic operation parts kit (operation system)

(4) Electric operation parts kit

※ Kit numbers cannot be used to place orders.

(1) Additional pump parts kit

Kit no. YA60033599 (vale, assist (cylinder))

Kit no. YA60033600 (pump, gear)

Kit no. YA60034236 (valve, assist (motor))

(2) Assist front piping parts kit

Kit no. YA60033591 (seat, screw (boom))

Kit no. YA60056497 (piping, arm)

Kit no. YA60033593 (seat, screw (arm))

Kit no. YA60057783 (nameplate)

(3) Hydraulic operation parts kit

Kit no. YA60056498 (piping, pilot)

Kit no. YA60034259 (mat, floor)

Kit no. YA60033613 (front lever)

Kit no. YA60033614 (electric operation parts (cab))

Kit no. YA60033615 (pilot piping)

Kit no. YA60033616 (electric operation parts)

Kit no. YA60033617 (cover (8))

Kit no. YA60014765 (guard)

Kit no. YA60025944 (bracket)

Kit no. YA60056495 (additional pump)

(08) YA00003669 ∼ 1/2 (08) YA00003669 ∼ 1/2

Kit no. YA60056496 (piping, boom)

If the guarantee term (five