Bz210-1 Shop Manual (JPN) SN 1001-Up Sebm031101 PDF

SEBM031101
MACHINE MODEL SERIAL NUMBER

BZ210-1 1001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
• BZ210-1 mounts the SAA6D102E-2 engine.

For details of the engine, see the 102 Series Engine Shop Manual.
© 2005
All Rights Reserved
Printed in Japan 02-05 (01)
00-1
(1)
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD............................................ 10-1
20 TESTING AND ADJUSTING ........................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
90 OTHERS ................................................................................................................................ 90-1
00-2 BZ210-1
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
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Q 00-2-1 (1) q 01-3 (1) q 10-22 (1) Q 10-50 (1) Q 10-80 (1)
Q 00-2-2 (1) q 01-4 q 10-23 (1) Q 10-51 (1) Q 10-81 (1)
Q 00-2-3 (1) q 01-5 q 10-24 (1) Q 10-52 (1) Q 10-82 (1)
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q 00-3 q 01-7 q 10-26 (1) Q 10-54 (1) Q 10-84 (1)
q 00-4 q 01-8 q 10-27 (1) Q 10-56 (1) Q 10-85 (1)
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q 00-22 q 10-17 (1) q 10-45 (1) Q 10-75 (1) Q 10-104 (1)
q 10-18 (1) q 10-46 (1) Q 10-76 (1) Q 10-106 (1)
(10-19) q 10-47 (1) Q 10-77 (1) Q 10-107 (1)
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Q 10-108 (1) Q 10-152 (1) Q 10-192 (1) q 20-118 (1) Q 20-158 (1)
Q 10-109 (1) Q 10-153 (1) Q 10-193 (1) q 20-119 (1) Q 20-159 (1)
Q 10-110 (1) Q 10-154 (1) Q 10-194 (1) q 20-120 (1) Q 20-160 (1)
Q 10-111 (1) Q 10-155 (1) Q 10-195 (1) q 20-121 (1) Q 20-161 (1)
Q 10-112 (1) Q 10-156 (1) Q 10-196 (1) q 20-122 (1) Q 20-162 (1)
Q 10-113 (1) Q 10-157 (1) Q 10-197 (1) q 20-123 (1) Q 20-163 (1)
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Q 10-116 (1) Q 10-159 (1) Q 10-199 (1) q 20-125 (1)
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Q 10-118 (1) Q 10-161 (1) Q 10-201 (1) q 20-127 (1) Q 20-202 (1)
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Q 10-121 (1) Q 10-164 (1) q 20-130 (1) Q 20-205 (1)
Q 10-122 (1) Q 10-165 (1) q 20-1 (1) Q 20-131 (1) Q 20-206 (1)
Q 10-123 (1) Q 10-166 (1) 20-2 Q 20-132 (1) Q 20-207 (1)
Q 10-124 (1) Q 10-167 (1) q 20-3 (1) Q 20-133 (1) Q 20-208 (1)
Q 10-125 (1) Q 10-168 (1) q 20-4 (1) Q 20-134 (1) Q 20-209 (1)
Q 10-126 (1) Q 10-169 (1) q 20-5 (1) Q 20-135 (1) Q 20-210 (1)
Q 10-128 (1) Q 10-170 (1) q 20-6 (1) Q 20-136 (1) Q 20-211 (1)
Q 10-129 (1) Q 10-171 (1) q 20-7 (1) Q 20-137 (1) Q 20-212 (1)
Q 10-130 (1) Q 10-172 (1) Q 20-8 (1) Q 20-138 (1) Q 20-213 (1)
Q 10-132 (1) Q 10-173 (1) Q 20-139 (1) Q 20-214 (1)
Q 10-133 (1) Q 10-174 (1) Q 20-140 (1) Q 20-215 (1)
Q 10-134 (1) Q 10-175 (1) q 20-101 (1) Q 20-141 (1) Q 20-216 (1)
Q 10-135 (1) Q 10-176 (1) q 20-102 (1) Q 20-142 (1) Q 20-217 (1)
Q 10-136 (1) Q 10-177 (1) q 20-103 (1) Q 20-143 (1) Q 20-218 (1)
Q 10-137 (1) Q 10-178 (1) q 20-104 (1) Q 20-144 (1) Q 20-219 (1)
Q 10-138 (1) Q 10-179 (1) q 20-105 (1) Q 20-145 (1) Q 20-220 (1)
Q 10-139 (1) Q 10-180 (1) q 20-106 (1) Q 20-146 (1) Q 20-221 (1)
Q 10-140 (1) Q 10-181 (1) q 20-107 (1) Q 20-147 (1) Q 20-222 (1)
Q 10-141 (1) Q 10-182 (1) q 20-108 (1) Q 20-148 (1) Q 20-224 (1)
Q 10-142 (1) Q 10-183 (1) q 20-109 (1) Q 20-149 (1) Q 20-225 (1)
Q 10-143 (1) Q 10-184 (1) q 20-110 (1) Q 20-150 (1) Q 20-226 (1)
Q 10-144 (1) Q 10-185 (1) q 20-111 (1) Q 20-151 (1) Q 20-227 (1)
Q 10-146 (1) Q 10-186 (1) q 20-112 (1) Q 20-152 (1) Q 20-228 (1)
Q 10-147 (1) Q 10-187 (1) q 20-113 (1) Q 20-153 (1) Q 20-229 (1)
Q 10-148 (1) Q 10-188 (1) q 20-114 (1) Q 20-154 (1) Q 20-230 (1)
Q 10-149 (1) Q 10-189 (1) q 20-115 (1) Q 20-155 (1) Q 20-231 (1)
Q 10-150 (1) Q 10-190 (1) q 20-116 (1) Q 20-156 (1) Q 20-232 (1)
Q 10-151 (1) Q 10-191 (1) q 20-117 (1) Q 20-157 (1) Q 20-233 (1)
00-2-2 BZ210-1
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Q 20-235 (1) Q 20-275 (1) Q 20-334 (1) Q 20-375 (1) Q 20-503 (1)
Q 20-236 (1) Q 20-276 (1) Q 20-335 (1) Q 20-376 (1) Q 20-504 (1)
Q 20-237 (1) Q 20-277 (1) Q 20-336 (1) Q 20-377 (1) Q 20-505 (1)
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Q 20-240 (1) Q 20-280 (1) Q 20-339 (1) Q 20-380 (1) Q 20-508 (1)
Q 20-241 (1) Q 20-340 (1) Q 20-381 (1) Q 20-509 (1)
Q 20-242 (1) Q 20-301 (1) Q 20-341 (1) Q 20-382 (1) Q 20-510 (1)
Q 20-243 (1) Q 20-302 (1) Q 20-342 (1) Q 20-383 (1) Q 20-511 (1)
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Q 20-246 (1) Q 20-305 (1) Q 20-345 (1) Q 20-386 (1) Q 20-514 (1)
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Q 20-249 (1) Q 20-308 (1) Q 20-348 (1) Q 20-389 (1) Q 20-517 (1)
Q 20-250 (1) Q 20-309 (1) Q 20-349 (1) Q 20-390 (1) Q 20-518 (1)
Q 20-251 (1) Q 20-310 (1) Q 20-350 (1) Q 20-391 (1) Q 20-519 (1)
Q 20-252 (1) Q 20-311 (1) Q 20-351 (1) Q 20-392 (1) Q 20-520 (1)
Q 20-253 (1) Q 20-312 (1) Q 20-352 (1) Q 20-393 (1) Q 20-521 (1)
Q 20-254 (1) Q 20-313 (1) Q 20-353 (1) Q 20-394 (1) Q 20-522 (1)
Q 20-255 (1) Q 20-314 (1) Q 20-354 (1) Q 20-395 (1) Q 20-523 (1)
Q 20-256 (1) Q 20-315 (1) Q 20-355 (1) Q 20-396 (1) Q 20-524 (1)
Q 20-257 (1) Q 20-316 (1) Q 20-356 (1) Q 20-397 (1) Q 20-526 (1)
Q 20-258 (1) Q 20-317 (1) Q 20-357 (1) Q 20-398 (1) Q 20-527 (1)
Q 20-259 (1) Q 20-318 (1) Q 20-358 (1) Q 20-399 (1) Q 20-528 (1)
Q 20-260 (1) Q 20-319 (1) Q 20-359 (1) Q 20-400 (1) Q 20-529 (1)
Q 20-261 (1) Q 20-320 (1) Q 20-360 (1) Q 20-401 (1) Q 20-530 (1)
Q 20-262 (1) Q 20-321 (1) Q 20-362 (1) Q 20-402 (1) Q 20-531 (1)
Q 20-263 (1) Q 20-322 (1) Q 20-363 (1) Q 20-403 (1) Q 20-532 (1)
Q 20-264 (1) Q 20-323 (1) Q 20-364 (1) Q 20-404 (1) Q 20-533 (1)
Q 20-265 (1) Q 20-324 (1) Q 20-365 (1) Q 20-405 (1) Q 20-534 (1)
Q 20-266 (1) Q 20-325 (1) Q 20-366 (1) Q 20-406 (1) Q 20-535 (1)
Q 20-267 (1) Q 20-326 (1) Q 20-367 (1) Q 20-407 (1) Q 20-536 (1)
Q 20-268 (1) Q 20-327 (1) Q 20-368 (1) Q 20-408 (1) Q 20-537 (1)
Q 20-269 (1) Q 20-328 (1) Q 20-369 (1) Q 20-409 (1) Q 20-538 (1)
Q 20-270 (1) Q 20-329 (1) Q 20-370 (1) Q 20-410 (1) Q 20-539 (1)
Q 20-271 (1) Q 20-330 (1) Q 20-371 (1) Q 20-411 (1) Q 20-540 (1)
Q 20-272 (1) Q 20-331 (1) Q 20-372 (1) Q 20-541 (1)
Q 20-273 (1) Q 20-332 (1) Q 20-373 (1) Q 20-501 (1) Q 20-542 (1)
BZ210-1 00-2-3
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Q 20-544 (1) Q 20-620 (1) Q 30-6 (1) Q 30-46 (1)
Q 20-545 (1) Q 20-621 (1) Q 30-7 (1) Q 30-47 (1)
Q 20-546 (1) Q 20-622 (1) Q 30-8 (1) Q 30-48 (1)
Q 20-547 (1) Q 20-623 (1) Q 30-9 (1) Q 30-49 (1)
Q 20-548 (1) Q 20-624 (1) Q 30-10 (1) Q 30-50 (1)
Q 20-549 (1) Q 20-625 (1) Q 30-11 (1) Q 30-51 (1)
Q 20-550 (1) Q 20-626 (1) Q 30-12 (1) Q 30-52 (1)
Q 20-551 (1) Q 20-627 (1) Q 30-13 (1) Q 30-53 (1)
Q 20-552 (1) Q 30-14 (1) Q 30-54 (1)
Q 20-553 (1) Q 20-701 (1) Q 30-15 (1) Q 30-55 (1)
Q 20-554 (1) Q 20-702 (1) Q 30-16 (1) Q 30-56 (1)
Q 20-555 (1) Q 20-703 (1) Q 30-17 (1) Q 30-57 (1)
Q 20-556 (1) Q 20-704 (1) Q 30-18 (1) Q 30-58 (1)
Q 20-557 (1) Q 20-705 (1) Q 30-19 (1) Q 30-59 (1)
Q 20-558 (1) Q 20-706 (1) Q 30-20 (1) Q 30-60 (1)
Q 20-559 (1) Q 20-707 (1) Q 30-21 (1) Q 30-61 (1)
Q 20-560 (1) Q 20-708 (1) Q 30-22 (1)
Q 20-561 (1) Q 20-709 (1) Q 30-23 (1)
Q 20-562 (1) Q 20-710 (1) Q 30-24 (1) q 90-1 (1)
Q 20-563 (1) Q 20-711 (1) Q 30-25 (1) q 90-3 (1)
Q 20-712 (1) Q 30-26 (1) q 90-5 (1)
Q 20-601 (1) Q 20-713 (1) Q 30-27 (1) q 90-7 (1)
Q 20-602 (1) Q 20-714 (1) Q 30-28 (1) q 90-9 (1)
Q 20-603 (1) Q 20-715 (1) Q 30-29 (1) q 90-11 (1)
Q 20-604 (1) Q 20-716 (1) Q 30-30 (1) q 90-13 (1)
Q 20-605 (1) Q 20-717 (1) Q 30-31 (1) Q 90-15 (1)
Q 20-606 (1) Q 20-718 (1) Q 30-32 (1) Q 90-17 (1)
Q 20-607 (1) Q 20-719 (1) Q 30-33 (1) Q 90-19 (1)
Q 20-608 (1) Q 20-720 (1) Q 30-34 (1) Q 90-21 (1)
Q 20-609 (1) Q 20-721 (1) Q 30-35 (1) Q 90-23 (1)
Q 20-610 (1) Q 20-722 (1) Q 30-36 (1) Q 90-25 (1)
Q 20-611 (1) Q 20-723 (1) Q 30-37 (1)
Q 20-612 (1) Q 20-724 (1) Q 30-38 (1)
Q 20-613 (1) Q 30-39 (1)
Q 20-614 (1) Q 30-40 (1)
Q 20-615 (1) q 30-1 (1) Q 30-41 (1)
Q 20-616 (1) q 30-2 (1) Q 30-42 (1)
Q 20-617 (1) q 30-3 (1) Q 30-43 (1)
Q 20-618 (1) Q 30-4 (1) Q 30-44 (4)
00-2-4 BZ210-1
(1)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
• Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B • Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material • Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 10-04
01 GENERAL
SPECIFICATION DRAWINGS...................................................................................................................... 01- 2

SPECIFICATIONS ........................................................................................................................................ 01- 3
WEIGHT TABLE ........................................................................................................................................... 01- 7
FUEL, COOLANT AND LUBRICANTS......................................................................................................... 01- 8
BZ210-1 01-1
GENERAL SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
DIMENSION CHART
DIMENSIONS
Item Unit BZ210-1
A Overall length mm 13,210

B Overall height (for transport) mm 4,560 (3,100)
C Overall width (for transport) mm 3,310 (2,850)
D Track shoe width mm 500
E Track gauge mm 2,350
F Length of track on ground mm 2,750
01-2 BZ210-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model BZ210-1
Serial Number 1001 and up
Type of machine Crawler type, diesel engine drive

Operating weight kg 20,500
Traveling speed km/h 3.2

Performance
Gradability Degrees 25
Ground pressure (standard shoe width) kPa {kg/cm2} 74 {0.75} (500)
Overall length mm 13,210
Overall width mm 3,310
Overall width (for transport) mm 2,850
Overall width of crawler mm 2,850

Dimensions
Overall height mm 4,560
Overall height (for transport) mm 3,100
Ground clearance mm 300
Length of track on ground mm 2,750
Track gauge mm 2,350

Model SAA6D102E-2
Type 4-cycle, water-cooled serial and vertical type,

direct injection, with turbocharger and aftercooler
No. of cylinders – Bore × Stroke mm 6 – 102 × 120
Piston displacement l {cc} 5.883 {5,883}

Rated horsepower kW/rpm {HP/rpm} 107/1,950 {143/1,950}
Maximum torque Nm/rpm {kgm/rpm} 610/1,500 {62.2/1,500}

Performance
Engine
High idling speed rpm 2,200 ± 30
Low idling speed rpm 1,050 ± 25
Minimum fuel consumption ratio g/kWh {g/HPh} 218 {159}

Starting motor 24V, 4.5kW
Alternator 24V, 35A
Battery 12V, 110Ah × 2

Type of radiator Corrugate/CWX-4
BZ210-1 01-3
Serial Number 1001 – 1100 1101 and up

No. of rollers
Carrier roller (single side) — 1

Undercarriage system
Track roller (single side) — 7
Shoe type Assembly-type triple grouser, 40 shoes at a single side

Track shoe
Shoe width mm 500
Tension adjustment unit Grease cylinder type with cushion springs

Traveling brake type Hydraulic lock
Maximum work rate m3/h 40 – 100 ( 1) 40 – 150 ( 1)
Full capacity
Soil conditions:
Type Clay, rudaceous, loam and crushed rock lands
Gravel size that can be mixed mm Max 200
Size of waste soil loader machine PC100 to PC200 class
Solidifying material Cement solidifying material, burnt lime (in 5 mm or less)
Soil feeder type Belt conveyer
Solidifying material hopper Raw soil hopper
Auxiliary feeder Used (Rotary raking rotor)

Soil entry direction Rear, left or right of machine
Height of soil hopper upper end mm 2,450
Width × length of soil hopper mm 2,400 × 2,900
Soil hopper capacity m3 2.0
Capacity of solidifying material m3 3 (Up to three flexible containers can be stored.)
hopper
Flexible container size Supplied as a single-ton flexible container
Solidifying material feeder type Rotary table type
Operation performance
Solidifying material feeder

m3/h 0.9 – 9.8 0.9 – 14.7
capacity
Solidifying material feed rate kg/m3 9 – 400
Mixer type Soil cutter, 3-axis rotary hammer, and aftercutter

Soil cutter type Three 5-row rotary cutters
500 (H mode), 150 (M mode), 500 (H mode), 150 (M mode),
Soil cutter speed rpm
or 75 (L mode) 150 (L mode), 225 (G mode)
No. of hammers — 4 per row, 3 rows per axis, and 3-axis rotary hammers
1st 2nd 3rd 1st 2nd 3rd
axis axis axis axis axis axis
Mixer
H mode 700 1,000 1,050 700 1,000 1,050

Hammer rotary speed
rpm
(without load) M mode 550 600 800 550 600 800
L mode 550 550 550 550 550 550
G mode — — — 550 600 700
Aftercutter type 51 rotary cutters
Aftercutter speed rpm 265
Maximum permissible clamp size
mm 200
of earth
1. The maximum work rate shows the value if the soil is broken into flakes. It varied depending on the type of
soil entered, the working conditions and others.
01-4 BZ210-1
(1)
Serial Number 1001 - 1100 1101 and up
Driving system Hydraulic motor

Primary belt conveyor
Operation performance
Belt width mm 900
Belt speed m/min 80 87
Type 3-stage extraction/retraction system

Crane
Hoisting capacity ton/m 2.63/1.6, 1.03/3.5

Boom length m 2.88 – 6.68
Type and quantity HPV95 + 95, variable displacement piston type:

Hydraulic pump
2 pumps
Delivery l/min 214 × 2
Set pressure MPa {kg/cm2} 37.2 {380}

Control valve
Type and quantity 7-spool and 8-spool type: one each

Hydraulic unit (for travel and operation)
Operation system Hydraulic system
Travel Type and quantity Variable capacity, piston type

(with brake valve and parking brake): 2 motors
Raw soil belt conveyor Type and quantity Fixed capacity, piston type: 1 motor
Soil cutter Type and quantity Orbit type: 1 cutter
Hydraulic motor
Rotary hammer Type and quantity Gear type: 3 hammers

Discharging belt conveyor Type and quantity Fixed capacity, piston type: 1 conveyor
Solidifying material feeder Type and quantity Orbit type: 3 feeders
Raking rotor Type and quantity Fixed capacity, piston type: 1 rotor
Aftercutter Type and quantity Orbit type: 1 cutter
Secondary belt conveyor Type and quantity Orbit type: 1 conveyor
(optional)
Air conditioner compressor Type and quantity Orbit type: 1 compressor
(optional)
Cylinder
Mixer case open/close cylinder Type and quantity Double-action piston type: 1 cylinder
Hydraulic oil tank Sealed type

Hydraulic oil filter Tank return side
Hydraulic oil cooler CF40-1 (air-cooling system)
BZ210-1 01-5
(1)
SPECIFICATIONS OF CRANE
Rated total load

Booms used: (1), (1)+(2)
Operating radius (m) 1.6 1.8 2.0 2.5 3.0 3.5 4.0 4.5 4.598
Rated total load (kg) 2,630 2,230 2,030 1,530 1,280 1,080 980 830 780
Booms used: (1), (2)+(3)

Operating radius (m) 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.493
Rated total load (kg) 1,230 1,230 1,230 1,030 880 780 680 630 580 530
NOTE: 1. The machine stability is not considered due to the enough strength of crane.
2. The crane is operated with the rated total load.
Working ranges
NOTE:All values are measured without loading, and no boom deflection is considered.
01-6 BZ210-1
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This weight table is for use when handling components or when transporting the machine.
Unit: kg
Serial Number 1001 and up
Engine assembly 749
• Engine 598
• Damper 6
• Hydraulic pump 145
Radiator, oil cooler assembly 110
Hydraulic tank, filter assembly (without hydraulic oil) 123
Fuel tank assembly (without fuel) 142
Engine frame 784
7-spool control valve 93
8-spool control valve 105
Travel motor 194 × 2
Soil belt conveyor motor 90
Soil cutter motor 26
Rotary hammer motor 22 × 3
Aftercutter motor 10
Discharging belt conveyor motor 21
Solidifying material feeder motor 11 × 3
Raking rotor motor 47
Crusher case open/close cylinder 7
Track frame assembly 3,967
• Track frame 2,647
• Idler 156 × 2
• Idler cushion 144 × 2
• Carrier roller 22 × 2
• Track roller 21 × 14
• Sprocket (including travel motor) 180 × 2
• Track cover 11 × 2
Track shoe assembly (standard 500 mm) 1,480 × 2
Crusher assembly 2,824
Soil hopper assembly 1,108
Soil feeder assembly 1,357
Solidifying material hopper assembly 538
Solidifying material feeder assembly 748
Discharging conveyor assembly 2,575
Crane assembly 653
BZ210-1 01-7
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
Use the recommended HO46HM oil.
01-8 BZ210-1
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ENGINE ACCESSORIES............................................................................................................................10- 2
RADIATOR, OIL COOLER, AND AFTERCOOLER.....................................................................................10- 3
POWER TRAIN SYSTEM DIAGRAM..........................................................................................................10- 4
TRACK FRAME AND RECOIL SPRING .....................................................................................................10- 6
IDLER ..........................................................................................................................................................10- 8
CARRIER ROLLER .....................................................................................................................................10- 9
TRACK ROLLER .........................................................................................................................................10- 10
SPROCKET.................................................................................................................................................10- 11
TRACK SHOE .............................................................................................................................................10- 12
ARRANGEMENT OF HYDRAULIC COMPONENT ....................................................................................10- 16
HYDRAULIC TANK .....................................................................................................................................10- 18
HYDRAULIC PUMP ....................................................................................................................................10- 20
PC-EPC VALVE ...........................................................................................................................................10- 36
CONTROL VALVE .......................................................................................................................................10- 40
CLSS ...........................................................................................................................................................10- 65
SELF PRESSURE REDUCING VALVE.......................................................................................................10- 79
TRAVEL MOTOR (FINAL DRIVE) ...............................................................................................................10- 86
TRAVEL JUNCTION VALVE........................................................................................................................10- 96
SOIL BELT CONVERTOR MOTOR ............................................................................................................10-100
RAKING ROTOR MOTOR...........................................................................................................................10-106
SOIL CUTTER MOTOR ..............................................................................................................................10-108
ROTARY HAMMER MOTOR.......................................................................................................................10-109
DISCHARGE BELT CONVEYOR MOTOR..................................................................................................10- 110
SOLIDIFYING MATERIAL FEEDER ...........................................................................................................10- 111
AFTERCUTTER MOTOR ............................................................................................................................10- 112
HYDRAULIC CYLINDER.............................................................................................................................10- 113
VALVE CONTROL .......................................................................................................................................10- 114
TRAVEL PPC VALVE ..................................................................................................................................10- 116
CRUSHER CASE OPEN/CLOSE PPC VALVE ...........................................................................................10-120
6-SPOOL SOLENOID VALVE (A)................................................................................................................10-121
6-SPOOL SOLENOID VALVE (B)................................................................................................................10-122
EPC VALVE .................................................................................................................................................10-124
WORK EQUIPMENT ...................................................................................................................................10-128
MIXER (CRUSHER) ....................................................................................................................................10-132
SOIL BELT CONVEYOR .............................................................................................................................10-140
MONITOR SYSTEM ....................................................................................................................................10-163
SENSORS ...................................................................................................................................................10-197
BZ210-1 10-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE ACCESSORIES
ENGINE ACCESSORIES
1. Drive plate 5. Damper assembly Outline

2. Torsion spring 6. Muffler The damper assembly is of wet type.
3. Stopper pin 7. Rear engine mount Amount of oil: 0.75l
4. Friction plate 8. Front engine mount
10-2 BZ210-1
(1)
RADIATOR, OIL COOLER,
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AND AFTERCOOLER
RADIATOR, OIL COOLER, AND AFTERCOOLER
1. Reservoir tank 6. Radiator outlet hose Specifications

2. Oil cooler 7. Radiator cap Radiator : CWX-4
3. Radiator 8. Net Oil cooler : CF40-1
4. Fan 9. Shroud
5. Radiator inlet hose 10. Aftercooler
BZ210-1 10-3
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
POWER TRAIN SYSTEM DIAGRAM
1. Idler 9. Engine
2. Soil cutter motor 10. Discharge belt conveyor motor
3. Final drive 11. Raking rotor motor
4. Travel motor 12. Solidifying material feeder motor
5. Air conditioner compressor motor (If equipped) 13. Crane
6. Hydraulic pump 14. Rotary hammer motor
7. Discharge belt conveyor 15. Crusher case open/close cylinder
8. Discharge belt conveyor motor
10-4 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
TRACK FRAME AND RECOIL SPRING
1. Idler 5. Sprocket
2. Track frame 6. Track shoe
3. Carrier roller 7. Track roller
4. Travel motor 8. Recoil spring
10-6 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit

Rebuild
9 Height of idler guide Track frame 84 89
Idler 82 77 Rebuild or replace
Track frame 185 193 Rebuild
10 Width of idler guide
Idler 183 175 Rebuild or replace
Free Installed Installed Free Installed
11 Recoil spring length length load length load Replace
78.5 kN 69.6 kN
505 390 494
{8,000 kg} {7,120 kg}
BZ210-1 10-7
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
IDLER
Unit: mm
Outside diameter of pro- Standard size Repair limit

1
jection of idler 539 529
Outside diameter of idler
2 489 477
tread Rebuild or
Width of projection of replace
3 52 42
idler
4 Overall width of idler 115 107
5 Width of idler tread 31.5 36.5
Standard Tolerance Standard Clearance

Clearance between size Shaft Hole size limit
6
shaft and bushing
–0.250 –0.160 0.044 –
54 1.5 Replace
–0.270 –0.206 0.110
Play of shaft in axial Standard clearance Clearance limit

7
direction 0.36 – 0.76 1.5
Thickness of idler tread Standard size Repair limit Rebuild or

8
(At center of tread width) 15.8 9.8 replace
10-8 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

1 Outside diameter of tread Rebuild or replace
116 106
Standard clearance Clearance limit
2 Play of roller in axial direction Replace
0.363 – 0.537 1.5
3 Thickness of carrier roller tread Rebuild or replace
17.7 12.7
BZ210-1 10-9
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm
Outside diameter of Standard size Repair limit

1
flange (Outside) 158 148
Repair by overlay-
Outside diameter of
2 130 125 ing welding or
tread
replace
3 Width of tread 35 30.5
4 Width of flange 26.5 —

Clearance between size Shaft Hole clearance limit
5
shaft and bushing
–0.250 +0.187 0.225 –
50 1.5
–0.270 –0.025 0.457
Replace bushing
Tolerance Standard
Standard Interfer-
interfer-
Interference between size Shaft Hole ence limit
6 ence
roller and bushing
+0.190 +0.090 0.020 –
57 —
+0.110 +0.060 0.130
Side clearance of Standard clearance Clearance limit

7 Replace
roller (Each side) 0.31 – 0.69 1.5
Standard size Repair limit Repair by overlay-
Thickness of track
8 ing welding or
roller tread 36.5 34 replace
10-10 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
Standard size Tolerance Repair limit

1 Wear of tooth root +1.0
547.4 535
–2.0
2 Wear of tooth tip 607 — 595 Rebuild or
3 Wear of tooth tip width 27 — 22 replace
4 Wear of tooth root width 42 ±1.5 39

+0.93
5 Thickness of tooth root 111.7 105.5
–2.32
BZ210-1 10-11
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
Unit: mm

1 Link pitch
175.25 178.25
Turn or
Turning
Standard size replace
2 Outside diameter of bushing Light load Heavy load
46.3 — 42.3
Standard size Repair limit Repair or
3 Height of link
86 81 replace
Thickness of link
4 24 Replace
(Press fitting part of bushing)
10-12 BZ210-1
(1)
Unit: mm
5 102.4
6 Shoe bolt pitch 57 Replace
7 8
8 Inside width 52.4
Repair or
9 Link Overall width 35
replace
10 Tread width 30.1
11 Projection of pin 5.5
12 Projection of regular bushing 3.75
13 Overall length of pin 173 Adjust or
14 Overall length of bushing 86.7 replace
15 Thickness of bushing 7.8

16 Thickness of spacer —
17 Bushing 39.2 – 137.2 kN {4 – 14 ton}
Press fitting
18 Regular pin 78.4 – 186.2 kN {8 – 19 ton} —
force
19 Master pin 39.2 – 98 kN {4 – 10 ton}
Tightening torque Retightening angle
(Nm{kgm}) (deg)
Shoe bolt Retighten
20 196.1 ± 19.6
120 ± 10
{20 ± 2}
Number of shoes (Each) 42 —
Tolerance Standard interfer-
Standard size
Interference between bushing Shaft Hole ence
21
and link
+0.387 +0.062
46 0.285 – 0.387
+0.347 +0.062
Interference between regular +0.150 –0.198
22 30 0.198 – 0.400
pin and link +0.150 –0.250
Tolerance
Standard size Standard clearance
Clearance between regular Shaft Hole
23
pin and bushing
+0.150 +0.830 Adjust or
30 0.180 – 0.830
+0.150 +0.330 replace
Tolerance Standard interfer-
Standard size
Interference between master Shaft Hole ence
24
pin and link
+0.020 +0.198
30 0.178 – 0.270
–0.020 –0.250
Tolerance
Standard size Standard clearance
Clearance between master pin Shaft Hole
25
and bushing
+0.200 +0.630
30 0.430 – 0.930
–0.300 +0.230
BZ210-1 10-13
(1)
Triple shoe
Swamp shoe
Unit: mm

1 Height
25 15
2 Thickness 8
3 24
Length at bottom Rebuild or replace
4 19
5 18
6 Length at top 11
7 18
10-14 BZ210-1
(1)
ARRANGEMENT OF
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC COMPONENT
ARRANGEMENT OF HYDRAULIC COMPONENT
1. Raking rotor motor

2. Soil belt conveyor motor
3. Rotary hammer motor (No. 2)
5. Soil cutter motor
7. Crane swing motor
8. Crane control valve
9. 8-spool control valve
10. 7-spool control valve
11. Crusher case open/close cylinder
12. Left travel motor
13. Right travel motor
14. Solidifying material feeder motor
15. Discharge belt conveyor motor
10-16 BZ210-1
ARRANGEMENT OF
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC COMPONENT
BZ210-1 10-17
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Sight gauge SPECIFICATIONS

2. Hydraulic tank Tank capacity: 200 l
3. Oil filler cap Amount of oil inside tank: 143 l
4. Filter element
5. Strainer Pressure valve
6. Bypass valve Relief cracking pressure:
7. Suction strainer 16.7 ± 6.9 kPa
{0.17 ± 0.07 kg/cm²}
Suction cracking pressure:
0 – 0.49 kPa
{0 – 0.005 kg/cm²}
Bypass valve set pressure:
150 ± 30 kPa
{1.5 ± 0.3 kg/cm²}
10-18 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
HPV95 + 95
1. Front main pump IM : PC mode selector current PENR : Rear pump control pressure
2. Rear main pump ISIG : LS set selector current detection port
3. LS valve PAF : Front pump delivery port PLSF : Front load pressure input port
4. PC valve PFC : Front pump delivery pres- PLSFC : Front load pressure detection
5. LS-EPC valve sure detection port port
6. PC-EPC valve PAR : Rear pump delivery port PLSR : Rear load pressure input port
PRC : Rear pump delivery pressure PLSRC : Rear load pressure detection port
detection port PS : Pump suction port
PBF : Pump pressure input port PSIG : LS set selector pressure detec-
PD1F : Case drain port tion port
PENF : Front pump control pressure PM : PC set selector pressure detec-
detection port tion port
PEPC : EPC basic pressure input port
Outline
• This pump consists of 2 variable capacity swash plate pis-
ton pumps, PC valve, LS valve, and EPC valve.
10-20 BZ210-1
(1)
1. Shaft (Front) 7. Cylinder block

2. Cradle 8. Valve plate
3. Case (Front) 9. End cap
4. Rocker cam 10. Shaft (Rear)
5. Shoe 11. Case (Rear)
6. Piston 12. Servo piston
BZ210-1 10-21
(1)
Function • Rocker cam (4) has flat surface A, and shoe (5)
• The rotation and torque transmitted to the pump is always pressed against this surface while slid-
shaft are converted into hydraulic energy, and ing in a circular movement.
pressurized oil is discharged according to the Rocker cam (4) brings high pressure oil at cylin-
load. der surface B with cradle (2), which is secured
• It is possible to change the discharge amount by to the case, and forms a static pressure bearing
changing the swash plate angle. when it slides.
• Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
Structure cylinder block (7).
• Cylinder block (7) is supported to shaft (1) by a • The cylinder block seals the pressure oil to valve
spline, and shaft (1) is supported by the front and plate (8) and carries out relative rotation. This
rear bearings. surface is designed so that the oil pressure bal-
• The tip of piston (6) is a concave ball, and shoe ance is maintained at a suitable level. The oil in-
(5) is caulked to it to form one unit. Piston (6) and side each cylinder chamber of cylinder block (7)
shoe (5) form a spherical bearing. is sucked in and discharged through valve plate
(8).
10-22 BZ210-1
(1)
Operation
1) Operation of pump
i) Cylinder block (7) rotates together with
shaft (1), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle is called the swash
plate angle.)
ii) Center line X of rocker cam (4) maintains
swash plate angle in relation to the axial
direction of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this difference F – E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged dur-
ing that stroke. On the other hand, the vol-
ume of chamber F becomes larger, and as
the volume becomes bigger, the oil is
sucked in.
iii) If center line X of rocker cam (4) is in line
with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does not
carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
BZ210-1 10-23
(1)
12
2) Control of discharge amount
• If the swash plate angle becomes larger,
the difference between volumes E and F be-
comes larger and discharge amount Q in-
creases.
• Swash plate angle is changed by servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement ( ) according to the signal pres-
sure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and rock-
er cam (4), which is supported by the cylin-
drical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving the
pressure is different on the left and the right,
so main pump discharge pressure (self pres-
sure) PP is always brought to the chamber
receiving the pressure at the small diameter
piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving the pres-
sure at the large diameter end. The relation-
ship in the size of pressure PP at the small
diameter piston end and pressure Pen at the
large diameter end, and the ratio between
the area receiving the pressure of the small
diameter piston and the large diameter pis-
ton controls the movement of servo piston
(12).
10-24 BZ210-1
(1)
LS VALVE
1. Plug PP : Pump port

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

2. Plug PP2 : Pump pressure pilot port
3. Pin PT : Drain port
4. Spool PM : PC mode selector pressure pilot port
5. Retainer PPL : PC control pressure output port
6. Seat PLP : LS control pressure output port
7. Cover
8. Wiring
BZ210-1 10-25
(1)
Function
(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure
PLS (=PP – PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port pres-
sure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control valve
output, and pressure Psig {called the LS selec-
tor pressure} from the proportional solenoid
valve enter this valve. The relationship between
discharge amount Q and differential pressure
PLS, (the difference between main pump
pressure PP and LS pressure PLS) (= PP –
PLS) changes as shown in the diagram at the
right.
(2) PC valve
When the pump discharge pressure PP1 (self-
pressure) and PP2 (other pump pressure) are
high, the PC valve controls the pump so that no
more oil than the constant flow (in accordance
with the discharge pressure) flows even if the
stroke of the control valve becomes larger. In
this way, it carries out equal horsepower control
so that the horsepower absorbed by the pump
does not exceed the engine horsepower.
In other words, If the load during the operation
becomes larger and the pump discharge pres-
sure rises, it reduces the discharge amount from
the pump; and if the pump discharge pressure
drops, it increases the discharge amount from
the pump. The relationship between the average
of the front and rear pump discharge pressures
(average discharge amount of F, R pumps (PP1
+ PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to the
PC-EPC valve solenoid shown as a parameter.
The controller senses the actual speed of the
engine, and if the speed drops because of an
increase in the load, it reduces the pump dis-
charge amount to allow the speed to recover. In
other words, when the load increases and the
engine speed drops below the set value, the
command current to the PC-EPC valve solenoid
from the controller increases according to the
drop in the engine speed to reduce the pump
swash plate angle.
10-26 BZ210-1
(1)
OPERATION
(1) LS valve
1) When control valve is at neutral position
• The LS valve is a three-way selector valve, with
pressure PLS (LS pressure) from the outlet port
of the control valve brought to spring chamber B,
and main pump discharge pressure PP brought
to port H of sleeve (8). The size of this LS pres-
sure PLS + force Z of spring (4) and the main
pump pressure (self pressure) PP determines
the position of spool (6).
• Before the engine is started, servo piston (12) is
pushed to the right. (See the diagram on the
right)
• When the engine is started and the control lever
is at the neutral position, LS pressure PLS is 0
MPa {0 kg/cm²}. (It is interconnected with the
drain circuit through the control valve spool.)
At this point, spool (6) is pushed to the left, and
port C and port D are connected. Pump pres-
sure PP enters the large diameter end of the
piston from port K and the same pump pressure
PP also enters port J at the small diameter end
of the piston, so the swash plate is moved to the
minimum angle by the difference in the area of
the piston (12).
BZ210-1 10-27
(1)
12
2) Operation in increase direction for pump dis- • For this reason, the pressure at the large diame-
charge amount ter end of servo piston (12) becomes drain pres-
• When the difference between the main pump sure PT, and pump pressure PP enters port J at
pressure PP and LS pressure PLS, in other the small diameter end, so servo piston (12) is
words, LS differential pressure PLS, becomes pushed to the right. Therefore, the swash plate
smaller (for example, when the area of opening moves in the direction to make the discharge
of the control valve becomes larger and pump amount larger.
pressure PP drops), spool (6) is pushed to the
right by the combined force of LS pressure PLS
and the force of spring (4).
• When spool (6) moves, port D and port E are
joined and connected to the PC valve. When this
happens, the PC valve is connected to the drain
port, so circuit D - K becomes drain pressure PT.
(The operation of the PC valve is explained lat-
er).
10-28 BZ210-1
(1)
3) Operation in decrease direction for pump • Main pump pressure PP also enters port J at the
discharge amount small diameter end of the piston, but because of
• The following explains the situation if the servo the difference in area between the large diameter
piston (12) moves to the left (the discharge end and the small diameter end of servo piston
amount becomes smaller). When LS differential (12), servo piston (12) is pushed to the left.
pressure PLS becomes larger (for example, • As a result, the swash plate moves in the direc-
when the area of opening of the control valve be- tion to make angle smaller.
comes smaller and pump pressure PP rises),
pump pressure PP pushes spool (6) to the left.
• When spool (6) moves, main port pressure PP
flows from port C and port D and from port K, it
enters the large diameter end of the piston.
BZ210-1 10-29
(1)
4) When servo piston is balanced • At this point, the relationship between the area
• Let us take the area receiving the pressure at the receiving the pressure at both ends of piston (12)
large diameter end of the piston as A1, the area is A0 : A1 = 1:2, so the pressure applied to both
receiving the pressure at the small diameter end ends of the piston when it is balanced becomes
as A0, and the pressure flowing into the large di- PP : Pen 2:1.
ameter end of the piston as Pen. If the main • The position where spool (6) is balanced and
pump pressure PP of the LS valve and the com- stopped is the standard center, and the force of
bined force of force Z of spring (4) and LS pres- spring (4) is adjusted so that it is determined
sure PLS are balanced, and the relationship is when PP – PLS = 2.2 MPa {22 kg/cm²}.
A0 x PP = A1 x Pen, servo piston (12) will stop
in that position, and the swash plate will be kept
at an intermediate position. (It will stop at a posi-
tion where the opening of the throttle from port D
to port E and from port C to port D of spool (6) is
approximately the same.)
10-30 BZ210-1
(1)
(2) PC Valve
1) When pump controller is normal
a. When the load on the actuator is small and
pump pressures PP1 and PP2 are low
i) Movement of PC-EPC solenoid (1) • the pressure (pressure of port C) output from
• The command current from the pump con- the PC valve changes according to this posi-
troller flows to PC-EPC solenoid (1).This tion.
command current acts on the PC-EPC valve • The size of command current X is deter-
and outputs the signal pressure. When this mined by the nature of the operation (lever
signal pressure is received, the force push- operation), the selection of the working
ing piston (2) is changed. mode, and the set value and actual value for
• On the opposite side to the force pushing this the engine speed.
piston (2) is the spring set pressure of a Other pump pressure
springs (4) and (6) and pump pressure PP1 This is the pressure of the pump at the
(self pressure) and PP2 (other pump pres- opposite end.
sure) pushing spool (3). Piston (2) stops at a For the F pump, it is the R pump pressure
position where the combined force pushing For the R pump, it is the F pump pressure
spool (3) is balanced, and
BZ210-1 10-31
(1)
ii) Action of spring

• The spring load of springs (4) and (6) in the • If the command circuit input to PC-EPC
PC valve is determined by the swash plate valve solenoid (1) changes further, the force
position. pushing piston (2) changes, and the spring
• If piston (9) moves to the left, spring (6) is load of springs (4) and (6) also changes ac-
compressed, and if it moves further to the cording to the value of the PC-EPC valve so-
left, spring (6) contacts seat (5) and is fixed lenoid command current.
in position. In other words, the spring load is
changed by piston (9) extending or com-
pressing springs (4) and (6).
10-32 BZ210-1
(1)
• Port C of the PC valve is connected to port E

of the LS valve (see (1) LS valve). Self pres-
sure PP1 enters port B and the small diame-
ter end of servo piston (9), and other pump
pressure PP2 enters port A.
• When pump pressures PP1 and PP2 are
small, spool (3) is on the right. At this point,
ports C and D are connected, and the pres-
sure entering the LS valve becomes drain
pressure PT. If port E and port G of the LS
valve are connected (see (1) LS valve), the
pressure entering the large diameter end of
the piston from port J becomes drain pres-
sure PT, and servo piston (9) moves to the
right. In this way, the pump discharge
amount moves in the direction of increase.
• As servo piston (9) moves further, springs
(4) and (6) expand and the spring force be-
comes weaker. When the spring force be-
comes weaker, spool (3) moves to the left,
so the connection between port C and port D
is cut, and the pump discharge pressure
ports B and C are connected. As a result, the
pressure at port C rises, and the pressure at
the large diameter end of the piston also ris-
es, so the movement of piston (9) to the right
is stopped.
• In other words, the stop position for piston (9)
(= pump discharge amount) is decided at the
point where the force of springs (4) and (6)
and the pushing force from the PC-EPC
valve solenoid and the pushing force created
by the pressures PP1 and PP2 acting on the
spool (3) are in balance.
BZ210-1 10-33
(1)
b. When load on actuator is large and pump dis- • If main pump pressure PP increases further
charge pressure is high and spool (3) moves further to the left, main
• When the load is large and pump discharge pump pressure PP1 flows to port C and acts
pressures PP1 and PP2 are high, the force to make the discharge amount the minimum.
pushing spool (3) to the left becomes larger When piston (9) moves to the left, springs (4)
and spool (3) moves to the position in the di- and (6) are compressed and push back
agram above. When this happens, as shown spool (3).
in the diagram above, part of the pressurized • When spool (3) moves to the right, the open-
oil from port B flows out through port C ing of port C and port D becomes larger. As
where the LS valve is actuated to port D, and a result, the pressure at port C (= J) drops,
the pressurized oil flowing from port C to the and piston (9) stops moving to the left.
LS valve becomes approximately half of • The position in which piston (9) stops when
main pump pressure PP. this happens is further to the left than the po-
• When port E and port G of the LS valve are sition when pump pressures PP1 and PP2
connected (see (1) LS valve), the pressure are low.
from port J enters the large diameter end of
servo piston (9), and servo piston (9) stops.
10-34 BZ210-1
(1)
• The relation of average pump pressure

(PP1 + PP2)/2 and the position of servo pis-
ton (9) forms a bent line because of the
double-spring effect of springs (4) and (6).
The relationship between average pump
pressure (PP1 + PP2)/2 and pump dis-
charge amount Q is shown in the figure at
the right.
• If command voltage X sent to PC-EPC

valve solenoid (1) increases further, the re-
lationship between average pump pressure
(PP1 + PP2)/2, and pump discharge
amount Q is proportional to the pushing
force of the PC-EPC valve solenoid and
moves in parallel. In other words, the push-
ing force of PC-EPC solenoid (1) is added
to the force pushing to the left because of
the pump pressure applied to the spool (3),
so the relationship between the average
pump pressure (PP1 + PP2)/2 and Q
moves from to in accordance with the
increase in X.
BZ210-1 10-35
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PC-EPC VALVE
PC-EPC VALVE
1. Body 5. Coil PSIG(PM) : To PC valve

2. Spool 6. Plunger PT : To tank
3. Spring 7. Connector PEPC : From self-reducing pressure valve
4. Rod
10-36 BZ210-1
(1)
Function
• The EPC valve consists of the proportional so-
lenoid portion and the hydraulic valve portion.
• When it receives signal current i from the pump
controller, it generates the EPC output pres-
sure in proportion to the size of the signal, and
outputs it to the PC valve.
Operation
1. When signal current is 0 (coil deenergized)
• When there is no signal current flowing from
the controller to coil (5), coil (5) is deenergized.
• For this reason, spool (2) is pushed to the left
in the direction of the arrow by spring (3).
• As a result, port PEPC closes and the pressu-
rized oil from the main pump does not flow to
the PC valve.
At the same time, the pressurized oil from the
PC valve passes from port PSIG(PM) through
port PT and is drained to the tank.
BZ210-1 10-37
(1)
2. When signal current is very small (coil en-

ergized)
• When a very small signal current flows to coil
(5), coil (5) is energized, and a propulsion force
is generated which pushes plunger (6) to the
right.
• Rod (4) pushes spool (2) to the right, and pres-
surized oil flows from port PEPC to port
PSIG(PM).
• When the pressure at port PSIG(PM) rises and
the load of spring (3) + the force acting on sur-
face of spool (2) becomes greater than the pro-
pulsion force of plunger (6), spool (2) is pushed
to the left. The circuit between port PEPC and
port PSIG(PM) is shut off, and at the same
time, port PSIG(PM) and port PT are connect-
ed.
• As a result, spool (2) is moved up or down until
the propulsion force of plunger (6) is balanced
with the load of spring (3) + pressure of port
PSIG(PM).
• Therefore, the circuit pressure between the
EPC valve and the PC valve is controlled in
proportion to the size of the signal current.
3. When signal current is maximum (coil ener-

gized)
• When the signal current flows to coil (5), coil
(5) is energized.
• When this happens, the signal current is at its
maximum, so the propulsion force of plunger
(6) is also at its maximum.
• For this reason, spool (2) is pushed fully to the
left by rod (4).
• As a result, the maximum flow of pressurized
oil from port PEPC flows to port PSIG(PM),
and the circuit pressure between the EPC
valve and PC valve becomes the maximum.
At the same time, port PT closes and stops
the oil from flowing to the tank.
10-38 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Outline • Since these valves are connected with each oth-
• The control valve consists of the following 2 er by the connecting bolts and the passages are
valves. connected inside, they are small in size and have
• 7-spool valve (High valve) high maintainability.
• 8-spool valve (Low valve) • This control valve has a simple structure since 1
spool in it corresponds to 1 work equipment com-
ponent.
1. 7-spool valve (High valve)
1. PT port block PA1: From No.3 hammer forward EPC valve

2. No.3 hammer valve PA2: From No.2 hammer forward EPC valve
3. No.2 hammer valve PA3: From No.1 hammer forward EPC valve
4. No.1 hammer valve PA4: From attachment 3 EPC valve
5. Attachment 3 valve PA5: From crane EPC valve
6. Crane valve PA6: From soil feeder forward EPC valve
7. Soil feeder valve PA7: From case open EPC valve
8. Case open/close valve
A1: No.3 hammer forward PB1: From No.3 hammer reverse EPC valve
A4: Attachment 2 PB4: From attachment 2 EPC valve
A5: Crane PB5: From optional EPC valve
A6: Soil feeder forward PB6: From soil feeder forward EPC valve
A7: Case open PB7: From case close EPC valve
B1: No.3 hammer reverse AA: Pressure sensor port (Pressure sensor is installed)
B2: No.2 hammer reverse P: From main pump
B3: No.1 hammer reverse TC: To tank
B4: Attachment 2 Ls: To main pump LS valve
B5: Optional
B6: Soil feeder reverse
B7: Case close
10-40 BZ210-1
(1)
7-spool valve (High valve)

*1. Tighten in the order of (1), (2),
(3), and (4) in 3 times.
BZ210-1 10-41
(1)
Sectional view
(1/7)
1. Safety-suction valve 10. Mounting part of suction and safety valves

2. Suction valve (No. 3 hammer A) (Soil feeder B)
3. Suction valve (No. 2 hammer A) 11. Mounting part of suction and safety valves
4. Suction valve (No. 1 hammer A) (Option B)
5. Mounting part of suction and safety valves 12. Mounting part of suction and safety valves
(Attachment 2A) (Attachment 2B)
(Crane A) (No. 1 hammer B)
(Soil feeder A) (No. 2 hammer B)
8. Mounting part of suction and safety valves (Case A) 15. Mounting part of suction and safety valves
9. Mounting part of suction and safety valves (Case B) (No. 3 hammer B)
Unit: mm
Free length
Installed Free If damaged or
Suction valve x Outside Installed load Installed load
16 length length deformed, replace
spring diameter
spring
5.50 ± 0.40 N 4.40 N
46.8 x 7.50 40.6 —
{0.56 ± 0.04 kg} {0.45 kg}
10-42 BZ210-1
(1)
(2/7)
1. Main relief valve 5. Spool (Attachment 2)

2. Spool (No. 3 hammer) 6. Spool (Crane/Optional)
3. Spool (No. 2 hammer) 7. Spool (Soil feeder)
4. Spool (No. 1 hammer) 8. Spool (Case open/close)
Unit: mm

Free length
Spool return x Outside Installed load Installed load
spring diameter
spring
222 ± 13.7 N 178 N
45.7 x 28.0 43.0 —
{22.6 ± 1.40 kg} {18.1 kg}
BZ210-1 10-43
(1)
(3/7)
1. Pressure compensation valve 6. Pressure compensation valve 11. Pressure compensation valve
F (No. 3 hammer) F (Soil feeder) R (Crane/Optional)
F (No. 2 hammer) F (Case open/close) R (Attachment 2)
3. Pressure compensation valve 8. Unload valve 13. Pressure compensation valve
F (No. 1 hammer) R (No. 1 hammer)
F (Attachment 2) R (Case open/close) R (No. 2 hammer)
F (Crane/Optional) R (Soil feeder) R (No. 3 hammer)
a Above "F" and "R" denote the following valves.

F: Flow control valve
R: Pressure reducing valve
10-44 BZ210-1
(1)
Unit: mm

Free length
Installed Free
Flow control x Outside Installed load Installed load
16 length length If damaged or
valve spring diameter
deformed, replace
9.81 ± 0.98 N 7.85 N spring
36.2 x 5.30 32.0 —
{1.0 ± 0.10 kg} {0.80 kg}
Pressure reduc- 17.7 ± 0.98 N 13.7 N
17 27.5 x 14.2 18.0 —
ing valve spring {1.80 ± 0.10 kg} {1.40 kg}
BZ210-1 10-45
(1)
(4/7)
1. LS pressure pickup plug 7. Check valve (Attachment 2)

2. LS bypass plug 8. Check valve (Attachment 2)
3. Pump pressure pickup plug 9. Check valve (No. 1 hammer)
4. Check valve (Case open/close) 10. Check valve (No. 2 hammer)
5. Check valve (Case open/close) 11. Check valve (No. 3 hammer)
6. Check valve (Optional)
Unit: mm

Free length
Check valve x Outside Installed load Installed load
spring diameter
spring
5.88 N 4.71 N
41.5 x 8.50 31.5 —
{0.60 kg} {0.48 kg}
10-46 BZ210-1
(1)
(5/7)
*1. No. 3 hammer, *2. No. 2 hammer
*3. No. 1 hammer, *4. Attachment 2
1. Suction valve (A) 6. Mounting part of suction and safety valves (A)
2. Mounting part of suction and safety valves (B) 7. Mounting part of suction and safety valves (B)
3. Spool (No. 1, 2, 3 hammers) 8. Spool (Attachment 2)
4. Pressure compensation valve F 9. Pressure compensation valve F
5. Pressure compensation valve R 10. Pressure compensation valve R
BZ210-1 10-47
(1)
(6/7) *5. Crane, *6. Soil feeder, *7. Case open/close
1. Mounting part of suction and safety valves (A) 11. Mounting part of suction and safety valves (A)
3. Spool (Crane) 13. Spool (Soil feeder)
6. Mounting part of suction and safety valves (A)
7. Mounting part of suction and safety valves (B)
8. Spool (Soil feeder) a Above "F" and "R" denote the following valves.
9. Pressure compensation valve F F: Flow control valve
10. Pressure compensation valve R R: Pressure reducing valve
10-48 BZ210-1
(1)
(7/7)
1. Pressure relief plug

2. Unload valve
3. Main relief valve
BZ210-1 10-49
(1)
2. 8-spool valve (Low valve)
1. PT port block PA1: From attachment 1 EPC valve

2. Attachment 1 valve PA2: From left travel forward PPC valve
3. Left travel valve PA3: From right travel reverse PPC valve
4. Right travel valve PA4: From discharge belt conveyor forward EPC valve
5. Discharge belt conveyor valve PA5: From soil cutter forward EPC valve
6. Soil cutter valve PA6: From solidifying material feeder forward EPC valve
7. Solidifying material feeder valve PA7: From raking rotor forward EPC valve
8. Raking rotor valve PA8: From attachment 3 EPC valve
9. Attachment 2 valve
10. Travel junction valve PB1: From attachment 1 EPC valve
PB2: From left travel reverse PPC valve
A1: Attachment 1 (Aftercutter forward) PB3: From right travel forward PPC valve
A2: Left travel forward PB4: From discharge belt conveyor reverse EPC valve
A3: Right travel reverse PB5: From soil cutter reverse EPC valve
A4: Discharge belt conveyor forward PB6: From solidifying material feeder reverse EPC valve
A5: Soil cutter forward PB7: From raking rotor reverse EPC valve
A6: Solidifying material feeder forward PB8: From air compressor EPC valve
A7: Raking rotor forward
A8: Attachment 3 AA: Pressure sensor port (Pressure sensor is installed)
P: From main pump
B1: Attachment 1 (Aftercutter) TC: To tank
B2: Left travel reverse Ls: To main pump LS valve
B3: Right travel forward PB1: From attachment 1 EPC valve
B4: Discharge belt conveyor reverse
B5: Soil cutter reverse
B6: Solidifying material feeder reverse
B7: Raking rotor reverse
B8: Air compressor (If equipped)
10-50 BZ210-1
(1)
8-spool valve (Low valve)

*1. Tighten in the order of (1), (2),
(3), and (4) in 3 times.
BZ210-1 10-51
(1)
Sectional view
(1/9)
1. Safety-suction valve 10. Mounting part of suction and safety valves

2. Mounting part of suction and safety valves (Air compressor B)
(Attachment 1A) 11. Safety-suction valve (Raking rotor B)
3. Suction valve (Left travel A) 12. Safety-suction valve (Solidifying material feeder B)
4. Suction valve (Right travel A) 13. Mounting part of suction and safety valves
5. Mounting part of suction and safety valves (Soil cutter B)
(Discharge belt conveyor A) 14. Mounting part of suction and safety valves
6. Mounting part of suction and safety valves (Discharge belt conveyor B)
(Soil cutter A) 15. Suction valve (Right travel B)
7. Safety-suction valve (Solidifying material feeder A) 16. Suction valve (Left travel B)
8. Safety-suction valve (Raking rotor A) 17. Mounting part of suction and safety valves
9. Mounting part of suction and safety valves (Attachment 1B)
(Attachment 3A)
10-52 BZ210-1
(1)
Unit: mm

Free length
Suction valve x Outside Installed load Installed load
spring diameter
spring
5.50 ± 0.40 N 4.40 N
46.8 x 7.50 40.6 —
{0.56 ± 0.04 kg} {0.45 kg}
BZ210-1 10-53
(1)
(2/9)
1. Main relief valve 6. Spool (Soil cutter)

2. Spool (Attachment 1) 7. Spool (Solidifying material feeder)
3. Spool (Left travel) 8. Spool (Raking rotor )
4. Spool (Right travel) 9. Spool (Attachment 3/Air compressor)
5. Spool (Discharge belt conveyor)
Unit: mm

Free length
Spool return x Outside Installed load Installed load
spring diameter
spring
222 ± 13.7 N 178 N
45.7 x 28.0 43.0 —
{22.6 ± 1.40 kg} {18.1 kg}
10-54 BZ210-1
(1)
(3/9)
10-56 BZ210-1
(1)
1. Pressure compensation valve F (Attachment 1) 10. Pressure compensation valve R

2. Pressure compensation valve F (Left travel) (Attachment 3/Air compressor)
3. Pressure compensation valve F (Right travel) 11. Pressure compensation valve R (Raking rotor )
4. Pressure compensation valve F 12. Pressure compensation valve R
(Discharge belt conveyor) (Solidifying material feeder)
5. Pressure compensation valve F (Soil cutter) 13. Pressure compensation valve R (Soil cutter)
6. Pressure compensation valve F 14. Pressure compensation valve R
(Solidifying material feeder) (Discharge belt conveyor)
7. Pressure compensation valve F (Raking rotor ) 15. Pressure compensation valve R (Right travel)
8. Pressure compensation valve F 16. Pressure compensation valve R (Left travel)
(Attachment 2/Air compressor) 17. Pressure compensation valve R (Attachment 1)
9. Unload valve
Unit: mm

Free length
Installed Free
Flow control x Outside Installed load Installed load
18 length length
valve spring diameter
If damaged or
9.81 ± 0.98 N 7.85 N
36.2 x 5.30 32.0 — deformed, replace
{1.0 ± 0.10 kg} {0.80 kg}
spring
19 27.5 x 14.2 18.0 —
ing valve spring {1.80 ± 0.10 kg} {1.40 kg}
20 28.2 x 14.5 26.0 —
ing valve spring {30 ± 0.30 kg} {2.40 kg}
BZ210-1 10-57
(1)
(4/9)
1. LS pressure pickup plug 6. Check valve (Soil cutter)

2. LS bypass plug 7. Check valve (Soil cutter)
3. Pump pressure pickup plug 8. Check valve (Discharge belt conveyor)
4. Check valve (Attachment 3) 9. Check valve (Attachment 1)
5. Check valve (Air compressor)
Unit: mm

Free length
Check valve x Outside Installed load Installed load
spring diameter
spring
5.88 N 4.71 N
41.5 x 8.50 31.5 —
{0.60 kg} {0.48 kg}
10-58 BZ210-1
(1)
(5/9) *1. Left travel, *2. Right travel
1. Suction valve (A) 6. Travel junction valve 10. Pressure compensation valve F
2. Suction valve (B) 7. Suction valve (A) 11. Pressure compensation valve R
3. Spool (Left travel) 8. Suction valve (B) a Above "F" and "R" denote the
4. Pressure compensation valve F 9. Spool (Right travel) following valves.
5. Pressure compensation valve R F: Flow control valve
Unit: mm

Free length
Travel junction Installed Free If damaged or
x Outside Installed load Installed load
12 spool return length length deformed, replace
diameter
spring spring
13.7 ± 1.0 N 10.1 N
17.7 x 8.20 13.0 —
{1.40 ± 0.10 kg} {1.10 kg}
BZ210-1 10-59
(1)
(6/9) *3. Attachment 1, *4. Discharge belt conveyor
1. Mounting part of suction and safety valves (A) 6. Mounting part of suction and safety valves (A)
3. Spool (Attachment 1) 8. Spool (Discharge belt conveyor)
10-60 BZ210-1
(1)
(7/9) *5. Soil cutter, *6. Solidifying material feeder
1. Mounting part of suction and safety valves (A) 6. Safety-suction valve (A)
2. Mounting part of suction and safety valves (B) 7. Safety-suction valve (B)
3. Spool (Soil cutter) 8. Spool (Solidifying material feeder)
BZ210-1 10-61
(1)
(8/9) *7. Raking rotor, *8. Attachment 2/Air compressor
1. Safety-suction valve (A) 6. Mounting part of suction and safety valves (A)
2. Safety-suction valve (B) 7. Mounting part of suction and safety valves (B)
3. Spool (Raking rotor) 8. Spool (Attachment 2/Air compressor)
10-62 BZ210-1
(1)
(9/9)
1. Pressure relief plug

2. Unload valve
3. Lift check valve
4. Main relief valve
Unit: mm

Free length
Lift check valve x Outside Installed load Installed load
spring diameter
spring
67.7 ± 4.90 N 56.4 N
67.7 x 20.0 42.5 —
{6.90 ± 0.50 kg} {5.75 kg}
BZ210-1 10-63
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
Features Structure
• CLSS stands for Closed center Load Sensing • The CLSS consists of a main pump (2 pumps),
System, and has the following features. control valve, and actuators for the work equip-
ment.
1) Fine control not influenced by load • The main pump body consists of the pump itself,
2) Control enabling digging even with fine control the PC valve and LS valve.
3) Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
4) Energy saving using variable pump control
BZ210-1 10-65
(1)
Basic principle
1. Control of pump swash plate angle
• The pump swash plate angle (pump delivery) is
controlled so that LS differential pressure PLS,
which is the difference between the pump dis-
charge pressure PP and the LS pressure PLS
(actuator load pressure) at the control valve out-
let, becomes constant.
(LS differential pressure PLS = Pump pres-
sure PP – LS pressure PLS)
• When the LS differential pressure PLS reduc-

es below the set pressure of the LS valve (when
the actuator load pressure is high), the pump
swash plate angle will move in the direction of
maximum. When the set pressure is raised
(when the actuator load pressure is low), the
pump swash plate will move in the direction of
minimum position.
a For the detail of the operation, see the para-
graph of "Hydraulic Pump."
10-66 BZ210-1
(1)
2. Pressure compensation
• A pressure compensation valve is installed to the In this way, the flow of oil from the pump is
outlet port side of the control valve to balance the divided (compensated) in proportion to the area
load. of opening S1 and S2 of each valve.
• When two actuators are operated together, this
valve acts to make pressure difference P be-
tween the upstream (inlet port) and downstream
(outlet port) of the spool of each valve the same
regardless of the size of the load (pressure).
BZ210-1 10-67
(1)
OPERATION OF EACH FUNCTION AND

VALVE
Hydraulic circuit diagrams and names of valves

7-spool valve (High valve)
1. Unload valve: Set pressure: 3.38 MPa {34.5 kg/cm2}

2. Main relief valve: Set pressure: 18.1 MPa {185 kg/cm2}
3. Pressure compensation valve
4. Safety-suction valve (Centralized safety valve): Set pressure: 17.2 MPa {175 kg/cm2}
5. Suction valve
10-68 BZ210-1
(1)
8-spool valve (Low valve)
1. Unload valve: Set pressure: 3.38 MPa {34.5 kg/cm2}

2. Main relief valve: Set pressure: 34.8 MPa {355 kg/cm2}
3. Pressure compensation valve
4. Safety-suction valve (Centralized safety valve): Set pressure: 17.2 MPa {175 kg/cm2}
5. Safety-suction valve (Ports A7 and B7): Set pressure: 11.8 MPa {120 kg/cm2}
6. Safety-suction valve (Ports A6 and B6): Set pressure: 18.6 MPa {190 kg/cm2}
7. Suction valve
8. Lift check valve
BZ210-1 10-69
(1)
UNLOAD VALVE
1. When the control valve is neutral
FUNCTION
• When the control valve is neutral, the delivery Q
equivalent to pump minimum swash plate angle
is released to tank circuit. At time, pump dis-
charge pressure PP is set to 2.45 MPa {25.0 kg/
cm2} with spring (3) inside the valve. (The LS
pressure PLS is 0 MPa {0 kg/cm2}.)
OPERATION 1. Unload valve

• The pump discharge pressure PP is applied to 2. Sleeve
the left end face of spool (4) and LS pressure 3. Spring
PLS is applied to the right end face. 4. Spool
• Since LS pressure PLS is 0 when the control
valve is neutral, pump discharge pressure PP is PLS : LS circuit (pressure)
only applied and is set with the lead to spring (3). PP : Pump circuit (pressure)
• When pump discharge pressure PP rises to T : Tank circuit
spring (3) load (2.45 MPa {25.0 kg/cm2}), spool
(4) will move toward the right side and pump cir-
cuit PP will interconnect to the tank circuit T
through the drill hole.
• Therefore, pump discharge pressure PP is set to
2.45 MPa {25.0 kg/cm2}.
10-70 BZ210-1
(1)
2. When the control valve is in the fine control pump discharge pressure PP is set to LS pres-
mode sure PLS + 2.5 MPa {25 kg/cm2}.
When the differential pressure between dis-
FUNCTION charge pressure PP and LS pressure PLS
• When the control valve is in the fine control mode comes to the spring (3) load (2.5 MPa {25 kg/
and the requested flow of the actuator is less cm2}), the unload valve will open and LS differ-
than the pump minimum swash plate angle, ential pressure PLS will come to 2.5 MPa {25
kg/cm2}.

• When the control valve is operated in the fine 2. Sleeve
control mode, LS pressure PLS will occur and 3. Spring
will be applied to the right end face of spool (4). 4. Spool
At the time the differential pressure between LS
pressure PLS and pump discharge pressure PP PLS : LS circuit (pressure)
increases because the opening area of the con- PP : Pump circuit (pressure)
trol valve spool is small. T : Tank circuit
• When the differential pressure between pump
discharge pressure PP and LS pressure PLS
comes to spring (3) load (2.5 MPa {25 kg/cm2}),
spool (4) will move to the right side and pump cir-
cuit PP will interconnect to tank circuit T.
• This means that pump discharge pressure PP is
set to the spring force (2.5 MPa {25 kg/cm2} + LS
pressure PLS, and LS differential pressure
PLS comes to 2.5 MPa {25 kg/cm2}.
BZ210-1 10-71
(1)
3. When the control valve is operated
FUNCTION
• If the required flow of the actuator increases
over the pump minimum swash plate angle
when the control valve is operated, the flow to
tank circuit T will be interrupted and pump deliv-
ery Q will be completely flown to the actuator cir-
cuit.

• When the control valve is operated with large 2. Sleeve
stroke, LS pressure PLS will occur and will be 3. Spring
applied to the right end face of spool (4). At the 4. Spool
time, the opening areas of the control valve spool
is large and the difference between LS pressure PLS : LS circuit (pressure)
PLS and pump discharge pressure PP is small. PP : Pump circuit (pressure)
• So, the differential pressure between pump dis- T : Tank circuit
charge pressure PP and LS pressure PLS does
not reach spring (3) load (2.5 MPa {25 kg/cm2})
and spring (3) pushes spool (4) to the left side.
• Then, pump circuit PP and tank circuit T are in-
terrupted, and pump delivery Q is completely
flown to the actuator circuit.
10-72 BZ210-1
(1)
LEADING OF LS PRESSURE
FUNCTION c is mounted on piston (5) halfway from pump

• The LS pressure is load pressure to the actuator circuit PP to pressure reducing valve (3), and the
on the outlet side of the control valve. orifice has the damper function.
• In case of a work equipment valve, pressure re- • The travel valve leads actuator circuit pressure A
ducing valve (3) of the pressure compensation directly to LS circuit PLS.
valve reduces pump discharge pressure PP to
the same level as actuator circuit pressure A and
leads the pressure to LS circuit PLS. Also, orifice
1. Work equipment valve
OPERATION • Both end face areas of pressure reducing valve

• When spool (1) is operated, pump discharge (3) are the same (SA = SLS), and actuator circuit
pressure PP will be led to actuator circuit A pressure PA (= A) is applied to SA side and re-
through bridge passage b from flow control valve duced pump discharge pressure PP is applied to
(2) and spool notch a. SLS side on the opposite side.
• Since pressure reducing valve (3) moves to the • Therefore, pressure reducing valve (3) balances
right at the same time, pump discharge pressure at the position where actuator circuit pressure
PP led from orifice c is reduced due to pressure PA becomes equal to the pressure of spring
loss at notch d and is led to LS circuit PLS and to chamber PLS1. Pump discharge pressure PP re-
spring chamber PLS1. duced at notch d comes to actuator circuit pres-
• At the time, LS circuit PLS is connected to tank sure A and is led to LS circuit PLS.
circuit T from LS bypass plug (4).
BZ210-1 10-73
(1)
2. Travel valve
OPERATION
• When spool (1) is operated, pump discharge
pressure PP will be led to actuator circuit A
through bridge passage b from flow control valve
(2) and spool notch a.
• At the same time, actuator circuit pressure PA
moves pressure reducing valve (3) to the right
side, and notches c and d interconnect to travel
junction circuit e and LS circuit PLS respectively.
• So, actuator circuit pressure PA (= A) is led from
notch c to LS circuit PLS through notch d.
a The travel circuit is different from the work
equipment circuit, actuator circuit pressure PA is
directly led to LS circuit PLS.
10-74 BZ210-1
(1)
LS BYPASS PLUG
FUNCTION
• This plug releases residual pressure of LS pres-
sure PLS.
• This plug slows the rising speed of LS pressure
PLS, causes pressure losses at the spool and
the throttle of the shuttle valve by the discarded
throttled flow and reduces the effective LS differ-
ential pressure for higher safety.
OPERATION 1. LS bypass plug

• Pressurized oil in LS circuit PLS flows from clear-
ance filter a in the space between LS bypass PLS : LS circuit (pressure)
plug (1) and the valve body to tank circuit T T : Tank circuit (pressure)
through orifice b.
BZ210-1 10-75
(1)
PRESSURE COMPENSATION VALVE
FUNCTION
• When the load pressure becomes lower than an-
other actuator and the flow is going to increase
during a compound operation, this valve com-
pensates the load pressure. (At the time, the load
pressure of another actuator under compound
operation (the upper side) is higher than that of
the actuator on this side (the lower side).
10-76 BZ210-1
(1)
OPERATION
• When the load pressure of another actuator side
(the upper side) rises during a compound opera-
tion, the flow in actuator circuit A on this side (the
lower side) is apt to increase.
• In this case, LS pressure PLS of another actua-
tor is applied to spring chamber PLS1 and push-
es pressure reducing valve (1) and flow control
valve (2) to the left side.
• Flow control valve (2) throttles the opening area
between pump circuit PP and spool upstream
PPA and causes a pressure loss between PP
and PPA.
• Flow control valve (2) and pressure reducing
valve (1) balance each other where the pressure
difference between PA applied to the both end
faces of pressure reducing valve (1) and PLS be-
comes the same as the pressure loss between
PP before and after the flow control valve and
PPA.
• So, the pressure differences between upstream
pressures PPA and downstream pressures PA
of the both spools under compound operation
become the same, and the pump flow is distrib-
uted in proportion to the opening area of each
spool notch a.
BZ210-1 10-77
(1)
AREA RATIO OF PRESSURE COMPENSATION VALVE
FUNCTION
• The pressure compensation valve slightly adjust the ratio (S2/S1) of area S1 on the left side of flow control
valve (2) and area S2 on the right side of pressure reducing valve (1) to suite the characteristics of each ac-
tuator and determines the compensation characteristics.
S1 : Area of flow control valve (2) – area of piston (3)
S2 : Area of pressure reducing valve (1) – area of piston (3)
Area ratio (S1:S2) and compensation characteristics

• When the ratio is 1.00 :
The expression [Pump (discharge) pressure PP – Spool notch upstream pressure PPB] [LS circuit pres-
sure PLS – Actuator circuit pressure PA (= A)] can be held, and the flow is distributed as per the spool
opening area ratio.
• When the ratio is more than 1.00:
The expression PP – PPB > PLS – PA (= A) can be held, and the flow is distributed less than the spool
opening area ratio.
• When the ratio is less than 1.00:
The expression PP – PPB < PLS – PA (= A) can be held, and the flow is distributed more than the spool
opening area ratio.
10-78 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE
P1 : From pump
PR : Supply to solenoid valve, PPC valve and EPC valve.
T : To hydraulic tank
BZ210-1 10-79
(1)
1. Control valve block 7. Spring (pressure reducing valve main)

2. Valve (sequence valve) 8. Valve (pressure reducing valve)
3. Spring 9. Spring (safety valve)
4. Screw 10. Ball
5. Poppet 11. Filter
6. Spring (pressure reducing valve pilot)
10-80 BZ210-1
(1)
FUNCTION
• The self pressure reducing valve reduces the
discharge pressure of the main pump and sup-
plies it to the solenoid valve, the PPC valve, etc.
as the control pressure.
BZ210-1 10-81
(1)
1. At engine stop (all low pressure)
OPERATION
• Spring (6) pushes poppet (5) to the seat, and the
circuit between ports PR and T is closed.
• Spring (7) pushes valve (8) to the left side, and
the circuit between ports P1 and PR is open.
• Spring (3) pushes valve (2) to the left side, and
the circuit between ports P1 and P2 is closed.
10-82 BZ210-1
(1)
2. At neutral and reduction of load pressure P2
Note : When load pressure P2 is lower than output

pressure PR of the self pressure reducing
valve.
OPERATION
• Spring (3) and the PR pressure (0 MPa {0 kg/
cm2} at the time of engine stop) pushes valve (2)
in the direction to close the circuit between ports
P1 and P2. When the hydraulic oil enters port P1,
the expression (P1 pressure Spring (7) force
+ ( d area x PR pressure)) holds, and the self
pressure reducing valve will adjust the openings
of ports P1 and P2 so that the P1 pressure can
be maintained higher than the PR pressure.
• When the PR pressure rises above the set pres-
sure, poppet (5) will open and the hydraulic oil
flows through the route from the port PR, hole a
in spool (8), poppet (5) opening to tank port T.
• Therefore, there will occur a differential pressure
around hole a in spool (8) and the spool will
move in the direction to close port P1 and the PR
opening. Then, the P1 pressure is reduced and
adjusted to a certain pressure (set pressure) with
the opening and is supplied as the PR pressure.
BZ210-1 10-83
(1)
3. At raise of load pressure P2
OPERATION
• When load pressure P2 rises due to operations,
the pump delivery will increase and the P1 pres-
sure will rise.
Then, the expression (P1 pressure > Spring (7)
force + ( d area x PR pressure)) will hold, and
valve (2) will move to the right side till the stroke
end. As a result, the opening between ports P1
and P2 will increase, the passage resistance will
become smaller to reduce engine loss horse-
power.
• When the PR pressure rises above the set pres-
sure, poppet (5) will open and the hydraulic oil
will flow through the route from port PR, hole a in
spool (8), poppet (5) opening to tank port T.
• Therefore, there will occur a differential pressure
around the hole a in spool (8) and the spool will
move in the direction to close port P1 and the PR
opening. Then, the P1 pressure is reduced and
adjusted to a certain pressure (set pressure) with
the opening and is supplied as the PR pressure.
10-84 BZ210-1
(1)
4. When abnormally high pressure is generated
OPERATION
• If the PR pressure of the self-reducing pressure
valve rises abnormally, ball (10) separates from
the seat against spring (9), and then the hydrau-
lic oil flows through output PR to T and the PR
pressure lowers. Accordingly, the devices re-
ceiving the hydraulic oil (PPC valve, solenoid
valve, etc.) are protected from the abnormally
high pressure.
BZ210-1 10-85
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR (FINAL DRIVE)
TRAVEL MOTOR (FINAL DRIVE)
A : From control valve (L.H./R.H. travel)

B : From control valve (L.H./R.H. travel)
C1 : To hydraulic tank (L.H. travel motor)
Plug (R.H. travel motor)
C2 : Plug (L.H. travel motor)
To hydraulic tank (R.H. travel motor)
D : From travel 2nd speed selector solenoid valve
10-86 BZ210-1
(1)
1. Plug 18. RV gear B

2. Check valve spring 19. Cover
3. Check valve 20. Driven gear
4. Return spring 21. Drive gear
5. Counterbalance valve 22. Drain plug
6. Safety valve 23. Hub
7. Safety valve spring 24. Regulator piston
8. End cover 25. Spindle
9. Regulator valve 26. Piston
10. Spring 27. Floating seal
11. Brake piston 28. Plate
12. Cylinder 29. Disc
13. Spring 30. Valve plate
14. Swash plate 31. Spring
15. Pivot 32. Piston
16. Crankshaft 33. Plug
17. RV gear A 34. Check valve
BZ210-1 10-87
(1)
SPECIFICATION
Type GM18VL-J
Theoretical delivery Hi 37.2 {37.2}

(cm3/rev{cc/rev}) Lo 52.7 {52.7}
Hi 2916.3
Rated speed (rpm)
Lo 2147.3
Brake releasing pressure 0.68
(MPa {kg/cm2}) {6.94}
Hi-Lo switching pressure 2.94
(MPa {kg/cm2}) {30}
Final drive reduction ratio 72
OUTLINE
Travel speed selection
• Swash plate (14) has 2 faces (x, y) behind it, and

is supported by pivot (15).
• When pressure of control chamber a rises, it
pushes regulator piston (24), then swash plate
angle becomes minimum, then travel speed
goes high.
10-88 BZ210-1
(1)
OPERATION
Operation of motor
At slow speed (the motor swash plate angle is maximized.)
• Since the travel 2nd speed selector solenoid

valve is deenergized, the pressurized oil from the
main pump does not flow to port D.
• Therefore, spring (10) has pressed regulator
valve (9) to the left side.
• So, regulator valve (9) stops the main pressu-
rized oil led from the control valve to the end cov-
er by pushing check valve (34).
• The pressurized oil in the control chamber drains
in the motor case through passage b of regulator
valve (9).
• Then, the main pressurized oil from cylinder
chamber c pushes swash plate (14) in the direc-
tion to maximize the swash plate angle and the
motor capacity is increased to the maximum for
slow speed travel.
BZ210-1 10-89
(1)
At high speed (the motor swash plate angle is minimized.)
• When the travel 2nd speed selector solenoid

valve is energized, the pilot pressure from the
main pump will flow in port D and push regulator
valve (9) in the right direction.
• Therefore, the main pressurized oil from the con-
trol valve passes through passage b of regulator
valve (9), flows in control chamber a and pushes
regulator piston (24) in the left direction.
• Then, swash plate (14) is pressed in the direction
to minimize the swash plate angle, and the motor
capacity is minimized for high speed travel.
10-90 BZ210-1
(1)
Operation of brake valve

• The brake valve consists of check valves (3a)
and (3b), counterbalance valve (5) and safety
valve (6), and the circuit configuration is as per
the right figure.
• Functions and operations of these components
are as follows :
Counterbalance valve, check valve

Function
• When traveling down a slope, the own weight
falling force will make the machine travel faster
than the motor rotation. So, traveling with re-
duced engine speed is very dangerous because
the motor idles and runs away.
These valves let the machine travel at a speed
appropriate for the engine speed (pump deliv-
ery) to prevent this danger.
Operation at oil supply

• When the travel lever is operated, the pressu-
rized oil from the control valve will be supplied to
port PA, push and open check valve (3a) and
flow from port MA on the motor inlet side to port
MB on the motor outlet side.
Since the motor outlet circuit is closed with
check valve (3b) and counterbalance valve (5),
however, the supply-side pressure will rise.
BZ210-1 10-91
(1)
• The pressurized oil on the supply side flows in

chamber S1 from orifice E1 of counterbalance
valve (5). When the pressure in chamber S1 ris-
es above the switching pressure of the counter-
balance valve, counterbalance valve (5) will be
pressed in the right direction.
So, the circuit between the outlet side port MB
and port PB will open, the motor outlet circuit will
open, and the motor will start rotating.
Brake operation at traveling downhill

• If the machine is going to run away when
traveling downhill, the motor will idle to reduce
the oil pressure on the motor inlet side and the
pressure in the chamber S1 through orifice E1.
When the pressure in chamber S1 drops below
the switching pressure of the counterbalance
valve, counterbalance valve (5) will be returned
in the left direction with return spring (4), and
outlet side port MB will be throttled.
Then, the pressure on the outlet side will rise
and rotation resistance will occur to the motor to
prevent the machine from running away.
This means that counterbalance valve (5)
moves to a position where the machine own
weight and the inlet side pressure balance with
the pressure at the outlet side port MB, and the
outlet circuit is throttled to control the speed to
the pump delivery.
10-92 BZ210-1
(1)
Safety valve
Function
• When stopping a travel (or traveling downhill),
counterbalance valve (5) will close the inlet and
outlet circuits of the motor. Since the motor
keeps rotating by inertia, however, the pressure
on the outlet side of the motor will rise abnormal-
ly and the motor and pipes may be damaged.
Then, the safety valve leads the abnormally high
pressure to the inlet side of the motor to prevent
the equipment from being damaged.
Operation
• When the pressurized oil being supplied from
port PA is stopped flowing at the time of travel
stop, return spring (4) will return counterbalance
valve (5) from the right side to the left side (the
neutral position).
• Though counterbalance valve (5) closes cham-
ber a on the outlet side circuit, the inertia lets the
motor rotate and the pressure in chamber a ris-
es.
• The highly pressurized oil in chamber a passes
through throttle b of safety valve (6a) and enters
in the chamber d from the chamber c. The pres-
surized oil entered in chamber d moves piston
(32) to the left side. Meantime, safety valve (6a)
is pushed to open by the pressurized oil in cham-
ber a, and the pressurized oil in chamber a flows
in chamber f through port e. Therefore, the pres-
surized oil in chamber a flows in chamber f at a
comparatively slow speed to control the pressure
in chamber a and also to prevent cavitation in
chamber f at the same time.
• When piston (32) reaches the stroke end, the
pressures in chambers d and c will rise, safety
valve (6a) will be closed again and the pressure
in chamber a will rise further.
• Then, safety valve (6b) will open and the pressu-
rized oil in chamber a will flow in chamber f from
chamber g. The pressure in chamber a can be
controlled in two stage as mentioned above, and
the hydraulic motor can be smoothly braked to
stop.
BZ210-1 10-93
(1)
Operation of parking brake

When operating travel
• When the travel lever is operated, the pressu-
rized oil from the pump will work on counterbal-
ance valve (5), open circuit a to the parking brake
and flow in chamber b of brake piston (11).
• The pressure in chamber b overcomes spring
(31) and pushes brake piston (11) in the left di-
rection.
• This will eliminate the press force to plate (28)
and disc (29), and plate (28) and disc (29) will
separate, and the brake force will be released.
When positioning travel neutral

• When the travel lever is brought to the neutral
position, counterbalance valve (5) will return to
the neutral position and circuit a to the parking
brake will be closed.
• The pressurized oil in chamber b of brake piston
(11) will be drained in the case, and spring (31)
will push the brake piston in the right direction.
• Therefore, plate (28) and disc (29) will be pushed
to each other, and the brake will come to work.
10-94 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
TRAVEL JUNCTION VALVE
10-96 BZ210-1
(1)
FUNCTION
• To compensate for any difference in the oil flow
in the left and right travel circuits while machine
travels in a straight line, the junction circuit opens
when the left and right travel spools are operat-
ed.
Accordingly, the flow rates of oil to the left and
right travel motors are almost the same when the
machine travels in a straight line, so the machine
deviates less.
• When the machine is steered, the pressure re-
ducing valve of the travel valve on the inside of
steering is returned by the difference of the load
pressure and the opening of the travel junction
valve spool is closed. Accordingly, the junction
circuit is closed and the machine can be steered.
OPERATION
When machine travels in a straight line
• If right and left travel spools (1) are operated, the
oil discharged from the pump flows through
pump circuit PP and circuit PA to actuator circuit
A.
• If the machine is operated to travel straight, the
oil pressure in actuator circuit PA becomes even
and right and left pressure reducing valves (2)
are pushed to the right by the same distance and
notch a and the junction circuit open.
• Left travel forward pressure P1 and right travel
forward PPC pressure P2 are led through shuttle
valves (5) to the spring chambers at both ends of
travel junction valve spool (4). Since P1 = P2,
spool (4) is position in neutral and notch d is
open to the junction circuit.
• Accordingly, the right and left travel actuator cir-
cuits are interconnected by the travel junction cir-
cuit. If any difference occurs in the flow of oil to
both travel motors, the difference is compensat-
ed to reduce travel deviation.
BZ210-1 10-97
(1)
When machine is steered during travel
10-98 BZ210-1
(1)
OPERATION
• While the machine is traveling in a straight line, if
the left travel spool (Left 1) is returned to the neu-
tral position and the machine is steered, a differ-
ence (Right A > Left A) is made between the
load pressures in right and left travel actuator cir-
cuits PA, and then LS pressure PLS becomes
the same as Right A which is the higher load
pressure.
• Accordingly, flow control valve (3) on the left trav-
el side is pushed to the left by LS circuit pressure
PLS, or load pressure Right A on the right travel
side. Accordingly, notch a on the left side is
closed and the right and left travel circuits are
stopped, and then the pressures P1 and P2 in
the spring chambers at both ends of travel junc-
tion valve spool (4) become different as P1 > P2.
As a result, spool (4) is set to the P1 side and cut
d is closed and the machine can be steered.
• When the spool is operated sharply, damper b
damps the transient characteristics of sudden
opening and closing of the junction circuit.
BZ210-1 10-99
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOIL BELT CONVERTOR MOTOR
SOIL BELT CONVERTOR MOTOR
a. Port C1 (To tank) Specifications

b. Port A (From control valve) Model : GMY09VL2
c. Port D (From travel speed solenoid valve)
d. Port B (From control valve) Hydraulic motor
e. Port C2 (To tank) Capacity (High speed/Low speed)
: 25.1/39.8 cm3/rev (Fixed to low speed)
Using pressure : 24.5 MPa {250 kg/cm2}
Revolving speed (High speed/Low speed)
: 2,773/1,785 rpm
Rated discharge : 72.5 l/min
Reduction gear unit

Reduction ratio : 62.4
Revolving speed (High speed/Low speed)
: 44.4/28.6 rpm
Output torque (High speed/Low speed)
: 5,330/8,430 Nm {543/860 kgm}
Brake
Releasing pressure : 0.45 MPa {4.6 kg/cm2}
10-100 BZ210-1
(1)
1. Check valve 11. Swash plate 21. Drain plug

2. Check valve spring 12. Floating seal 22. Center shaft
3. Counterbalance valve 13. RV gear 23. Regulator piston
4. Return spring 14. RV gear 24. Case
5. End cap 15. Crankshaft 25. Spindle
6. Spring 16. Driven gear 26. Piston
7. Regulator valve 17. Cover 27. Cylinder
8. Brake piston 18. Drive gear 28. Brake spring
9. Plate 19. Shaft 29. Valve plate
10. Disc 20. Coupling 30. Check valve
BZ210-1 10-101
(1)
Operation of motor
1. When speed is low (When motor swash plate angle is at maximum)
* The motor of this model is fixed to the low speed.
• Pilot port D is connected to the hydraulic tank

and no oil pressure is applied to it.
• Accordingly, regulator valve (6) is pressed to the
left (i) by spring (7).
• The main hydraulic oil from the control valve
pushes check valve (32) and flows to end cover
(5), but it is stopped by regulator valve (6).
• The hydraulic oil in chamber a of regulator piston
(23) is drained through passage b of regulator
valve (6) into the motor case.
• As a result, swash plate (11) is pushed toward
the maximum angle by the main hydraulic oil in
cylinder P, and then the motor capacity is set to
the maximum and the revolving speed is low-
ered.
10-102 BZ210-1
(1)
Operation of revolution brake

1. When revolution is started
• If the feeder switch is turned ON, the hydraulic oil
from the pump operates counterbalance valve
spool (3) to open the passage to the parking
brake. Then, the oil pushes check valve (31)
open and flows in chamber a of brake piston (8).
• The pressure in chamber a pushes brake piston
(8) to the left (i) against spring (28).
• As a result, the force pressing plate (26) and disc
(27) is lost, and then plate (26) and disc (27) are
separated from each other and the braking force
is released.
2. When revolution is stopped

• If the feeder switch is turned OFF, counterbal-
ance valve spool (3) returns to the neutral posi-
tion and the passage to the parking brake is
closed.
• The hydraulic oil in chamber a of brake piston (8)
is drained through the orifice of check valve (31)
into the case, and then brake piston (8) is
pressed to the right (o) by spring (28).
• As a result, plate (26) and disc (27) are pressed
to each other and the brake is applied.
BZ210-1 10-103
(1)
Operation of brake valve
FUNCTION
• When the feeder switch is turned OFF, the brake
valve stops the revolution of the motor immedi-
ately to prevent revolution caused by the inertia
of the feeder.
Operation for feeding

• If the feeder switch is turned ON, the hydraulic oil
from the control valve flows in port PA and push-
es check valve (2a) open, and then flows through
motor inlet port MA to motor outlet port MB.
• Since the motor outlet is closed by check valve
(2b) and spool (3) at this time, the pressure on
the supply side rises. (Fig. 1)
• The hydraulic oil on the supply side flows through
orifice E1 of spool (3) to chamber S1. If the pres-
sure in chamber S1 rises higher than the spool
changeover pressure, spool (3) is pushed to the
right (o).
• As a result, port MB is connected to port PB and
the motor outlet opens, and then the motor starts
revolution. (Fig. 2)
Braking operation for stopping revolution

• When revolution is stopped, the motor continues
running and the oil pressure on the motor inlet
side lowers. As a result, the pressure in chamber
S1 lowers through orifice E1, too.
• If the pressure in S1 lowers below the spool
changeover pressure, spool (3) is returned to the
left (i) by spring (4) and port MB on the outlet
side is narrowed.
• As a result, the pressure on the outlet side rises
and revolution resistance is generated in the mo-
tor to prevent the motor from running.
In other words, spool (3) moves to a position
where the pressure on the inlet side is balanced
with the pressure in port MB on the outlet side to
narrow the outlet circuit and control the speed
according to the pump discharge. (Fig. 3).
10-104 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RAKING ROTOR MOTOR
RAKING ROTOR MOTOR
a. Port PP (To tank)

b. Port A (Raking rotor control valve)
c. Port B (Raking rotor control valve)
d. Port DR (To tank)
Specifications Reduction gear unit

Model : PHV-350 Reduction ratio : 52.7
Rated speed (High speed/Low speed)
Hydraulic motor : 60.5/37.5 rpm
Capacity (High speed/Low speed) Rated output torque : 3,334 Nm {340 kgm}
: 11.4/18.6 cm3/rev
(Fixed to low speed)
Rated using pressure : 24.5 MPa {250 kg/cm2}
Rated speed (High speed/Low speed)
: 3,190/1,975 rpm
Rated discharge : 37.5 l/min
10-106 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RAKING ROTOR MOTOR
1. Drain plug 13. Output shaft

2. Cover 14. No. 1 sun gear
3. No. 2 planetary gear 15. No. 2 planetary carrier
4. Ring gear 16. No. 2 sun gear
5. No. 1 planetary gear 17. Plug
6. Housing 18. Spool return spring
7. Piston 19. Check valve spring
8. Cylinder 20. Counterbalance valve spool
9. Valve plate 21. 2nd-speed spool
10. Brake valve 22. Plug
11. Center spring 23. Check valve
12. Swash plate
BZ210-1 10-107
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOIL CUTTER MOTOR
SOIL CUTTER MOTOR
1. Spring 11. Shaft face seal Specifications

2. Inner face seal 12. Valve drive Type : Orbit roll type
3. Outer face seal 13. Balancing ring sub-assembly Model : 6-200ACA-F
4. Valve 14. Valve housing sub-assembly Capacity : 195 cm3/rev.
5. Valve plate 15. Steel ball Rated pressure : 22.1 MPa {225 kg/cm2}
6. Geroler assembly Rated output torque: 618 Nm {63 kgm}
7. Drive Rated speed : 490 rpm
8. Bearing housing A. Port A
9. Shaft sub-assembly B. Port B
10. Shaft seal
10-108 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ROTARY HAMMER MOTOR
ROTARY HAMMER MOTOR
1. Rear case Specifications

2. Drive gear Type : Gear
3. Bearing Model : GPM1-COC50B1F-112
4. Bearing Displacement : 49.9 cm3/rev.
5. Seal Rated pressure : 17.2 MPa {175 kg/cm2}
6. Shaft Max. speed : 2,700 rpm
7. Front case
8. Driven gear
9. Gear case
BZ210-1 10-109
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DISCHARGE BELT CONVEYOR MOTOR
DISCHARGE BELT CONVEYOR MOTOR
a. Port Md (To tank) Specifications

b. Port MA (From control valve) Applicable
Unit 1001 – 1100 1101 and up
serial No.
c. Port MB (From control valve) Model MSE02-0 MSE02-2
d. Port S (Blind) Capacity cc/rev. 332 398
Max. pressure MPa {kg/cm } 2
34.3 {350}
Max. speed rpm 200 165
Output torque Nm {kgm}/rpm 736 {75}/77 824 {84}/84
10-110 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLIDIFYING MATERIAL FEEDER
SOLIDIFYING MATERIAL FEEDER
1. Pinion gear 8. Plug Specifications

2. Housing 9. Ball Type : Orbit roll type
3. Valve plate 10. Valve drive Model : 2-200DO-E+AD0745B
4. Valve 11. Geroler Displacement : 195 cc/rev.
5. Valve housing 12. Drive shaft Rated pressure : 13.2 MPa {135 kg/cm2}
6. Pin 13. Wear plate Rated output torque : 373 Nm {38 kgm}
7. Spring Rated speed : 350 rpm
BZ210-1 10-111
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AFTERCUTTER MOTOR
AFTERCUTTER MOTOR
1. Pinion gear 8. Plug Specifications

2. Housing 9. Ball Applicable serial No. 1001 – 1100 1101 and up
3. Valve plate 10. Valve drive Type Orbit roll type
4. Valve 11. Geroler Model 2-080AB2G2-E 2-130AB2G2-E
5. Valve housing 12. Drive shaft Displacement (cc/rev.) 80.7 131
6. Pin 13. Wear plate Rated pressure (MPa {kg/cm2}) 20.6 {210} 18.1 {185}
7. Spring Rated output torque (Nm {kgm}) 235 {24} 343 {35}
Rated speed (rpm) 850 550
10-112 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
Unit: mm

Clearance between pis- size Shaft Hole clearance limit
1
ton rod and bushing
–0.020 +0.033 0.020 – Replace
30 0.405
–0.072 +0.033 0.105 bushing
Clearance between pis-
–0.090 +0.099 0.130 –
2 ton rod support shaft and 30 1.0
–0.130 +0.040 0.229
bushing
Clearance between cyl-
–0.090 +0.099 0.130 – Replace pin
3 inder bottom support 30 1.0
–0.130 +0.040 0.229 and bushing
shaft and bushing
BZ210-1 10-113
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE CONTROL
VALVE CONTROL
1. Hydraulic pump 6. 5-spool solenoid valve

2. 7-spool control valve 7. EPC valve
3. Crusher open/close valve 8. 8-spool control valve
4. Travel PPC valve 9. Hydraulic tank
5. 6-spool solenoid valve
10-114 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
a. Port P (From main pump) d. Port P1 (Left reverse)

b. Port T (To tank) e. Port P3 (Right reverse)
c. Port P2 (Left forward) f. Port P4 (Right forward)
10-116 BZ210-1
(1)
1. Plate 5. Metering spring

2. Body 6. Centering spring
3. Piston 7. Valve
4. Collar 8. Bolt
BZ210-1 10-117
(1)
OPERATION
1) In neutral
Ports A, B of the control valve and ports P1, P2
of the PPC valve are connected to drain cham-
ber D through fine control hole f of spool (1).
(Fig. 1)
2) In fine control operation (Neutral o Fine con-

trol)
If disc (5) starts pushing piston (4), retainer (9) is
pushed, and then spool (1) is pushed down
through metering spring (2).
Accordingly, fine control hole f is disconnected
from drain chamber D and connected to pump
pressure chamber PP almost simultaneously,
and then the pilot oil of the control pump flows
through fine control hole f and port P1 to port A.
If the pressure in port P1 is increased, spool (1)
is pushed back, and then fine control hole f is
disconnected from pressure chamber PP and
connected to drain chamber D almost simulta-
neously and the pressure in port P1 is released.
Accordingly, spool (1) moves up and down so
that the force of metering spring (2) will be bal-
anced with the pressure in port P1. The posi-
tional relationship between spool (1) and body
(10) (that fine control hole f is between drain
hole D and pump pressure chamber PP) does
not change until retainer (9) touches spool (1).
As a result, metering spring (2) is compressed in
proportion to the stroke of the control lever and
the pressure in port P1 also rises in proportion
to the stroke of the control lever.
Then, the control valve spool moves to a posi-
tion where the pressure in chamber A (which is
the same as the pressure in port P1) is balanced
with the force of the control valve spool return
spring. (Fig. 2)
10-118 BZ210-1
(1)
3) In fine control operation (When control lever

is returned)
If disc (5) is returned, spool (1) is pushed up by
the force of centering spring (3) and pressure in
port P1.
As a result, fine control hole f is connected to
drain chamber D and the oil in port P1 is
released.
If the pressure in port P1 lowers too much, spool
(1) is pushed down by metering spring (2) and
fine control hole f is disconnected from drain
chamber D and connected to pump pressure
chamber PP almost simultaneously. Then, the
pump pressure is applied until the pressure in
port P1 rises to the level equivalent to the posi-
tion of the lever.
While the control valve spool is moving, oil in
drain chamber D flows in through fine control
hole f’ of the valve on the stopped side, and
then flows through port P2 into chamber B. (Fig.
3)
4) At full stroke
If disc (5) pushes down piston (4) and retainer
(9) pushes down spool (1), fine control hole f’ is
disconnected from drain chamber D and con-
nected to pump pressure chamber PP. Accord-
ingly, the pilot oil from the control pump flows
through fine control hole f and port PP into
chamber A to push the control valve spool.
The oil returning from chamber B flows through
port P2 and fine control hole f’ into drain cham-
ber D. (Fig. 4)
BZ210-1 10-119
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CRUSHER CASE OPEN/CLOSE PPC VALVE
CRUSHER CASE OPEN/CLOSE PPC VALVE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
a. To port T (tank)
b. Port P (From control pump)
c. Port P1
d. Port P2
10-120 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 6-SPOOL SOLENOID VALVE (A)
6-SPOOL SOLENOID VALVE (A)
1. Solenoid valve for reverse rotation of T. To tank

discharge belt conveyor A1. To discharge belt conveyor reverse port of
2. Solenoid valve for secondary belt conveyor 8-spool valve
3. Solenoid valve for vibratory sieve A2. To secondary belt conveyor port of 8-spool valve
4. Solenoid valve for forward rotation of A3. To vibratory sieve port of 7-spool valve
discharge belt conveyor A4. To discharge belt conveyor forward port of
5. Solenoid valve for aftercutter 8-spool valve
6. Solenoid valve for solidifying material feeder A5. To aftercutter port of 8-spool valve
A6. To solidifying material feeder port of 8-spool valve
P1. From pump
BZ210-1 10-121
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 6-SPOOL SOLENOID VALVE (B)
6-SPOOL SOLENOID VALVE (B)
1. Solenoid valve for soil cutter T. To tank

2. Solenoid valve for raking rotor A1. To soil cutter port of 8-spool valve
3. Solenoid valve for air compressor A2. To raking rotor port of 8-spool valve
4. Solenoid valve for rotary hammer A3. To air conditioner compressor port of 8-spool valve
5. Solenoid valve for soil belt conveyor A4. To rotary hammer port of 7-spool valve
6. Solenoid valve for travel PPC lock A5. To soil belt conveyor port of 7-spool valve
A6. To travel PPC valve port
P1. From pump
10-122 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 6-SPOOL SOLENOID VALVE (B)
1. Connector
2. Movable core
3. Coil
4. Spool
5. Block
6. Spring
OPERATION
When solenoid is deactivated
• Since the signal current flows from the controller,
solenoid (3) is deactivated.
Accordingly, spool (4) is pressed to the left by
spring (6).
As a result, the passage from P to port A is
closed and the oil does not flow from the main
pump to the actuator.
At this time, the oil from the actuator flows
through port A to port T, and then it is drained
into the tank.
When solenoid is excited

• If the signal current flows from the controller into
solenoid (3), solenoid (3) is excited.
Accordingly, spool (4) is pushed to the right.
As a result, the oil from the main pump flows
through port P and inside of spool (4) to port A,
and then flows to the actuator.
At this time, port T is closed and the oil does not
flow to the tank.
BZ210-1 10-123
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EPC VALVE
EPC VALVE
1. Belt conveyor EPC 9. Block a. Port T (To tank)

2. Solidifying material feeder EPC 10. Body b. Port C1 (To belt conveyor port of 7-spool valve)
3. Soil cutter EPC 11. Spool c. Port C2 (To solidifying material feeder port of 8-
4. Crane EPC 12. Spring spool valve)
5. Rotary hammer No.3 EPC 13. Push pin d. Port C3 (To soil cutter port of 8-spool valve)
6. Rotary hammer No.2 EPC 14. Coil e. Port C4 (To crane port of 7-spool valve)
7. Rotary hammer No.1 EPC 15. Plunger f. Port C5 (To rotary hammer No. 3 port of 7-spool
8. Raking rotor EPC 16. Connector valve)
g. Port C6 (To rotary hammer No. 2 port of 7-spool
valve)
h. Port C7 (To rotary hammer No. 1 port of 7-spool
valve)
i. Port C8 (To raking rotor port of 8-spool valve)
j. Port P (From main pump)
10-124 BZ210-1
(1)
FUNCTION
• The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion.
• When it receives signal current i from the
contoroller, it generates the EPC output pressure
in proportion to the size of the signal, and outputs
it to the control valve.
OPERATION
1. When signal current is 0 (coil de-energized)
• There is no signal current flowing from the
controller to coil (14), coil (14) is de-ener-
gized. For this reason, spool (11) is pushed
to the right by spring (12).
• As a result, port P closes and the pressu-
rized oil from the front pump does not flow to
the control valve. At the same time, the pres-
surized oil from the control valve passes
from port C through port T and is drained to
the tank.
BZ210-1 10-125
(1)
2. When signal current is very small (coil ener-

gized)
• When a very small signal current flows to coil
(5), coil (5) is energized, a propulsion force is
generated, and this pushes plunger (6) to the
left.
• Push pin (4) pushed spool (2) to the left, and
pressurized oil flows from port P to port C.
When the pressure at port C rises and the
load of spring (3) + the force acting on sur-
face a of spool (2) becomes greater than the
propulsion force of plunger (6), spool (2) is
pushed to the right. The circuit between port
P and port C is shut off, and at the same
time, port C and port T are connected.
• As a result, spool (2) moves up and down so
that the propulsion force of plunger (6) is bal-
anced with the load of spring (3) + pressure
of port C. Therefore, the circuit pressure be-
tween the EPC valve and the control valve is
controlled in proportion to the size of the sig-
nal current.
3. When signal current is maximun (coil energized)

• When the signal current flows to coil (5), coil
(5) is energized. When this happens, the sig-
nal current is at its maximum, so the propul-
sion force of plunger (6) is also at its
maximum. For this reason, spool (2) is
pushed fully to the left by push pin (4).
• As a result, the flow of pressurized oil from
port P flows at its maximum to port C, and
the circuit pressure between the EPC valve
and control valve becomes the maximum. At
the same time, port T closes and stops the oil
from flowing to the tank.
10-126 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
APPEARANCE
10-128 BZ210-1
(1)
STRUCTURE OUTLINE
1. Soil hopper 11. Discharging belt conveyor

2. Solidifying material feeder 12. 3-axis rotary hammer
3. Monitor lamp (green) and beacon lamp (red) 13. Soil belt conveyor
4. Solidifying material hopper 14. Crane
5. Soil cutter 15. Crane switch
6. Mixer (soil cutter and rotary hammer) 16. Crane control lever
7. Travel lever 17. Solidifying material presence paddle switch
8. Mixer open/close lever 18. Soil sensor
9. Radio controller antenna 19. Raking rotor
10. Operator panel
BZ210-1 10-129
(1)
PRINCIPLE OF SOIL TYPE IMPROVEMENT
1. Soil hopper 7. Soil cutter

2. Soil 8. Mixer (crusher)
3. Raking rotor 9. 3-axis rotary hammer
4. Solidifying material feeder 10. Discharged soil
5. Solidifying material 11. Discharging belt conveyor
6. Solidifying material hopper 12. Soil belt conveyor
Outline
1. Soil (2) is entered in soil hopper (1), and it is
sent to mixer (8) by soil belt conveyor (12) and
raking rotor (3).
2. Solidifying material (5) of solidifying material
hopper (6) is sprayed onto the soil by solidifying
material feeder (4).
3. The soil and the solidifying material are entered
in mixer (8), and they are cut and crushed by
soil cutter (7) and 3-axis rotary hammer (9).
Also, the soil and the solidifying material are
mixed at the same time.
4. The mixed soil is discharged as the discharged
soil (10) from mixer (8) by discharging belt con-
veyor (11).
10-130 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MIXER (CRUSHER)
MIXER (CRUSHER)
APPEARANCE
10-132 BZ210-1
(1)
1. Crusher case 5. Soil cutter motor

2. Crusher open/close case 6. Rotary hammer motor No. 1
3. Crusher case open/close cylinder 7. Rotary hammer motor No. 2
4. Inspection cover 8. Rotary hammer motor No. 3
BZ210-1 10-133
(1)
SECTION VIEW (CLOSE-UP)
10-134 BZ210-1
(1)
1. Soil cutter
2. Rotary hammer No. 1
Unit: mm

Clearance between mount- size clearance limit
Shaft Hole
5 ing pin and bracket of Replace
crusher open/close cylinder –0.090 +0.2 0.190 –
30 1.0
–0.130 +0.1 0.330
Clearance between mount-
–0.090 +0.117 0.170 – Replace
6 ing pin and bushing of 30 —
–0.130 +0.080 0.247 bushing
crusher open/close cylinder
Clearance between crusher
–0.090 +0.2 0.190 –
7 case connection pin and 30 — Replace
–0.130 +0.1 0.330
case
BZ210-1 10-135
(1)
SOIL CUTTER
10-136 BZ210-1
(1)
1. Arm 9. Soil cutter shaft cover

2. Soil cutter motor 10. Retainer
3. Coupling 11. Holder
4. Flange 12. Cover
5. Seal cage 13. Retainer
6. Holder 14. Retainer
7. Retainer 15. Set pin for maintenance
8. 18 cutters
Unit: mm

Clearance between arm con- size Shaft Hole clearance limit
16
nection pin and arm
–0.025 +0.5 0.125 –
40 —
–0.064 +0.1 0.564
Clearance between arm con- +0.130 +0.039 0.130 –
17 40 1.0
nection pin and bushing +0.070 0 0.109
Replace
Interference between soil +0.039 +0.046 0.039 –
18 55 —
cutter shaft and retainer +0.020 0 –0.026
Interference between soil +0.039 0 0.020 –
19 55 —
cutter shaft and bearing +0.020 –0.015 0.054
Clearance between holder 0 +0.063
20 125 0 – 0.103 —
and arm –0.040 0
BZ210-1 10-137
(1)
ROTARY HAMMER
10-138 BZ210-1
(1)
1. Crusher case 9. Hammers (12 × 3)

2. Rotary hammer motor 10. Rotary hammer shaft
3. Coupling 11. Case
4. Flange 12. Spacer
5. Flange 13. Flange
6. Flange 14. Cover
7. Retainer 15. Holder
8. Case 16. Holder
Unit: mm

Clearance between rotary size clearance limit
Shaft Hole
17 hammer connection pin and
hammer Shaft: 36 +0.3 0 0.600 –
—
Hole: 35.5 +0.1 –0.1 0.900
Replace
Clearance between rotary +0.039 +0.3 0.061 –
18 65 —
hammer shaft and retainer +0.020 +0.1 –0.280
Interference between rotary +0.039 0 0.020 –
19 65 —
hammer shaft and bearing +0.020 –0.015 0.054
BZ210-1 10-139
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOIL BELT CONVEYOR
SOIL BELT CONVEYOR
1. Soil belt conveyor (Iron shoe type) 7. Soil belt conveyor frame
2. Soil belt conveyor speed sensor (limit switch) 8. Idler cushion
3. Soil belt conveyor motor 9. Idler
4. Sprocket 10. Carrier roller (without flange)
5. Seal 11. Carrier roller (with flange)
6. Mixer 12. Slide plate
10-140 BZ210-1
(1)
BZ210-1 10-141
(1)
IDLER AND IDLER CUSHION
10-142 BZ210-1
(1)
1. Idler
2. Floating seal
3. Support
4. Idler shaft
5. Bushing
6. Plate
7. Cylinder
8. Recoil spring
9. Bracket
10. Nut
11. Lubricator
12. Rod
Specifications
Idler cushion grease refilling amount: 120 cc
Idler lubricating oil refilling amount: 20 cc
Unit: mm
Outer diameter (OD) of pro- Standard size Repair limit

13
truding portion 377 339
14 Tread OD 335 327 Rebuild or
15 Width of protruding portion 39 31 replace
16 Total width 75 70
17 Tread width 18 22

Clearance between shaft size Shaft Hole clearance limit Replace
18
and bushing bushing
–0.025 +0.142 0.105 –
35 1.5
–0.064 +0.080 0.206
19 Idler side clearance
0.25 1.0
Replace
Free Installed Installed Free Installed
20 Recoil spring length length load length load
26.9 kN 24.0 kN
302 238.2 295.0
{2,748 kg} {2,446 kg}
BZ210-1 10-143
(1)
CARRIER ROLLER (WITH FLANGE)
Unit: mm

1 Flange OD
123 117 Rebuild or
2 Tread OD 95 87 replace
3 Flange width 41 35
4 Total width 110 — —
5 Tread width 34.5 37.5 Rebuild or
6 Tread thickness 26.5 22.5 replace

Clearance between shaft size Shaft Hole clearance limit
7
and busing
–0.025 +0.142 0.105 –
35 1.5
–0.050 +0.080 0.192
Replace
Tolerance Standard bushing
Standard Interfer-
interfer-
Interference between roller size Shaft Hole ence limit
8 ence
and bushing
+0.079 +0.039 0.015 –
42 —
+0.054 0 0.079
9 Roller side clearance Replace
0.25 0.81
10-144 BZ210-1
(1)
CARRIER ROLLER (WITHOUT FLANGE)
Unit: mm
Standard size Repair limit Rebuild or

1 Tread OD
70 65 replace
2 Tread width 100 — —

Rebuild or
3 Tread thickness 9 6.5
replace
Tolerance Standard
Standard Interfer-
interfer-
Clearance between shaft size Shaft Hole ence limit
4 ence
and bearing
+0.013 0 –0.023 – Replace
25 —
–0.008 –0.010 0.008
Interference of roller and 0 +0.018 –0.012 –
5 52 —
bearing –0.013 –0.012 0.031
BZ210-1 10-145
(1)
SHOE
1. Regular bushing Specifications

2. Regular pin Shoe width : 610 mm
3. Master bushing Link pitch : 135 mm
4. Master pin No. of shoes : 64 shoes (32 × 2 rows)
5. Shoe
6. Link
7. Shoe nut
8. Shoe bolt
10-146 BZ210-1
(1)
SOIL HOPPER AND RAKING ROTOR
10-148 BZ210-1
(1)
1. Soil hopper 7. Cover

2. Raking rotor motor 8. Raking rotor shaft
3. Plate 9. Bracket
4. Plate 10. Plate
5. Raking rotor frame 11. Bearing unit
6. Raking rotor
Unit: mm
Tolerance Standard
Standard Interfer-
interfer-
Interference between rotor size Shaft Hole ence limit
12 ence Replace
shaft and bearing unit
0 0 0.015 –
65 —
–0.030 –0.015 –0.030
BZ210-1 10-149
(1)
HOPPER FRAME
10-150 BZ210-1
(1)
1. Hopper frame
2. Guard
3. Stopper bracket
4. Weight
5. Lever assembly
6. Plate
7. Shaft
8. Proximity switch
BZ210-1 10-151
(1)
10-152 BZ210-1
(1)
1. Base
2. Blade
3. Plate
4. Solidifying material feeder motors (3 pcs)
5. Cover
6. Cover
7. Case
8. Feeder
9. Plate
10. Circle
11. Proximity switch
12. Plate
13. Bearing housing
BZ210-1 10-153
(1)
SOLIDIFYING MATERIAL HOPPER
10-154 BZ210-1
(1)
1. Solidifying material hopper

2. Solidifying material detection paddle switch
3. Inspection cover
4. Cover
5. Shutter
6. Cover
7. Shaft
8. Cover
9. Cutter
10. Net
11. Beacon light (red)
12. Monitor lamp (green)
13. Solidifying material display lamp
BZ210-1 10-155
(1)
DISCHARGING BELT CONVEYOR
10-156 BZ210-1
(1)
1. Mount bracket 14. Belt cleaner

2. Mount bracket 15. Motor flange
3. Mount bracket 16. Carrier roller
4. Conveyor frame 17. Roller bracket
5. Mount bracket 18. Guard
6. Belt 19. Tail pulley
7. Discharging belt conveyor motor 20. Tail pulley shaft
8. Hydraulic pressure hose assembly 21. Tail plate
9. Roller 22. Tail plate
10. Snap roller 23. Slide plate
11. Head pulley 24. Bar
12. Bearing 25. Tail pulley bracket
13. Plate 26. Belt tension adjusting bolt
BZ210-1 10-157
(1)
AFTERCUTTER
10-158 BZ210-1
(1)
1. Mount bracket
2. Cover
3. Cutter shaft
4. Arm
5. Cutter
6. Cover
7. Bearing
8. Coupling
9. Flange
10. Aftercutter motor
11. Cover
BZ210-1 10-159
(1)
CRANE
1. Crane
2. Crane control box
3. Crane mounting bracket
10-160 BZ210-1
(1)
Crane Specifications
Crane type MC-J263AW (Special)
Lifting capacity 2.63 tons
Crane capacity 4.20 tons•m (2.63 tons × 1.6 m)
Maximum working
6.493 m
range
Boom length 2.88 – 6.675 m
Boom stroke 1.90 m + 1.895 m = 3.795 m
Performance
Winding speed
40 m/min (4th layer)
(rope speed)
Hook winding speed
10 m/min (4th layer)
(4 rope windings)
Boom extension
3.795 m/19 sec.
speed
Boom rise time 1º – 75º /10 sec.
Swing range 360º (continuous)
Swing speed 1.6 rpm
Double-action hydraulic cylin-
der, direct pushing type; 2 sets
Boom extract/
(Direct coupling to automatic
retract device
hydraulic lock device)
(2- and 3-stage sequential)
Double-action hydraulic cylin-
Boom rise/ der, direct pushing type; 2 sets
fall device (Direct coupling to automatic
hydraulic lock device)
Axial plunger motor and spur
Winch
Equipment and Structure
reduction gear
Winch brake Automatic mechanical brake
Hydraulic motor drive warm
Swing device and spur reduction gear
(supported by ball bearings)
Swing brake Automatic motor lock device
Automatic 3-stage, pentangular
Boom
boom
2.6-ton capacity, and 4 rope
Hook
windings
A1. Boom Down (to derrick cylinder head) Configuration: 6 × WS (26) ø8
A2. Hook Down (to winch motor B port) Winch rope
mm dia. × 45 m
A3. Boom Extract (to telescopic cylinder bottom section)
Automatic storage by dedicate
A4. Left swing (to swing motor A port) Hook storage
lever operation
B1. Boom Up (to derrick cylinder bottom section)
B2. Hook Up (to winch motor A port) Radio control Specific small electric power
device type
B3. Boom Retract (to telescopic cylinder head)
B4. Right swing (to swing motor B port) Hydraulic pressure safety valve
P. Pump port Automatic hydraulic lock device
Safety devices
T. Tank port
Overload protection device (load meter)
G. For release of swing motor brake
D2. For connection of swing motor drain Overwinding protection device
Load protection device
Load indicator (with angle meter)
Sling wire rope holder
BZ210-1 10-161
(1)
HYDRAULIC CIRCUIT DIAGRAM OF CRANE
ELECTRIC CIRCUIT DIAGRAM OF CRANE
10-162 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
• The monitor system monitors the condition of the

machine with sensors installed on various parts
of the machine. It processes and immediately
displays the obtained information on the panel
notifying the operator of the condition of the ma-
chine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when the
machine has troubles.
2. Gauge section to display the condition con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
• The monitor panel also has various switches and
functions to operate the machine control system.
• The monitor system provides the functions to set
up the work load, solidifying material addition
amount, and mixing operations.
BZ210-1 10-163
(1)
1. Monitor panel
Outline
• The monitor panel has the functions to display
various items and the functions to select modes
and electric parts.
The monitor panel has a CPU (Central Process-
ing Unit) in it to process, display, and output the
information.
The monitor display unit consists of LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
10-164 BZ210-1
(1)
Input and output signals

CN-P01 CN-P02 CN-P03
Pin Input/ Pin Input/ Pin Input/
Signal name Signal name Signal name
No. output No. output No. output
1 Key ON Input Engine water tempera- 1 NC Input
1 Input
2 Key ON Input ture 2 NC Input
3 NC 2 Fuel level Input 3 NC Input
4 Starting signal Input 3 Radiator water level Input 4 NC Input
5 NC 4 NC 5 NC Input
6 GND 5 Air cleaner clogging Input 6 NC Input
7 GND 6 NC 7 Serial CTR signal Input
8 VB + Input 7 Engine oil pressure Input 8 Serial RTS signal Input
9 NC 8 Engine oil level Input Input/
9 Serial TXD signal
10 NC Output
Input/
9 N/W signal
11 NC Output
Input/
10 Serial RXD signal
12 NC Output
Input/
10 N/W signal
Output 11 Boost switch Input
11 Battery charge Input 12 NC
Hydraulic oil tempera- 13 GND

12 Input
ture (analog) 14 Cancel (Shield) Input
13 GND (for analog signal) 15 Cancel (Positive) Input
14 NC 16 Cancel (Negative) Input
15 NC
16 NC
17 NC
18 Preheat Input
19 Light switch Input
20 N/W GND
BZ210-1 10-165
(1)
MACHINE OPERATION AND DISPLAY SECTION (ALL INDICATORS ARE LIT.)
1. Service meter 14. Fuel level monitor

2. Mode monitor 15. Crane operation monitor
3. Radiator water level monitor 16. Hydraulic oil temperature gauge
4. Charge level monitor 17. Hydraulic oil temperature monitor
5. Engine water temperature gauge 18. Work load setup monitor
6. Engine oil pressure monitor 19. Solidifying material addition amount monitor
7. Engine water temperature monitor 20. Engine water temperature gauge
8. Preheating monitor 21. Work load accumulation monitor
9. Eco-accelerator setup monitor 22. Solidifying material addition accumulation monitor
10. Soil presence monitor 23. Fuel gauge
11. Engine oil temperature monitor 24. Operation status monitor
12. Air cleaner clogging monitor 25. Maintenance time monitor
13. Fuel gauge
10-166 BZ210-1
(1)
MONITOR ITEMS AND DISPLAY
Symbol Display item Display method
Continuous set time Preheating monitor status

Up to 30 sec. ON
Preheating
From 30 sec. to 40 sec. Flashes
SAP00526
More than 40 sec. OFF
Engine water
—
temperature
Hydraulic oil See gauge display on the next page
—
temperature
— Fuel level
BZ210-1 10-167
(1)
Temperature,
Gauge Range Indicator Buzzer sound
volume
A1 105 Red
A2 102 Red
Engine water temper- A3 100 Green

ature (ºC) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil temper- B3 100 Green

ature (ºC) B4 80 Green
B5 40 Green
B6 20 White
C1 289 Green
C2 244.5 Green
C3 200 Green
Fuel level (l)
C4 100 Green
C5 60 Green
C6 41 Red
10-168 BZ210-1
(1)
Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil
temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are dis-
played.
Check before When engine is When engine is

Symbol Display item
starting item stopped running
When abnormal, lights

Engine oil pressure --
up and buzzer sounds
SAP00519
Battery charge -- Lights up when abnormal

SAP00522
Radiator water When abnormal, lights

Lights up when abnormal
level up and buzzer sounds
SAP00520
Engine oil level Lights up when abnormal --

SAP00523
Air cleaner
-- Lights up when abnormal
clogging
SAP00521
Lights up when there is a warning. Lights up for only

Maintenance
30 sec. after key is turned ON, then goes out.
The problems that have occurred are displayed in order from the left.
When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is dis-
played.
Condition of hydraulic oil Color of symbol
Low temperature (below B6 or equivalent) Black on white background

Normal (B6 - B2) No display
High temperature (above B2) White on red letters
BZ210-1 10-169
(1)
During work time (Related items are always indicated.)
Category Symbol Display item Display range Display method
Soil presence/ The soil sensor status is indi-

Soil sensor (ON or OFF)
absence cated
It is displayed at the cen-

ter immediately after
Mixer mode The set mode is shown
setup. Hi, Mi, Lo or Sand
is shown in the work mode
It is displayed at the cen-
ter immediately after
Travel speed The set speed is shown.
setup. Lo, Mi or Hi is
shown
Operating or Released The operating status is

Eco-accelerator
status shown.
Displayed in the Manual The operation status is

Manual mode
mode. shown.
When the Crane Main SW is

turned ON:
• Lights when the Crane
Operating or Released Manual/Radio Control SW
Monitor Crane
status is set to "Radio Control".
• Lights when the Crane
Manual/Radio Control SW
is set to "Manual".
On the Work Mode Main

Setup work load The set work load is shown
Screen
Cumulative Work On the Work Mode Main The cumulative work load is
Load Screen shown
Specified solidify- The specified solidifying

On the Work Mode Main
ing material addi- material addition amount is
Screen
tion amount shown
Cumulative solidify- The cumulative solidifying

On the Manual Mode
ing material addi- material addition amount is
Main Screen
tion amount shown
Each equipment On the Manual Mode The status of each equipment

status Main Screen is shown
Service Service meter indi- When the service meter is Lights when the service
Meter cator operating meter is operating
10-170 BZ210-1
(1)
SWITCH PANEL
1. Mode selector switch (Numeric key 1) 9. LCD monitor adjustment switch (Numeric key 3)
2. Soil/Solidifying material set switch (Numeric key 4) 10. Clogging history switch (Numeric key 6)
3. Set switch for setting of other items (Numeric key 7) 11. Printer switch (Numeric key 9)
4. Check switch of set items 12. Maintenance switch
5. Buzzer cancel switch (Numeric key 2) 13. Return/Clear switch
6. Mixer monitor screen selector switch (Numeric key 5) 14. Upward movement switch
7. Equipment monitor screen selector switch (Numeric key 8) 15. Downward movement switch
8. Machine monitor screen selector switch (Numeric key 0) 16. Entry confirmation switch
• Mode selector switch

Use this switch to set the mixture level of the
Mode
mixer. Display Status after setup
selected
When this switch is pressed, the Mixture Mode
screen appears for mode selection. When an
The hammer and soil cutter
operation mode is selected according to the rotate at high speed.
work level, the mixture level appropriate the H Hi
(Appropriate for soil improve-
works is set. ment by better soil mixing)
The "H" (High) mode limits the work rate to 60%.
rotate at the middle speed.
M Mid
(Appropriate for normal soil
improvement)
rotate at the low speed.
L Lo (Appropriate for better fuel
consumption and economic
operations)
* 1 : Serial No. 1001 – 1100 The hammer rotates at the

*1 S Sand
* 2 : Serial No. 1101 and up middle speed but the soil cutter
rotates at the low speed.
*2 G G (Appropriate for sandy soil
improvement)
BZ210-1 10-171
(1)
• Soil/Solidifying material switch • Equipment monitor screen selector switch

Sets the soil or solidifying material. When this Use this key to check the status of each equip-
key is pressed, the screen is switched between ment. When this key is pressed, the equipment
the solidifying material setup screen and soil status indicator screen is displayed for checking
setup screen, and the solidifying material addi- of the operating status of each equipment.
tion amount and work load can be set. The
addition amount of solidifying material (kg/m3), • Machine monitor screen selector switch
gravity, and modified coefficient can be set. Use this key to check the machine status. When
Also, the work load (m3/hour) and the modified this key is pressed, the machine status indica-
coefficient of soil can be set. tion screen is displayed for checking of the
engine water temperature, hydraulic oil temper-
• Set switch for setting of other items ature, and fuel level.
Use this key to set the attachments and others.
When this key is pressed, the main screen for • LCD monitor adjustment switch
setting of other windows is displayed for setup of Use this key to adjust the liquid crystal display
various items. (LCD) brightness and contrast levels.
• Check switch of set items • Clogging history switch

Use this key to set the raking rotor rotation direc- Use this key to check the clogging history of
tion and check the other setup items. When this each equipment. When this key is pressed, the
key is pressed, the main screen for setting of clogging history display screen of each equip-
other windows is displayed for checking of vari- ment is displayed. It can be used for checking
ous items. of the equipment which was stopped due to
overloading and the number of times when the
• Buzzer cancel switch equipment was stopped. If the equipment was
Use this key to stop the buzzer if a machine NOT stopped due to clogging, nothing is dis-
error is detected and the buzzer sounds on the played on the screen.
multiple monitor. The buzzer sounds during:
• Coolant level error • Printer switch
• Engine oil pressure error Use this key to set up the printer and print out an
• Overheat of engine water temperature information.
• Fuel dial potentiometer error
• Pump PC-EPC valve disconnection or short- • Maintenance switch
circuiting Use this key to check the maintenance item sta-
• Governor motor A, B phase disconnection or tus. When this key is pressed, the maintenance
shortcircuiting item screen is displayed. When each item is
selected, its maintenance period and status can
• Mixer monitor screen selector switch be checked.
Use this key to check the work load and the
solidifying material. When this key is pressed, • Screen operation switches
the mixer setup screen is displayed for checking (Return, Upward movement, Downward move-
of the specified work load, specified solidifying ment, and Entry confirmation switches)
material addition amount, cumulative work load, Use these keys to check the maintenance items.
and cumulative solidifying material addition
amount.
10-172 BZ210-1
(1)
EXPLANATION OF FUNCTIONS
Mixer Mode Setup function
• Use this key to set or change the mixer parame-

ter. When an operation mode is selected accord-
ing to the desired operation, an appropriate
mixer parameter is selected. However, the up-
per limit of work load is limited to 60% in the H
mode.
Mode
Display Status after setup
selected

rotate at high speed.
H Hi
(Appropriate for soil improve-
ment by better soil mixing)
rotate at the middle speed.
M Mid
(Appropriate for normal soil
improvement)
rotate at the low speed.
L Lo (Appropriate for better fuel
consumption and economic
operations)
The hammer rotates at the
*1 S Sand
middle speed but the soil cutter
rotates at the low speed.
*2 G G (Appropriate for sandy soil
improvement)
* 1 : Serial No. 1001 – 1100

* 2 : Serial No. 1101 and up
How To Use
a Use the mixer mode setup function on the nor-
mal operation screen.
a The following gives an example to switch the "L
mode" to the "H mode."
1. Press Mixer monitor screen selector switch (1)

to call the Mixer Mode Setup screen.
a Select "03 L" (Current setup) to highlight it on
the Mixer Mode Setup screen.
2. Enter "01" to select the mode using keys (14)

and (15) or their numeric keys.
a Shift the cursor to "01 H" (After modification)
to highlight it.
3. After the selection has completed, press key

(16). The H mode (Hi) marking will be displayed
at the center of the screen, and the normal work
screen will be displayed again.
a The "H Mode" is displayed at the left upper
end position of the normal work screen.
BZ210-1 10-173
(1)
FUNCTION OF SETTING SOIL AND

SOLIDIFYING MATERIAL
• This function is used to set or change the items
related to soil and solidifying material. As for the
solidifying material, the quantity of solidifying ma-
terial (kg/m3), specific gravity, and correction co-
efficient can be set. As for the soil, the production
(m3/H) and correction coefficient can be set.
a The circled numbers in the figure show the
numeral keys.
Using method
a Use this function while the ordinary work screen
is displayed.
a In this section, the procedure for changing the
quantity of the solidifying material from "60" to
"100" is explained as an example.
1. Press soil/solidifying material setting switch (2)
of the monitor to go to the solidifying material
setting screen.
a Quantity of "60" is reverse highlighted in the
solidifying material setting screen.
a When selecting either of the other 2 items
(coefficient or specific gravity), press opera-
tion switch (14) or (15).
2. After selecting, press input check switch (16).
The "box" to input a value is reverse highlighted
at the right upper part of the setting screen.
3. Input quantity of "100" with the numeral keys.
a Input a value within the solidifying material
setting range.
4. After inputting the value, press input check
switch (16).
The changed value "100" is displayed as the
quantity.
5. Change the other 2 items (coefficient and spe-
cific gravity) and press operation switch (14) or
(15) to select "Soil".
a The cursor moves and "Soil" is reverse high-
lighted.
The soil setting screen appears.
7. Similarly to the solidifying material, set the pro-
duction and correction coefficient.
8. After changing the values in the soil setting
screen, press operation switch (14) or (15) to
select "Main".
a The cursor moves and "Main" is reverse
highlighted.
The screen before pressing soil/solidifying mate-
rial setting switch (2) appears.
10-174 BZ210-1
(1)
a When the quantity of the solidifying material is

set, the automatic production correcting screen
may appear.
If it appears, perform the following.
1) Press operation switch (14) or (15) or
numeral keys to select "00 YES".
a The cursor moves and "00 YES" is re-
verse highlighted.
2) After selecting, input check switch (16).
Then, the quantity is set first and the pro-
duction is corrected to the settable maxi-
mum value automatically.
a If "01 NO" is selected, setting is returned to the
default values (shown below) (Note that setting
does not return to the values before correction).
<Default values>
• Production : 50 m3/h
• Production correction coefficient : 1.00
• Quantity of solidifying material : 50 kg/m3
• Solidifying material correction coefficient
: 1.00
• Specific gravity of solidifying material
: 1.0
BZ210-1 10-175
(1)
FUNCTION OF SETTING ATTACHMENT

• This function is used to set or change an attach-
ment.
• When installing an attachment, you are required
to register and set it.
When changing the attachment according to the
type of work, you are required to change its set-
ting.
Using method
is displayed.
a In this section, the procedure for changing
"ATT1" from the aftercutter to the belt conveyor
is explained as an example.
1. Press other item setting switch (3) of the monitor
to go to the other item setting screen.
a "00 RETURN" is reverse highlighted in the
other item setting screen.
2. Press operation switch (14) or (15) to select "01

Setting ATT".
a The cursor moves and "01 Setting ATT" is
reverse highlighted.
"OK" is displayed at the right lower part of the
other item setting screen, and then the Set ATT
screen appears.
Set ATT screen.

ATT1" to be changed in the Set ATT screen.
a The cursor moves and "01 ATT1" is reverse
highlighted.
The Set ATT1 screen appears.
a "02 Aftercutter" (the current setting) is re-
verse highlighted in the Set ATT1 screen.
10-176 BZ210-1
(1)

Conveyor" instead of "02 After cutter".
a The cursor moves and "01 Conveyor" (the
changed setting) is reverse highlighted.
ATT1 setting screen, and then the Set ATT
screen appears.
a "01 ATT1: Conveyor" is reverse highlighted
in the Set ATT screen.
a The attachment of "ATT1" is changed by the
above operation.
a Change or set ATT2 and ATT3 similarly to ATT1.
a The items of the air compressor are changed
differently from ATT1 - ATT3. Select "Installed"
or "Not installed" for them.
The procedure for changing and setting those
items is as follows.
1) Press operation switch (14) or (15) to select
"04 Air compressor".
a The cursor moves and "04 Air compres-
sor" is reverse highlighted.
2) After selecting, press input check switch
(16).
The air compressor setting screen appears.
a "01 Equipment" (the current setting) is
displayed on the air compressor setting
screen.
3) Press operation switch (14) or (15) to select
"02 Not equipment".
a The cursor moves and "02 Not equip-
ment" (the changed setting) is reverse
highlighted.
4) After selecting, press input check switch
(16).
"OK" is displayed at the right lower part of
the air compressor setting screen, and then
the Set ATT screen appears.
a "04 Air compressor: Not equipment" is
reverse highlighted in the Set ATT
screen.
BZ210-1 10-177
(1)
FUNCTION OF SETTING CUMULATIVE

VALUE DISPLAY
• The cumulative value display is set to "Show"
when the machine is delivered. This function is
used not to use the cumulative value display.
Using method
is displayed.
d isp la y fr om "Show" to "Do not sho w" is
explained as an example.
setting option screen.

cumulative value".
a The cursor moves and "02 cumulative value"
is reverse highlighted.
other item setting screen, and then the cumula-
tive value showing screen appears.
a "01 Show" is reverse highlighted in the cu-
mulative value showing screen.

Do not show" in the cumulative value showing
screen.
a The cursor moves and "02 Do not show" is
cumulative value showing screen, and then the
other item setting screen appears.
a "02 Setting cumulative value" is reverse
highlighted in the setting option screen.
10-178 BZ210-1
(1)
FUNCTION OF SETTING CLOCK

• If the service power is turned OFF by disconnect-
ing the battery case, etc., the clock must be set
again.
If the power is turned OFF, the multi-monitor dis-
plays error code 12.
Using method
clock display from "Year: 99, Month: 12, Day:
31, Hour: 12, Minute: 59" to "Year: 01, Month:
02, Day: 03, Hour: 04, Minute: 05" is explained
as an example.
Setting clock time".
a The cursor moves and "03 Setting clock
time" is reverse highlighted.

other item setting screen, and then the clock
setting screen appears.
a "Year: 99, Month: 12, Day: 31, Hour: 12,
Minute: 59" is reverse highlighted in the
clock setting screen.
4. Press operation switch (14) or (15) to select item

to be changed (Year, Month, Day, Hour, or
Minute) in the clock setting screen.
a The cursor moves and the selected item in
the clock setting screen is reverse highlight-
ed. In this example, select the year of "99".
a "OK" is displayed at the right lower part of the
clock setting screen, and you can input a val-
ue.
6. Press numeral keys "0" and "1" to input the year
of "01".
a The input year of "01" is reverse highlighted.
BZ210-1 10-179
(1)
7. Using operation switches (14) and (15), select

the month, day, hour, and minute and input a
new value for each of them with the numeral
keys.
a Leave an item which does not need to be
changed as it is. Input a new value for only
an item which needs to be changed.
8. After inputting the values for the items to be
changed, press input check switch (16).
clock setting screen, and then the setting option
screen appears.
10-180 BZ210-1
(1)
FUNCTION OF SETTING CHOICE OF

• This function is used to set or change the type of
the solidifying material feeder.
Using method
is displayed.
type of the solidifying material feeder from
"small amount" to "standard" is explained as an
example.
to go to the setting option screen.
Choice of S.M feeder".
a The cursor moves and "04 Choice of S.M
feeder" is reverse highlighted.

setting option screen, and then the Choice of
S.M feeder setting screen appears.
a "02 Small amount" is reverse highlighted in
the Choice of S.M feeder setting screen.

STD" in the Choice of S.M feeder setting screen.
a The cursor moves and "01 STD" is reverse
highlighted.
Choice of S.M feeder setting screen, and then
the setting option screen appears.
a "04 Choice of S.M feeder" is reverse high-
lighted in the other item setting screen.
BZ210-1 10-181
(1)
FUNCTION OF SETTING ROTOR

ROTATION FWD/REV
• When sand is used as material, if the raking rotor
turns in the normal direction, it repeats automatic
reverse operation frequently because as it is
overloaded and the working efficiency is low-
ered.
In this case, automatic reverse operation caused
by overload can be prevented and the working
efficiency is improved by normally turning the
raking rotor in the reverse direction.
Using method
is displayed.
turning direction of the raking rotor from "for-
ward" to "reverse" is explained as an example.

Rotor rotation FWD/REV".
a The cursor moves and "05 Rotor rotation
FWD/REV" is reverse highlighted.
setting option screen, and then the Setting rotor
running direction setting screen appears.
a "01 FWD" is reverse highlighted in the Set-
ting rotor running direction setting screen.

REV" in the Setting rotor running direction set-
ting screen.
a The cursor moves and "02 REV" is reverse
highlighted.
Setting rotor running direction setting screen,
and then the setting option screen appears.
a "05 Rotor rotation FWD/REV" is reverse
highlighted in the setting option screen.
10-182 BZ210-1
(1)
FUNCTION OF SETTING USE OF SOIL

CUTTER
• If the soil contains much gravel, the effect of the
soil cutter is reduced. In this case, the soil cutter
should be raised so that it will not be used. This
function is used for this purpose.
Even if the soil cutter is set to "Do not use", it re-
volves at speed of about 50 rpm so that soil will
not stick to it.
Using method
is displayed.
soil cutter from "use" to "disuse" is explained as
an example.

Use of soil cutter".
a The cursor moves and "06 Use of soil cutter"
setting option screen, and then the soil cutter
use setting screen appears.
a "01 Use" is reverse highlighted in the soil cut-
ter use setting screen.

Do not use" in the soil cutter use setting screen.
a The cursor moves and "02 Do not use" is re-
verse highlighted.
soil cutter use setting screen, and then the set-
ting option screen appears.
a "06 Use of soil cutter" is reverse highlighted
in the setting option screen.
BZ210-1 10-183
(1)
FUNCTION OF SETTING SOIL CUTTER CONTROL PRESSURE
Serial No. 1101 and up

• If the soil contains much gravel or many stones, the sensor senses rise of the soil cutter motor pressure and
this function is used to lower the soil cutter speed temporarily so that the gravel will pass easily.
• Change the sensing pressure of the motor in the following cases.
The sensing pressure can be set in the range from 7.8 to 34.3 MPa {from 80 to 350 kg/cm2} and is set to 7.8
MPa {80 kg/cm2} when the machine is delivered.
When soil contains much gravel

Lower the sensing pressure (to 7.8 MPa {80 kg/cm2}, for example) so that the gravel will pass easily.
When handling hard clay, sludge cake, etc.

Heighten the sensing pressure (to 34.3 MPa {350 kg/cm2}, for example) to maintain the quality of the
improved soil without lowering the cutter speed even when the motor drive pressure is high.
Setting method
1. In the setting screen, select "11: Cutter ctrl.
pressure" and press input check switch (c).
"OK" is displayed at the right lower part, and
then the setting cutter control screen appears.
The figure at right shows the screen in which
"11: Cutter ctrl. pressure" is selected and input
check switch (c) is pressed.
"OK" disappears soon.
2. "OK" disappears and the setting cutter control

screen appears.
3. If the UP or DOWN switch (b) is pressed in this

screen, the selected part changes.
Select "01: Change" and press input check
switch (c).
"OK" is displayed at the right lower part, and
then the setting cutter control screen appears.
10-184 BZ210-1
(1)
4. Press the UP or DOWN switch (b) to select a

number, and then press input check switch (c).
The box to input a value appears.
5. Input a desired value with the numeral keys.

The input value is displayed.
If the input value is correct, press input check
switch (c).
The set pressure in the screen changes.
In the example of the screen at right, the set
pressure is set to 34.3 MPa {350 kg/cm2}.
6. Press UP or DOWN switch (b) to move to

"RETURN", and then press input check switch
(c).
"OK" is displayed and the setting option screen
appears.
BZ210-1 10-185
(1)
FUNCTION OF SETTING
ECO-ACCELERATOR
• This function is used to control the engine speed
automatically to the necessary minimum level
according to each working condition and ma-
chine condition to reduce the fuel consumption.
Using method
is displayed.
eco-accelerator from "OFF" to "ON" is explained
as an example.

a The cursor moves and "06 Use of soil cutter
" is reverse highlighted.
3. Press operation switch (15) to display "07 Eco-
accelerator" and the set items after it.
a "07 Eco-accelerator" is reverse highlighted

setting option screen, and then the setting eco-
accelerator screen appears.
a "02 Eco-accelerator OFF" is reverse high-
lighted in the setting eco-accelerator screen.
10-186 BZ210-1
(1)

Eco-accelerator ON" in the eco-accelerator set-
ting screen.
a The cursor moves and "01 Eco-accelerator
ON" is reverse highlighted.
setting eco-accelerator screen, and then the
setting option screen appears.
in the other item setting screen.
BZ210-1 10-187
(1)
FUNCTION OF SETTING BATCH

PROCESSING
• This function is used to set a length of time and
stop the soil belt conveyor automatically after
that time.
Example of use: This function is useful when it is
required to stop the work tempo-
rarily after each dump truck is
filled.
In this case, set the production
first, and then measure the time
required to fill a dump truck.
Set the measured time as the
batch process time.
Using method
is displayed.
batch process from "Do not batch-process" to
"Batch-proccess" is explained as an example.

a The cursor moves and "06 Use of soil cutter
" is reverse highlighted.

Batch processing".
a The cursor moves and "08 Batch process-
ing" is reverse highlighted.
setting option screen, and then the setting batch
process screen appears.
a "02 Do not batch-process" is reverse high-
lighted in the setting batch process screen.
10-188 BZ210-1
(1)

Batch-process" in the setting batch process
screen.
a The cursor moves and "01 Batch-process" is
setting batch process screen, and then the set-
ting batch process time screen appears.
a "60" minutes is reverse highlighted in the
setting batch process screen.
8. Press operation switch (14) or (15), and "60"
minutes and "RETURN" are reverse highlighted
alternately in the setting batch process time
screen.
Select "60" minutes.
a The cursor moves and "60" minutes is re-
verse highlighted.
9. Press input check switch (16).
The "box" to input a value appears at the right
upper part of the setting batch process time
screen.
10. Input the set time of "70" minutes with the
numeral keys.
a A value up to 99 can be input as the time.
11. After inputting, press input check switch (16).
setting batch process time screen, and then "60"
minutes changes to "70" minutes.
12. Press operation switch (14) or (15) to select

"RETURN" in the setting batch process time
screen.
a The cursor moves and "RETURN" is reverse
highlighted.
The setting batch process screen appears
again.
a The cursor moves and "01 Batch-process" is
a If "02 Do not batch-process" is selected in the
setting batch process screen, setting of the
batch process is reset and the setting option
screen appears again.
BZ210-1 10-189
(1)
FUNCTION OF SETTING SOLIDIFYING

MATERIAL ADDITION
• This function is used to stop adding solidifying
material for the second pass of soil which needs
to be passed twice.
a If stop of addition of solidifying material is set,
the integrated value of soil in the monitor does
not increase.
Using method
is displayed.
solidifying material from "Add" to "Do not add" is
explained as an example.

Soil cutter use".
a The cursor moves and "06 Use of soil cutter"

Addition of H.M.".
a "09 Addition of H.M." is reverse highlighted.
setting option screen, and then the setting S.M
addition screen appears.
a "01 Add" is reverse highlighted in the S.M
addition setting screen.
10-190 BZ210-1
(1)

Do not add" in the setting S.M addition screen.
a The cursor moves and "02 Do not add" is re-
verse highlighted.
setting S.M addition screen, and then the other
item setting screen appears.
a "09 Addition of H.M." is reverse highlighted in
BZ210-1 10-191
(1)
MAINTENANCE FUNCTION
When the time of replacement, check, or addition for
the 11 maintenance items approaches, if the mainte-
nance switch (12) is pressed, the caution lamp (yel-
low or red) lights up for 30 seconds in the monitor
display after the key is turned ON to urge the opera-
tor to maintain the oil and grease.
a Maintenance items
Replacement
Monitor period (h)
Maintenance item
No. Initial set
screen (H)
01 Engine oil 500

02 Engine oil filter 500
03 Fuel filter 500
04 Hydraulic oil filter 1000
Hydraulic tank
05 500
breather
06 Corrosion resistor 1000
07 Damper case oil 1000
08 Final drive case oil 2000
10 Hydraulic oil 5000
Soil belt conveyor
22 2000
motor oil
23 Raking rotor motor oil 5000
a The above replacement period is set for each

item and the time before the maintenance is
shortened as the machine is operated.
The contents of the displayed caution depends
on the time left. The relationship between them
is as follows.
Display Condition
Time before mainte-

None nance of every item is
longer than 30 hours.
Time before mainte-
Forecast display (Black
nance of 1 or more
symbol is displayed on yel-
items is shorter than 30
low background)
hours.
Warning display (White
Maintenance time of at
symbol is displayed on red
least 1 item has passed.
background)
10-192 BZ210-1
(1)
CHECK OF CONDITION OF MAINTENANCE

ITEM
a Use this function while the ordinary travel screen
is displayed.
1. Press maintenance switch (12) to display the
maintenance table screen.
a In this screen, the maintenance items are
displayed by symbols.
2. Press operation switch (14) or (15), or input a
maintenance item No. "01" to "08, "10", "22", or
"23" to select an item.
a The cursor moves and the selected item is
a Similarly to "Relationship between time left
and display of caution" in the previous page,
an item having 30 hours or less before the
maintenance time is indicated in yellow and
an item, the maintenance time of which has
passed, is indicated in red.
MAINTENANCE OPERATION
The maintenance reset screen appears.
2. Check the contents of the maintenance reset
screen. If there is no problem, press input check
switch (16) to go to the check screen.
To return to the maintenance table screen
because of a mistake, etc., press return switch
(13).
3. Check the contents of the check screen. If there
is no problem, press input check switch (16) to
reset the maintenance time.
After the maintenance is reset, the maintenance
table screen appears again. To return to the
maintenance table to check the current time left
or select another item, press return switch (13).
a In the check screen, the symbol of the main-
tenance item and the set time are displayed
in large sizes.
a If the maintenance time of an item is reset,
the background color of that item becomes
the same as the background color of the
screen so that the operator will see that the
maintenance time has been reset.
BZ210-1 10-193
(1)
FUNCTION OF ADJUSTING BRIGHTNESS

AND CONTRAST OF MONITOR
This function is used to adjust the brightness and
contrast of the display.
Adjusting method
a Use this function while the ordinary travel screen
is displayed.
1. Press LCD monitor adjustment switch (9) to dis-
play the adjustment screen.
a Relationship between each symbol in menu and
meaning
No. Symbol Meaning
00 Return mark Return
01 Contrast
02 Brightness
2. Press operation switch (14) or (15), or input "00"

to "02" to select the brightness or contrast.
The adjustment screen appears.
a You can return to the ordinary travel screen
by selecting "00" with return switch (13) or
the numeral keys and pressing input check
switch (16).
4. Press operation switch (14) or (15).
No. Symbol Meaning
14 Bar graph lengthens to right
15 Bar graph shortens to left
FUNCTION OF CHECKING SERVICE METER

• While the starting switch is turned OFF, hold
monitor return switch (13) and operation switch
(14) simultaneously, and the service meter is in-
dicated on the display.
• The service meter is indicated only when the
above 2 switches are held. If the switches are re-
leased, the service meter goes off. It takes 3 – 5
seconds to indicate the service meter after the
switches are held.
10-194 BZ210-1
(1)
USER CODE DISPLAY FUNCTION
• If the machine operation has failed, a user code

is displayed on the screen to prompt the operator
for an action to be taken.
• The user code is displayed at the hydraulic oil
gauge section.
• If multiple user codes are generated, all of them

are displayed one after the other every 2 sec-
onds.
• When the user code is displayed, press the

Check switch of set items. Both the service code
and the failure code will be displayed.
• If multiple service and/or failure codes are gener-

ated, all of them can be displayed one after the
other every 2 seconds. However, if a service or
failure code that does not cause the user code is
generated, it is not displayed by the User Code
Display function.
BZ210-1 10-195
(1)
• If a phone number has been set by the phone

number entry of the Service Menu, the phone
number can be displayed by switching the serv-
ice/failure code. For the phone number setup
details, see the "Monitor Panel Special Func-
tions" of Testing and Adjusting Section.
• When an error screen is displayed on the moni-

tor, press Check switch of set items (16) and the
above error screen will be switched to Screen A
(Service/failure code) and Screen B (Destination
phone number) as shown at right. Screens A
and B are switched every 3 seconds. However,
if the destination phone number is not registered
yet, screen B is not displayed.
10-196 BZ210-1
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS
SENSORS
• The signal from each sensor is input to the panel
directly.
Either side of a sensor of contact type is always
connected to the chassis ground.
Name of sensor Type of sensor When normal When abnormal
Engine oil level Contact ON (Closed) OFF (Open)
Engine oil pressure Contact OFF (Open) ON (Closed)
Hydraulic oil temperature Resistance — —
Coolant temperature Resistance — —
Fuel level Resistance — —
Clogging of air cleaner Contact OFF (Closed) ON (Open)
Proximity switch Resistance — —
Pressure switch Resistance — —
Solidifying material sens-
Contact OFF (Closed) ON (Open)
ing paddle switch
BZ210-1 10-197
(1)
Engine oil level sensor, Hydraulic oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Engine oil pressure sensor (For low pressure)
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Coolant temperature sensor, Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
10-198 BZ210-1
(1)
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
BZ210-1 10-199
(1)
Proximity switch
1. Switch
2. Operation indicator lamp
3. Connector
Pressure switch
(Raking rotor, discharge belt conveyor, soil
cutter, and rotary hammer)
Outline
• This pressure switch is an ON-OFF switch to 1. Pressure switch
prevent an overload. 2. Wiring harness
• This switch is installed to the inlet of the hy- 3. Connector
draulic motor. If the applied pressure reaches
the set pressure, this switch is turned OFF.
Specifications
For discharge belt
For raking rotor For soil cutter For rotary hammer
conveyor
Model name CE11-174-H
Pressure range
0 – 34.3 {0 – 350} 0 – 19.6 {0 – 200} 0 – 19.6 {0 – 200} 0 – 34.3 {0 – 350}
(MPa {kg/cm2})
Set pressure
10.8 {110} 18.6 {190} 14.7 {150} 16.2 {165}
(MPa {kg/cm2})
10-200 BZ210-1
(1)
Solidifying material paddle switch
1. Paddle
2. Shaft
3. Motor
4. Cable
5. Connector
Specifications Operation
Model name: DHL-100 1. When there is no solidifying material
Paddle speed: Approx. 2 rpm The paddle revolves freely. Accordingly, circuit
Static torque: Approx. 9.8 Nm {1 kgm} (5) from power supply (2) to the level indicator
lamp is connected and the solidifying material
Outline indicator lamp lights up.
• This switch is installed to the bottom of the solid- 2. When there is solidifying material
ifying material hopper to check presence of solid- The paddles is stopped by the solidifying mate-
ifying material. rial. Accordingly, circuit (5) from power supply
• If there is no solidifying material, the paddle re- (2) to the level indicator lamp is disconnected
volves freely. If there is solidifying material, the and the solidifying material indicator lamp goes
paddle stops because of the resistance of the so- off.
lidifying material.
Presence of the solidifying material is sensed by
revolution of the paddle.
BZ210-1 10-201
(1)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE ......................................................................................... 20-2
STANDARD VALUE TABLE FOR CHASSIS ....................................................................................... 20-3
TESTING AND ADJUSTING .................................................................................................................. 20-101
TROUBLESHOOTING ........................................................................................................................... 20-201
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert
k When carrying out work together with other workers, always use signals and do not let unauthorized
the safety pins, and use blocks to prevent the machine from moving.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed
people near the machine.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
when the water is still hot, the water will spurt out and cause burns.
BZ210-1 20-1
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Engine SAA6D102E-2
New machine Troubleshooting

Item Measuring conditions Unit
standard value standard value
High idling 2,150 ± 70 2,150 ± 70
Engine speed Low idling rpm 1,030 ± 50 1,030 ± 50
Rated rotation speed 1,950 1,950

During quick acceleration Max. 1.0 Max. 2.0
Exhaust gas color Bosch index
During high idling Max. 0.5 Max. 1.5
Intake valve 0.25 —
Valve clearance
mm
(in room temperature)
Exhaust valve 0.51 —
Oil temperature: 40 – 60 ºC MPa {kg/cm2} Min. 2.4 {Min.24.6} Difference between
Compression cylinders:
pressure Min. 1.0 {Min. 10.3}
(Engine speed: 250 rpm)
Within water temperature
operating range
Blow-by pressure kPa {mmH2O} Max. 1.2 {Max.123} 5.1 {520}
During rated output
Within water temperature
operating range
Hydraulic pressure
MPa {kg/cm2}
(SAE15W-40 oil) During high idling 0.39 – 0.64 {4.0 – 6.5} 0.25 {2.6}
During low idling Min. 0.15 {Min. 1.5} 0.09 {0.9}

Whole speed range
Oil temperature ºC 80 – 110 120
(within oil pan)
Fuel injection Before top dead center
º 11 ± 1 11 ± 1
timing (BTDC)
Deflection when pressed
Tension of fan belt with finger force of approx. mm 8 Min. 6, Max. 10
58.8 N {6 kg}
20-2 BZ210-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

.
Category Item Measuring conditions Unit
• Engine water temperature:
Within operating range
Engine • Hydraulic oil temperature:
During relief of a single pump rpm 2,000 ± 100 2,000 ± 100
speed Within operating range
• Engine high idling
• During travel relief (shoe lock)
Control
valve
All control valves mm 8.0 ± 0.5 8.0 ± 0.5
spool
stroke
Mixer unit open/close lever 28 ± 2 28 ± 2

• Engine stop
Operation • Center of lever
lever Travel lever • Read the maximum value until mm 112 ± 12 112 ± 12
stroke the stroke end (except for the
neutral play)
Play of operation lever Max. 20 Max. 30
• Hydraulic oil temperature:

Operation Within operating range
force of • Engine high idling 24.5 ± 5.9 Max. 39.2
Travel lever N {kg}
control • Center of lever {2.5 ± 0.6} {Max. 4.0}
lever • Read maximum value until stroke
end
• Engine high idling MPa 3.38 ± 1.0 3.38 ± 1.0
Unload pressure
• Pump output pressure when all {kg/cm2} {34.5 ± 10} {34.5 ± 10}
control levers are in neutral posi-
tion
Relief pressure of soil belt 19.1 ± 1.5 19.1 ± 2.0
conveyor motor {195 ± 15} {195 ± 20}
Relief pressure of raking rotor 14.8 ± 1.0 14.8 ± 1.5
motor {150 ± 10} {150 ± 15}
Relief pressure of (3 parallel) 21.6 ± 1.5 21.6 ± 2.0
solidifying material feeder motors {220 ± 15} {220 ± 20}
Hydraulic
pressure Relief pressure of soil cutter 20.2 ± 1.5 20.6 ± 2.0
motor • Hydraulic oil temperature: Within {205 ± 15} {220 ± 20}
operating range
Relief pressure of rotary hammer MPa 19.1 ± 1.5 19.1 ± 2.0
motors (No. 1, 2 and 3) {kg/cm2} {195 ± 15} {195 ± 20}
• Pump output pressure when
Relief pressure of mixer case measurement circuit is relieved 20.2 ± 1.5 20.2 ± 2.0
open/close cylinder {205 ± 15} {205 ± 20}
Relief pressure of discharging 20.2 ± 1.5 20.2 ± 2.0
belt conveyor motor {205 ± 15} {205 ± 20}
Relief pressure of aftercutter 20.2 ± 1.5 20.2 ± 2.0
motor {205 ± 15} {205 ± 20}
Relief pressure of (right and 35.8 ± 1.5 35.8 ± 2.5
left) travel motors {365 ± 15} {365 ± 25}
BZ210-1 20-3
(1)

Relief pressure of air com- 20.2 ± 1.5 20.2 ± 2.0

pressor motor {205 ± 15} {205 ± 20}
Relief pressure of secondary 20.2 ± 1.5 20.2 ± 2.0

belt conveyor motor {205 ± 15} {205 ± 20}
• Hydraulic oil temperature: Within
operating range
Relief pressure of tertiary belt MPa 20.2 ± 1.5 20.2 ± 2.0
conveyor motor {kg/cm2} {205 ± 15} {205 ± 20}
• Pump output pressure when
measurement circuit is relieved
Relief pressure of vibration 19.1 ± 1.5 19.1 ± 2.0
roller motor {195 ± 15} {195 ± 20}
Relief pressure of crane 19.1 ± 1.5 19.1 ± 2.0

(source pressure) {195 ± 15} {195 ± 20}
No-load operating pressure of 3.4 +2.0

–1.0 3.4 +3.0
–1.0
soil belt conveyor motor {35 +20
–10 } {35 +30
–10 }

–1.0 2.5 +3.0
–1.0
raking rotor motor {25 +20
–10 } {25 +30
–10 }
No-load operating pressure of 3.4 +2.0 3.4 +3.0

–1.0 –1.0
(3 parallel) solidifying material
feeder motors • Hydraulic oil temperature: {35 +20
–10 } {35 +30
–10 }
Hydraulic Within operating range
pressure No-load operating pressure of • Engine high idling MPa 2.9 +2.0
–1.0 2.9 +3.0
–1.0
soil cutter motor • Pump output pressure {kg/cm2} {30 +20
–10 } {30 +30
–10 }
• Manual mode
• Separate forward rotation 3.4 +2.0 3.4 +3.0
No-load operating pressure of –1.0 –1.0
rotary hammer motor {35 +20
–10 } {35 +30
–10 }
No-load operating pressure of 4.9 +2.0 4.9 +3.0

–1.0 –1.0
discharging belt conveyor
motor {50 +20
–10 } {50 +30
–10 }

–1.0 2.0 +3.0
–1.0
aftercutter motor {20 +20
–10 } {20 +30
–10 }

• Engine high idling MPa 3.23 ± 0.2 2.84 – 3.43
Control circuit source pressure
• Output pressure of self-reducing {kg/cm2} {33 ± 2} [29 – 35]
pressure valve when all control
levers are in neutral position
• Hydraulic oil tem- When all levers

perature: Within 3.9 ± 1.0 3.9 ± 1.0
are in neutral
operating range {40 ± 10} {40 ± 10}
position
• Engine high MPa
LS differential pressure
idling {kg/cm2}
• Pump output When half-
2.2 ± 0.1 2.2 ± 0.1
pressure – LS stroke travel-
{22 ± 1} {22 ± 1}
pressure ing (idling)
20-4 BZ210-1
(1)

Hydraulic drift of travel mm 0 0

• Engine stopped
• Face the sprocket upward and
stay on the 12º slope.
• Natural traveling distance of
machine for 5 minutes
Travel motor leakage l/min Max. 20 Min. 40

• Lock the shoe by lock pin (1) and
relief the travel circuit
Traveling

Travel speed • Hydraulic oil temperature: sec. 20.6 – 24.8 19.7 – 26.4
• Primary conveyor in travel posi-
tion
• The time required to travel 20
meters on a flat plane after 10-
meter or more runup
•Engine full speed
•Hydraulic oil temperature: 45 - 55 ºC
•Primary conveyor in travel position
•High travel speed
•The time required to travel 20 m
on a flat plane after 10 m or more
runup
aTravel on a horizontal firm plane
Travel deviation mm Max. 200 Max. 300
20m
10m BKP00107
aMeasure distance "x"
BZ210-1 20-5
(1)

Serial No. 1001 – 1100
Axis No. 1 650 – 750 620 – 780
H mode
Axis No. 2 950 – 1050 920 – 1080
Axis No. 3 1000 – 1100 970 – 1130
Axis No. 1 500 – 600 470 – 630
M mode
(1) Rotary hammer

Axis No. 2 rpm 550 – 650 520 – 680
speed (no load)
Axis No. 3 750 – 850 720 – 880
Axis No. 1 500 – 600 500 – 660
L mode
Axis No. 2 500 – 600 500 – 660

Axis No. 3 500 – 600 500 – 660
H mode 450 – 550 420 – 580
(2) Soil cutter
M mode rpm 135 – 165 125 – 175
speed
L mode 65 – 85 60 – 90
• Hydraulic oil tempera-
ture: Within operating
(3) Solidifying Minimum value 0.53 – 0.58 0.51 – 0.60
range
material feeder • Operating mode rpm
speed Maximum value • All work equipments 6.01 – 6.65 5.85 – 6.86
activated
Minimum value 1.93 – 2.61 1.71 – 3.17
Work equipment speed
(4) Belt speed of

soil belt con- m/min
Work equipment
veyer Maximum value 9.66 – 13.1 8.55 – 15.9
(5) Belt speed of discharging belt con-

m/min 70 – 90 65 – 95
veyor
(6) Aftercutter speed rpm 264 – 324 234 – 354
(7) Open/close Opening 13.5 – 20.5 10 – 24

time of mixer Separate opening/closing
sec.
case open/ of mixer case
close cylinder Closing 13.5 – 20.5 10 – 24
Telescopic Boom rise
Rise to fall 8.5 – 11.5 7.5 – 12.5

/fall
Fall to rise 6.5 – 8.7 5.7 – 9.5

(extraction)
Full extract 12.8 – 17.3 11.3 – 18.9
Full retract 14.5 – 19.6 12.8 – 21.3

(8) Crane operation
Separate crane operation sec.
time
Hoist up 4.9 – 6.7 4.4 – 7.3
Hoisting
Hoist down 4.9 – 6.7 4.4 – 7.3
Right swing 34.9 – 47.2 30.8 – 51.3

Swing
Left swing 34.9 – 47.2 30.8 – 51.3
20-6 BZ210-1
(1)

Axis No. 1 650 – 750 620 – 780
H mode
Axis No. 2 950 – 1050 920 – 1080
Axis No. 3 1000 – 1100 970 – 1130
Axis No. 1 500 – 600 470 – 630
M mode
Axis No. 2 550 – 650 520 – 680
(1) Rotary hammer Axis No. 3 750 – 850 720 – 880
rpm
speed (no load) Axis No. 1 500 – 600 500 – 660
L mode
Axis No. 2 500 – 600 500 – 660

Axis No. 3 500 – 600 500 – 660
Axis No. 1 500 – 600 500 – 660
G mode
Axis No. 2 550 – 650 520 – 680

Axis No. 3 650 – 750 620 – 780
H mode 450 – 550 420 – 580
(2) Soil cutter M mode • Engine high idling 135 – 165 125 – 175
rpm
speed L mode • Hydraulic oil tempera- 135 – 165 125 – 175
G mode ture: Within operating 214 – 236 204 – 248
range
(3) Solidifying Minimum value • Operating mode 0.53 – 0.58 0.51 – 0.60
material feeder • All work equipments rpm
speed activated 6.01 – 6.65 5.85 – 6.86
Maximum value
Work equipment speed
(9 – 9.94) (8.76 – 10.25)

Work equipment
(4) Belt speed of Minimum value 1.93 – 2.61 1.71 – 3.17

soil belt con- m/min
veyer 9.66 – 13.1 8.55 – 15.9
Maximum value
(14.2 – 19.2) (12.6 – 23.3)
(5) Belt speed of discharging belt con-
m/min 77 – 97 72 – 102
veyor
(6) Aftercutter speed rpm 243 – 287 215 – 314
(7) Open/close Opening 13.5 – 20.5 10 – 24
time of mixer Separate opening/closing
sec.
case open/ of mixer case
close cylinder Closing 13.5 – 20.5 10 – 24
Telescopic Boom rise
Rise to fall 8.5 – 11.5 7.5 – 12.5

/fall
Fall to rise 6.5 – 8.7 5.7 – 9.5

(extraction)
Full extract 12.8 – 17.3 11.3 – 18.9
Full retract 14.5 – 19.6 12.8 – 21.3

(8) Crane operation
Separate crane operation sec.
time
Hoist up 4.9 – 6.7 4.4 – 7.3
Hoisting
Hoist down 4.9 – 6.7 4.4 – 7.3
Right swing 34.9 – 47.2 30.8 – 51.3

Swing
Left swing 34.9 – 47.2 30.8 – 51.3
Values in ( ) shall be applied to only G mode and L mode.
BZ210-1 20-7
(1)

Work
equipment
• Pump speed: at 1,950 rpm with 310 mA PC current
Lower limit of
Test pump deliv- Delivery pressure
Check- Average pressure Delivery standard troubleshooting
ery pressure of another pump
point (MPa {kg/cm2}) value Q (l/min) standard value Q
(MPa {kg/cm2}) (MPa {kg/cm2})
(l/min)
Any P1 P2 P1+P2 See the graph See the graph

2
aAdjust pump delivery pressures P1 and P2 to the average pressure as much as possible and measure the
pressures. Avoid measuring the pressure in the bend area of the graph as an error increases in this area.
aWhen the pump pressure is measured on the machine and if the engine speed cannot be set to the specified
speed by the fuel dial, calculate the pump delivery at the specified speed based on both the engine speed
during measurement and the pump delivery.
20-8 BZ210-1
(1)
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ...........................................................20-102
TESTING AND ADJUSTING ENGINE SPEED ...........................................................................................20-104
MEASURING EXHAUST GAS COLOR ......................................................................................................20-105
ADJUSTING VALVE CLEARANCE .............................................................................................................20-106
MEASURING COMPRESSION PRESSURE ..............................................................................................20-108
MEASURING BLOW-BY PRESSURE ........................................................................................................20-109
TESTING AND ADJUSTING FUEL INJECTION TIMING ...........................................................................20-110
MEASURING ENGINE OIL PRESSURE ....................................................................................................20-112
ADJUSTING ENGINE SPEED SENSOR ....................................................................................................20-112
EMERGENCY ESCAPE METHOD WHEN ENGINE CONTROL SYSTEM HAS TROUBLE......................20-113
TESTING AND ADJUSTING TRACK SHOE TENSION..............................................................................20-114
TESTING AND ADJUSTING SOIL BELT CONVEYOR SHOE TENSION ..................................................20-115
TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT AND TRAVEL CIRCUITS.........20-116
TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE ....................................................20-120
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURE ........................................20-121
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE ........................................20-124
MEASURING SOLENOID VALVE OUTPUT PRESSURE...........................................................................20-128
MEASURING PPC VALVE OUTPUT PRESSURE......................................................................................20-131
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT ..............................................................20-132
MEASURING OIL LEAKAGE ......................................................................................................................20-132
BLEEDING AIR FROM EACH PART...........................................................................................................20-133
PROCEDURE FOR TESTING DIODES......................................................................................................20-135
SPECIAL FUNCTION OF MONITOR PANEL .............................................................................................20-136
BZ210-1 20-101
(1)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Q'ty
Testing/Adjusting item Part No. Part name Remarks
Testing and adjusting 1 799-205-1100 Tachometer kit 1 6.0 – 99999.9 rpm

A
engine speed 2 795-790-2500 Adapter 1 For 102E-2 engine
1 799-201-9001 Handy smoke checker 1
Measuring exhaust gas
B Commercially Bosch index: 0 – 9
color 2 Smoke meter 1
available
1 795-799-1131 Gear 1 For 102E-2 engine
Adjusting valve clearance C Commercially
2 Feeler gauge 1 (Intake: 0.25 mm, Exhaust: 0.51 mm)
available
Measuring compression 1 795-502-1205 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
D
pressure 2 795-502-1700 Adapter 1 For 102E-2 engine
Measuring blow-by pres- 1 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
E
sure 2 795-790-1950 Tool (Nozzle) 1 For 102E-2 engine
1 795-799-1131 Gear 1
Testing and adjusting fuel
F 2 795-799-1900 Pin assembly 1 For 102E-2 engine
injection timing
3 795-799-1950 Lock pin 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil pres-
G Pressure gauge:
sure 790-261-1204 Digital hydraulic tester 1
58.8 MPa {600 kg/cm2}
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
0.98 MPa {10 kg/cm2}
Testing and adjusting work Pressure gauge:
equipment and swing circuit 799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
pressure 1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting con- J Pressure gauge:
790-261-1204 Digital hydraulic tester 1
trol circuit basic pressure 58.8 MPa {600 kg/cm2}
Testing and adjusting pump 799-101-5220 Nipple 1
PC control circuit pressure 2 Size: 10 x 1.25 mm
07002-11023 O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting pump Pressure gauge:
K 790-261-1204 Digital hydraulic tester 1
LS control circuit pressure 58.8 MPa {600 kg/cm2}
799-101-5220 Nipple 2
2 Size: 10 x 1.25 mm
07002-11023 O-ring 2
3 799-401-2701 Differential pressure gauge 1 49 MPa {500 kg/cm2}
Pressure gauge:
Measuring solenoid valve 1 {25, 60, 400, 600 kg/cm2}
L
output pressure Pressure gauge:
58.8 MPa {600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
Pressure gauge:
Measuring PPC valve out-
M {25, 60, 400, 600 kg/cm2}
put pressure
Pressure gauge:
58.8 MPa {600 kg/cm2}
Commercially
Measuring oil leakage — Measuring cylinder 1
available
Measuring coolant temper-
— 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
ature and oil temperature
20-102 BZ210-1
(1)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Q'ty
Testing/Adjusting item Part No. Part name Remarks
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}

—
and pressing effort 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Scale 1
hydraulic drift available
Measuring work equipment Commercially
— Stopwatch 1
speed available
Measuring voltage and Commercially
— Tester 1
resistance available
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connec-
tors and electric circuit diagram of each system.
BZ210-1 20-103
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING ENGINE SPEED
TESTING AND ADJUSTING ENGINE SPEED
a Testing and adjusting tools for engine speed 3. Measure the engine speed under each meas-
urement condition.
Symbol Part No. Part Name 1) Low idling speed:
1 799-205-1100 Tachometer kit i) Set the fuel control dial to the low idling
A
2 795-790-2500 Adapter position (MIN).
ii) Stop the whole work equipment and set
a The engine speed can be also tested with the all the control levers in neutral.
monitoring function of the monitor panel (special 2) High idling speed:
function of the monitor panel). i) Turn the ECO mode OFF.
ii) Set the fuel control dial to the high idling
k When installing and removing the measuring in- position (MAX).
struments, take care not to touch a hot part. iii) Stop the whole work equipment and set
all the control levers in neutral.
Testing 3) 1-pump relief speed:
1. Open the engine hood and remove cover (1). i) Set the fuel control dial to the high idling
a Use the filter wrench to remove the cover. position (MAX).
ii) Select the travel mode.
iii) Put a bar between the travel shoe and
sprocket to lock the sprocket.
iv) Relieve the travel circuit.
4. After finishing measurement, remove the meas-

uring instruments and return the removed parts.
Adjusting
1. Adjusting low idling speed
a If the low idling speed is out of the standard
range, adjust it with the adjustment function
of the monitor panel.
a For the adjustment procedure, see SPECIAL
2. Install adapter A2 and connect pickup set (1)
FUNCTION OF MONITOR PANEL.
and meter of tachometer kit A1.
2. Adjusting governor spring
a If the high idling speed is out of the standard
range or the engine speed is unstable (the
engine hunts), adjust the installed dimension
of the governor spring with the adjustment
function of the monitor panel.
a For the adjustment procedure, see SPECIAL
FUNCTION OF MONITOR PANEL.
20-104 BZ210-1
(1)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

a Measuring instruments for exhaust gas color
Symbol Part No. Part Name

1 799-201-9001 Handy smoke checker
B Commercially
2 Smoke meter
available
k When installing and removing the measuring in-

struments, take care not to touch a hot part.
a If an air source and an electric power source are
not available in the field, use handy smoke
checker B1. When recording official data, use
smoke meter B2.
2) Connect the probe hose, receptacle of the

1. Measuring with handy smoke checker B1 accelerator switch, and air hose to smoke
1) Stick a sheet of filter paper to smoke meter B2.
checker B1. a Limit the supplied air pressure to 1.5
2) Insert the exhaust gas intake pipe in the MPa {15 kg/cm2}.
exhaust pipe. 3) Connect the power cable to a receptacle of
3) Run the engine and raise the engine coolant power source.
temperature to the operating range. a Before connecting the cable, check that
4) Accelerate the engine suddenly or run it at the power switch of the smoke meter is
high idling and operate the handle of smoke turned OFF.
checker B1 so that the filter paper will 4) Loosen the cap nut of the suction pump and
absorb the exhaust gas. fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter
B2.
5) Remove the filter paper and compare it with

the attached scale.
6) After finishing measurement, remove the
measuring instruments and return the
removed parts. 6) Run the engine and raise the engine coolant
temperature to the operating range.
2. Measuring with smoke meter B2 7) Accelerate the engine suddenly or run it at
1) Insert probe [1] of smoke meter B2 in the high idling and press the accelerator pedal
outlet of the exhaust pipe and fix it to the of smoke meter B2 and collect the exhaust
exhaust pipe with a clip. gas into the filter paper.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
removed parts.
BZ210-1 20-105
(1)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

a Adjusting instruments for valve clearance

1 795-799-1131 Gear
C
2 Commercially available Feeler gauge
1. Open the engine hood and remove the fan

guard on the counterweight side.
2. Remove all cylinder head covers (1).
5. While the No. 1 cylinder is at the compression

top dead center, adjust the valve clearances
marked with q in the following figure according
to the following procedure.
3. Remove cap (2) and install gear C1.
1) Insert feeler gauge C2 in clearance "b"

between rocker arm (4) and valve stem (5)
and adjust the valve clearance with adjust-
ment screw (6).
a With the feeler gauge inserted, turn the
adjustment screw to a degree that you
can move the feeler gauge lightly.
4. Rotate the crankshaft forward with gear C1 to 2) Fix adjustment screw (6) and tighten locknut
bring the stamped "1.6TOP" line "a" of the crank
3 Locknut:
(7).
pulley to pointer (3) and set the No. 1 cylinder to
the compression top dead center. 24 ± 4 Nm {2.45 ± 0.41 kgm}
a When the No. 1 cylinder is at the compres- a After tightening the locknut, check the
sion top dead center, the rocker arm of the valve clearance again.
No. 1 cylinder can be moved by the valve a After adjusting the clearances of all the
clearance with the hand. If the rocker arm valves marked with q, go to the following
cannot be moved, the No. 1 cylinder is not at procedure.
the compression top dead center. In this
case, rotate the crankshaft one more turn.
20-106 BZ210-1
(1)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
6. Rotate the crankshaft forward with gear C1 to

bring stamped "1.6TOP" line "a" of the crank
the compression top dead center.
7. While the No. 6 cylinder is at the compression

top dead center, adjust the valve clearances
marked with Q.
a Measure the clearances according to the
procedure of step 5.
8. After finishing measurement, return the removed
3 Cylinder head cover mounting bolt:

parts.
24 ± 4 Nm {2.45 ± 0.41 kgm}
BZ210-1 20-107
(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pres- 6. Remove governor spring (2).
sure
7. Put governor lever (3) of the fuel injection pump
Symbol Part No. Part Name to the stopper on the STOP side and fix it.
1 795-502-1205 Compression gauge
D
2 795-502-1700 Adapter
k When measuring the compression pressure,

take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating
part.
1. Adjust the valve clearance.

a For details, see Adjusting valve clearance.
2. Prepare for measuring the engine speed.

a See Testing and adjusting engine speed.
8. Crank the engine with the starting motor and
3. Warm up the engine until the engine oil temper- measure the compression pressure.
ature is 40 – 60°C. a Read the compression gauge when its point-
er is stabilized.
4. Remove nozzle holder (1) of the cylinder to be a When measuring the compression pressure,
measured. measure the engine speed, too, and check
that it is in the measurement condition range.
2 Nozzle holder:
3 Nozzle holder:
Anti-seizure material (MOLYCOAT 1000)
60 ± 9 Nm {6.12 ± 0.92 kgm}
5. Install adapter D2 to the nozzle holder mounting

part and connect gauge assembly of com-
3 Adapter: 60 ± 9 Nm {6.12 ± 0.92 kgm}

pression gauge D1.
20-108 BZ210-1
(1)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

a Measuring instruments for blow-by pressure

1 799-201-1504 Blow-by kit
E
2 795-790-1950 Tool (Nozzle)
1. Install tool E2 to blow-by hose (1) and connect

the gauge of blow-by kit E1.
2. Start the engine and lock the travel mechanism.
k Put pin between the sprocket and track

frame to lock the travel mechanism secure-
ly.
3. Start the engine and raise the engine coolant

temperature and hydraulic oil temperature to the
operating range.
4. Run the engine at high idling and measure the

blow-by pressure under the following condition.
• Relieve the travel circuit.
a Read the blow-by pressure gauge when its
pointer is stabilized.

BZ210-1 20-109
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

a Testing and adjusting instruments for fuel injec- 4. Push timing pin (3) of the drive gear into the
tion timing front cover side to fix the drive gear of the fuel
injection pump to the injection timing.
Symbol Part No. Part Name a Since the injection timing must be adjusted
1 795-799-1131 Gear very accurately, be sure to fix the drive gear
F 2 795-799-1900 Pin assembly to the injection timing.
3 795-799-1950 Lock pin a Pushing depth of timing pin: 8 mm
a If you cannot push in the pin, rotate the
crankshaft forward or in reverse a little with
Testing
gear F1.
1. Open the engine hood and remove the fan
a If it is difficult to check with the timing pin in-
guard on the counterweight side.
stalled to the engine, you may use metallic
2. Remove cover (1) and install gear F1.
pin assembly F2.
3. Rotate the crankshaft forward with gear F1 to

5. Remove plug (4) of the fuel injection pump.
bring stamped "1.6TOP" line "a" of the crank
6. Turn over and insert timing pin (5) of the fuel
the compression top dead center.
injection pump and check that its cut is fitted to
a Remove the head cover of the No. 1 cylinder
projection "b" in the pump.
and check that the rocker arm can be moved
a If you can insert the timing pin smoothly, the
by the valve clearance with the hand. If the
injection timing is correct.
rocker arm cannot be moved, the No. 1 cyl-
a If you cannot insert the timing pin, the injec-
inder is not at the compression top dead
tion timing is not correct. In this case, adjust
center. In this case, rotate the crankshaft
the injection timing.
one more turn.
a If it is difficult to check with the timing pin in-
stalled to the fuel injection pump, you may
use metallic pin assembly F3.
20-110 BZ210-1
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
7. After finishing testing, remove the measuring 4. Install the fuel injection pump.
3 Cylinder head cover mounting bolt:

instruments and return the removed parts. a See DISASSEMBLY AND ASSEMBLY, Re-
moval and installation of fuel injection pump
k Return timing pin (3) of the drive gear and

24 ± 4 Nm {2.45 ± 0.41 kgm} assembly.
timing pin (5) of the fuel injection pump with- 5. After finishing adjustment, remove the adjusting
out fail. instruments and return the removed parts.
k Before starting the engine, check that timing

a When adjusting, leave gear F1 and timing
pin (3) as they are.
pin (3) of the drive gear and timing pin (5) of
Adjusting the fuel injection pump are returned.
a If the fuel injection timing is not correct, adjust it
according to the following procedure.
1. Using timing pin (3), check that the injection tim-

ing of the drive gear is fixed.
a If the timing pin was returned after testing, in-
sert it again according to the testing proce-
dure.
2. Remove the fuel injection pump.

a See DISASSEMBLY AND ASSEMBLY, Re-
moval and installation of fuel injection pump
assembly.
3. Turn over and insert timing pin (5) of the fuel

injection pump and rotate the shaft to fit the cut
of the pin to projection "b" in the pump.
a After adjusting the timing of the fuel injection
pump, tighten and fix plug (4).
BZ210-1 20-111
(1)
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
MEASURING ENGINE OIL ADJUSTING ENGINE SPEED

PRESSURE SENSOR
a Measuring instruments for engine oil pressure a Remove engine speed sensor (1) before adjust-
ing it and check that its tip is free from steel
Symbol Part No. Part Name chips and flaws, and then install it.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
G
Hydraulic tester
2 799-401-2320
(1.0 MPa {10 kg/cm2})
1. Remove oil pressure pickup plug (1) from the

top of the engine oil filter.
1. Screw in sensor (1) until its tip touches the tooth
3 Threads: Gasket sealant (LG-6)

tip of flywheel ring gear (2).
2. Return sensor (1) by the specified angle.

a Returning angle of sensor: 1 ± 1/6 turn
a Adjust clearance "a" between the sensor tip
2. Install nipple of hydraulic tester G1 and con- and gear tooth tip to 1.25 – 1.75 mm.
nect hydraulic tester G2.
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}

3. Fixing sensor (1) with nut (3).
3. Start the engine and raise the engine coolant

4. After finishing adjustment, check that the moni-
4. Measure the oil pressure during low idling and tor panel displays the engine speed normally by
high idling. using the monitoring function.
a For the monitoring function, see "Special
5. After finishing measurement, remove the meas- function of monitor panel".
20-112 BZ210-1
(1)
EMERGENCY ESCAPE METHOD
TESTING AND ADJUSTING WHEN ENGINE CONTROL SYSTEM HAS TROUBLE
EMERGENCY ESCAPE METHOD WHEN ENGINE CONTROL

SYSTEM HAS TROUBLE
a If the engine cannot be controlled because of a 3. Remove bolt (4) and connect governor spring
trouble in the engine control devices such as the (3), and then return bolt (4).
fuel control dial, engine throttle and pump con- a Lean the governor motor lever toward the
troller, governor motor potentiometer, etc., fix fuel injection pump so that it will not interfere
the engine speed and escape according to the with the governor spring.
following procedure. a The governor lever of the fuel injection pump
a The emergency escape method is a temporarily is fixed close to the high idling.
method. Accordingly, find out the cause of the
trouble and repair it immediately after escaping.
1. Disconnect connector E11 (1) of the governor

motor and connector E10 (2) of the governor
potentiometer.
k If the governor motor connector is not dis-

connected, the governor motor may operate
suddenly and may cause mechanical dam-
age while the engine is running. According-
ly, be sure to disconnect it.
4. Start the engine and move the machine to a
safe place.
5. Disconnect governor spring (3) and stop the

engine.
k You must stop the engine while it is running

at high speed. Take care not to touch a hot
part or get caught in a rotating part.
a Push in the governor spring toward the fuel
injection pump until the fuel injection pump
stops injection.
a Hold the governor spring until the engine
2. Disconnect governor spring (3) from the gover- stops completely. If you release it before the
nor motor. engine stops completely, the fuel injection
pump returns to the low idling position auto-
matically and the engine does not stop.
BZ210-1 20-113
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION
Testing Adjusting
1. Run the engine at low idling and drive the a If the track shoe tension is abnormal, adjust it
machine forward by the length of track on according to the following procedure.
ground, and then stop slowly.
2. Place straight steel bar [1] on the track shoe 1. When tension is too high
between the idler and the 1st carrier roller. Loosen valve (1) slowly to discharge the grease.
k Since the valve may jump out because of

a As the steel bar, use an L-shape steel, etc.
which will be deflected less.
the high-pressure grease, do not loosen it
3. Measure maximum clearance "a" between steel more than 1 turn.
bar [1] and track shoe.
• Standard maximum clearance "a": 10 – 30 2. When tension is low
mm Add grease through grease fitting (2).
a If the shoe is not tensed well, slowly move
the machine forward and in reverse.
20-114 BZ210-1
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING SOIL BELT CONVEYOR SHOE TENSION
TESTING AND ADJUSTING SOIL BELT CONVEYOR

SHOE TENSION
Testing Adjusting
1. Run the engine at low idling and rotate the soil a If the soil belt conveyor shoe tension is abnor-
belt conveyor shoe by 1 turn, and then stop mal, adjust it according to the following proce-
slowly. dure.
2. Measure maximum clearance "a" between the 1. When tension is too high
center of the underside of the frame and the soil Loosen valve (1) slowly to discharge the grease.
k Since the valve may jump out because of

belt conveyor shoe.
• Standard maximum clearance "a": 100 – 200
mm the high-pressure grease, do not loosen it
more than 1 turn.
2. When tension is low

Add grease through grease fitting (2).
a If the shoe is not tensed well, slowly rotate
the belt conveyor 2 – 3 turns.
BZ210-1 20-115
(1)
TESTING AND ADJUSTING OIL PRESSURES
TESTING AND ADJUSTING IN WORK EQUIPMENT AND TRAVEL CIRCUITS

IN WORK EQUIPMENT AND TRAVEL CIRCUITS
a Testing and adjusting instruments for oil pres-
sures in work equipment and travel circuits

1
J
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
a The oil pressures in the work equipment and

travel circuits (pump discharge pressures) can
be checked with the monitoring function of the
monitor panel (the special function of the moni-
tor panel), too. 2) Install nipple J2 and connect it to the oil
pressure gauge of hydraulic tester J1.
Measuring a Use the oil pressure gauge of 58.8 MPa
1. Preparation work {600 kg/cm2}.
k Retract the crane, close the mixer case, and

stop the engine. Operate the control lever
several times to release the residual pres-
sure from the piping, and then loosen the oil
filler cap of the hydraulic tank gradually to
release the pressure from the hydraulic
tank.
1) Remove oil pressure pickup plugs (1) and
(2).
• Plug (1): For front pump circuit
(7-spool control valve)
• Plug (2): For rear pump circuit
3) Start the engine and raise the hydraulic oil

20-116 BZ210-1
(1)
2. Combination of pump, actuator, and valve 5. Measuring hammer starting pressure

a The front pump supplies oil pressure to the (7-spool control valve)
7-spool control valve and the rear pump sup- 1) Start the engine.
plies oil pressure to the 8-spool control 2) While running the engine at high idling, start
valve. the hammer and measure the oil pressure.
a Note that different actuators relieve different a The pressure when the hammer starts is in-
valves. dicated.
Pump Actuator Relieved valve 6. Measuring relief pressure of raking rotor

(Unload) Unload valve (8-spool control valve)
Mixer case open/ 1) Put stone [2] between the soil belt conveyor
Main relief valve
7-spool control valve
close and raking rotor and start the engine.

Soil feeder Main relief valve 2) While running the engine at high idling, start
Front Crane Main relief valve the hammer and relieve its circuit and meas-
pump Attachment 3 ure the oil pressure.
Main relief valve
(Vibratory sieve) a The relief pressure of the safety valve of the
No.1 hammer Main relief valve raking rotor circuit is indicated.
No.2 hammer Main relief valve a The relief pressure of the raking rotor is low-
No.3 hammer Main relief valve er than the main relief pressure of the 8-
(Unload) Unload valve spool control valve.
Attachment 2
(Secondary belt con- Safety valve 7. Measuring relief pressure of solidifying mate-
veyor) rial feeder (8-spool control valve)
a The relief pressure of the solidifying material
8-spool control valve
Raking rotor Safety valve

Solidifying material feeder cannot be measured.
Safety valve a The relief pressure of the solidifying material
Rear feeder
pump Soil cutter Safety valve feeder is lower than the main relief pressure
of the 8-spool control valve.
Discharge belt con-
Safety valve
veyor
8. Measuring relief pressure of safety valve of 8-
Right travel Main relief valve
spool control valve
Left travel Main relief valve
(Soil cutter, discharge belt conveyor, and at-
Attachment 1
Safety valve tachments 1 and 2)
(Aftercutter)
1) Start the engine.
2) Disconnect the quick coupler of attachment
3. Measuring unload pressure 1 (aftercutter) and turn the switch ON.
(7-spool/8-spool control valve) 3) While running the engine at high idling,
1) Start the engine. relieve the safety valve and measure the oil
2) While running the engine at high idling, set pressure.
all the control levers in neutral and measure a The relief pressure of the safety valve of the
the oil pressure. 8-spool control valve is indicated.
a The unload pressure of the unload valve is a The relief pressure of the safety valve is low-
indicated. er than the main relief pressure of the 8-
spool control valve.
4. Measuring main relief pressure of 7-spool
control valve
(Mixer case open/close, soil feeder, crane,
and attachment 3)
1) Start the engine.
2) While running the engine at high idling,
relieve the mixer case open/close cylinder
on the open side, and measure the oil pres-
sure.
a The relief pressure of the main relief valve of
the 7-spool control valve is indicated.
BZ210-1 20-117
(1)
9. Measuring relief pressure of travel circuit Adjusting

1) Start the engine and lock the travel mecha- a The unload valve and safety valve are not
nism. adjustable.
k Put pin [2] between the sprocket and 1. Adjusting main relief pressure (7-spool con-
track frame to lock the travel mecha- trol valve)
nism securely. a If the relief pressure of the work equipment
circuit is abnormal, adjust main relief valve
(3) according to the following procedure.
2) While running the engine at high idling,

relieve the travel circuit and measure the oil
pressure. 1) Disconnect the pilot hose.
a The relief pressure of the main relief valve is 2) Loosen locknut (7) and turn holder (8) to
indicated. adjust.
a If the holder is
• turned to the right, the pressure ris-
es.
• turned to the left, the pressure low-
ers.
a Quantity of adjustment per turn of hold-
3 Locknut:
er: Approx. 12.5 MPa {128 kg/cm2}
53.5 ± 4.9 Nm {5.5 ± 0.5 kgm}
3) After finishing adjustment, check the oil

pressure again according to the procedure
described above.
a When measuring the oil pressure, con-
nect the pilot hose.
20-118 BZ210-1
(1)
2. Adjusting main relief pressure (8-spool con-

trol valve)
a If the relief pressure of the work equipment
and travel circuit is abnormal, adjust main re-
lief valve (4) according to the following pro-
cedure.
1) Disconnect the pilot hose.

2) Loosen locknut (5) and turn holder (6) to
adjust.
a If the holder is
• turned to the right, the pressure ris-
es.
• turned to the left, the pressure low-
ers.
a Quantity of adjustment per turn of hold-
3 Locknut:
er: Approx. 12.5 MPa {128 kg/cm2}
53.5 ± 4.9 Nm {5.5 ± 0.5 kgm}
3) After finishing adjustment, check the oil

pressure again according to the procedure
described above.
a When measuring the oil pressure, con-
nect the pilot hose.
BZ210-1 20-119
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT

BASIC PRESSURE
a Testing and adjusting instruments for control cir- 3. Start the engine and raise the hydraulic oil tem-
cuit oil pressure perature to the operating range.
Symbol Part No. Part Name 4. While running the engine at high idling, set all
799-101-5002 Hydraulic tester the control levers in neutral and measure the oil
1
790-261-1204 Digital hydraulic tester pressure.
J
799-101-5220 Nipple (10 x 1.25 mm)
2 5. After finishing measurement, remove the meas-
07002-11023 O-ring
a Do not adjust the relief valve for the control cir-
Measuring
cuit basic pressure.
stop the engine. Operate the control lever sev-
eral times to release the residual pressure from
the piping, and then loosen the oil filler cap of
the hydraulic tank gradually to release the pres-
sure from the hydraulic tank.
1. Remove oil pressure pickup plug (1) of the self-

reducing pressure valve on the engine side of
the 7-spool control valve.
2. Install nipple J2 and connect it to the oil pres-

sure gauge of hydraulic tester J1.
a Use the oil pressure gauge of 5.9 MPa {60
kg/cm2}.
20-120 BZ210-1
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL

PRESSURE
a Testing and adjusting instruments for pump PC
control circuit oil pressure

1
J
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
Measuring
a Before measuring the pump PC control circuit oil
pressure, check that the work equipment and
travel circuit oil pressure and the control circuit
basic pressure are normal.

1. Measuring PC valve output pressure (servo

piston inlet pressure)
a Measure the PC valve output pressure (ser-
vo piston inlet pressure) and pump dis-
ch arge p r ess ure si m ul t ane ousl y a nd
compare them. 2) Install nipple J2 and connect it to oil pres-
1) Remove oil pressure pickup plugs (1), (2), sure gauge [1] of hydraulic tester J1.
(3), and (4). a Use the oil pressure gauge of 58.8 MPa
• (1): For front pump discharge pressure {600 kg/cm2}.
• (2): For rear pump discharge pressure
• (3): For front pump PC valve output
pressure
• (4): For rear pump PC valve output
pressure
BZ210-1 20-121
(1)
2. Measuring PC-EPC valve output pressure

1) Remove oil pressure pickup plug (5).
2) Install nipple J2 and connect it to the oil

pressure gauge of hydraulic tester J1.
a Use the oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

4) While running the engine at high idling
under the following condition, measure the
pump discharge pressure and PC valve out-
put pressure (servo piston inlet pressure) 3) Start the engine and raise the hydraulic oil
simultaneously. temperature to the operating range.
• Travel mode 4) While running the engine at high idling and
• Work equipment and travel circuits: Re- low idling, set all the control levers in neutral
lief and measure the oil pressure.
a Method of judgment: a If the PC-EPC valve pressure changes
If the pump discharge pressure and PC as shown below, it is normal.
valve output pressure (servo piston out-
put pressure) are in the following ratio, Control Oil
Engine
levers pressure
they are normal.
2.9 MPa
Low idling
Measured oil {30 kg/cm2}
Ratio of oil pressure Neutral
pressure 0 MPa
High idling
Pump discharge {0 kg/cm2}
1
pressure
PC valve output pres-
Approx. 3/5
sure
a If the PC valve or the servo piston is ab-

normal, the PC valve output pressure
(servo piston output pressure) is "the
same as the pump discharge pressure"
or "almost 0".
20-122 BZ210-1
(1)
Adjusting 2. After finishing adjustment, check that the PC

a If either of the following phenomena occurs and valve output pressure (servo piston inlet pres-
the PC valves seem to be defective, adjust PC sure) is normal according to the procedure
valves (6) and (7) according to the procedure described above.
shown below.
• As the working load increases, the engine

speed lowers remarkably.
• The engine speed is normal but the work
equipment speed is low.
1. Loosen locknut (8) and turn adjustment screw

(9) to adjust PC valve.
a If the holder is
• turned to the right, the pump absorption
torque increases.
• turned to the left, the pump absorption
torque decreases.
a The adjustable range of the adjustment
screw is as follows.
• Left turning: Max. 1 turn
3 Locknut:
• Right turning: Max. 1/2 turn (Max. 180°)
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
BZ210-1 20-123
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL

PRESSURE
a Testing and adjusting instruments for pump LS
control circuit oil pressure

1
K 799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
Measuring
a Before measuring the pump LS control circuit oil
pressure, check that the work equipment and
travel circuit oil pressure and the control circuit
basic pressure are normal.

1. Measuring LS valve output pressure (servo

piston inlet pressure)
a Measure the LS valve output pressure (ser-
vo piston inlet pressure) and pump dis-
ch arge p re ssu re si mu lt a neo usl y an d 2) Install nipple K2 and connect it to oil pres-
compare them. sure gauge [1] of hydraulic tester K1.
1) Remove oil pressure pickup plugs (1), (2), a Use the oil pressure gauge of 58.8 MPa
(3), and (4). {600 kg/cm2}.
• (1): For front pump discharge pressure
• (3): For front pump LS valve output
pressure
• (4): For rear pump LS valve output pres-
sure
20-124 BZ210-1
(1)
a Method of judgment:
If the pump discharge pressure and LS
valve output pressure (servo piston out-
put pressure) are in the following ratio,
they are normal.
Ratio of oil
pressure
Measured Run discharge belt
oil pressure Set all levers conveyor forward
in neutral Run soil belt con-
veyor forward
Pump discharge
1
pressure
Almost same
LS valve output
Approx. 3/5
pressure

removed parts.
2. Measuring LS differential pressure

a As the LS differential pressure, measure
pump discharge pressure and LS pressure
(actuator load pressure) simultaneously and
calculate the difference between them.
1) Remove oil pressure pickup plugs (1), (2),
(3), and (4).
• (1): For front pump discharge pressure
3) Start the engine and select the manual
mode.
• (3): For front pump LS pressure
• When measuring front circuit: Run dis-
• (4): For rear pump LS pressure
charge belt conveyor forward.
• When measuring rear circuit: Run soil
belt conveyor forward.
5) While running the engine at high idling
under the following condition, measure the
pump discharge pressure and LS valve out-
put pressure (servo piston inlet pressure)
simultaneously.
• Select the manual mode and operate the
control lever singly.
BZ210-1 20-125
(1)
2) Install nipple K2 and connect it to oil pres- 3) Start the engine and select the manual
sure gauge of hydraulic tester K1 or dif- mode.
ferential pressure gauge K3. • When measuring front circuit: Run dis-
a When using differential pressure gauge: charge belt conveyor forward.
Connect the pump discharge pressure • When measuring rear circuit: Run soil
to the high pressure side and connect belt conveyor forward.
the LS pressure to the low pressure 4) Start the engine and raise the hydraulic oil
side. temperature to the operating range.
Since the differential pressure gauge 5) While running the engine at high idling
needs a 12-V power source, connect it under the following condition, measure the
to a battery. pump discharge pressure and LS pressure
a When using oil pressure gauge: (actuator load pressure) simultaneously.
Use the oil pressure gauge of 58.8 MPa • Working mode
{600 kg/cm2}. • Run discharge belt conveyor forward
Since the differential pressure is about • Run soil belt conveyor forward
3.9 MPa {40 kg/cm2} at maximum, mea- a Calculation of LS differential pressure:
sure it by installing the same gauge to LS differential pressure = Pump dis-
the pickup plugs alternately. charge pressure – LS pressure
a If the LS differential pressure is as fol-
lows, it is normal.
LS differential
Operation of levers
pressure
Unload pressure
Set all levers in neutral (See standard
value)
Run discharge belt con-
Max. LS differen-
veyor forward
tial pressure (See
Run soil belt conveyor
standard value)
forward

removed parts.
20-126 BZ210-1
(1)
3. Adjusting LS differential pressure

a If the LS differential pressure is abnormal, adjust
LS valves (6) and (7) according to the following
procedure.
1) Loosen locknut (8) and turn adjustment

screw (9) to adjust the LS valve.
a If the adjustment screw is
• turned to the right, the differential
pressure rises.
• turned to the left, the differential
pressure lowers.
a Quantity of adjustment (LS differential
pressure) per turn of adjustment screw:
3 Locknut: 49 – 64 Nm {5 – 7 kgm}
1.3 MPa {13.3 kg/cm2}
2) After finishing adjustment, check that the LS

differential pressure is normal according to
the procedure described above.
BZ210-1 20-127
(1)
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
MEASURING SOLENOID VALVE OUTPUT PRESSURE

a Measuring instruments for solenoid valve output k Lower the work equipment to the ground and
pressure stop the engine. Operate the control lever sev-
Symbol Part No. Part Name the piping, and then loosen the oil filler cap of
799-101-5002 Hydraulic tester the hydraulic tank gradually to release the pres-
1
L 790-261-1204 Digital hydraulic tester sure from the hydraulic tank.
2 799-401-3100 Nipple (Size 02)
1. Disconnect the outlet hose of the solenoid valve
to be measured.
a Before measuring the solenoid valve output
a There are 2 sets of a 6-spool solenoid valve
pressure, check that the control circuit basic
(A and B) and 1 set of an 8-spool solenoid
pressure is normal.
valve (C).
Measuring solenoid valve Disconnecting hose Measuring solenoid valve Disconnecting hose
Discharge belt conveyor
A1 8-spool PB4 B5 Soil feeder reverse 7-spool PB6
reverse
A2 Attachment 3 8-spool PA8 B6 Travel lock —
A3 Attachment 2 7-spool PA4 C1 Soil feeder forward 7-spool PA6
Discharge belt conveyor Solidifying material feeder
A4 8-spool PA4 C2 8-spool PA6
forward forward
A5 Attachment 1 8-spool PA1 C3 Soil cutter forward 8-spool PA5
Solidifying material feeder
A6 8-spool PB6 C4 Crane 7-spool PA5
reverse
B1 Soil cutter reverse 8-spool PB5 C5 No.3 hammer forward 7-spool PA1
B2 Raking rotor reverse 8-spool PB7 C6 No.2 hammer forward 7-spool PA2
B3 Air compressor 8-spool PB8 C7 No.1 hammer forward 7-spool PA3
B4 Impact hammer reverse 7-spool PB3 C8 Raking rotor forward 8-spool PA7
20-128 BZ210-1
(1)
2. Install adapter L2 and connect the disconnected

hose again.
3. Install the nipple of hydraulic tester L1 and con-

nect it to the oil pressure gauge.
kg/cm2}.
4. Start the engine and raise the hydraulic oil tem-

perature to the operating range.
5. Start the engine and raise the hydraulic oil tem-

a For the condition for turning the solenoid
valve ON or OFF, see the operation table of
each solenoid valve.
a The operating condition of the solenoid valve
can be checked with the monitoring function
of the monitor panel (Special function of ma-
chine monitor).
a If the output pressure is as shown in the fol-
lowing table, the solenoid valve is normal.
a For 6-spool solenoid valves A and B
Solenoid valve Output pressure

OFF (De-energized) 0 MPa {0 kg/cm2}
ON (Energized) 3 MPa {30 kg/cm2}
a For 8-spool solenoid valve C
Solenoid valve Output pressure

OFF (De-energized) 0 MPa {0 kg/cm2}
ON (Energized) 2.4 MPa {24 kg/cm2}

BZ210-1 20-129
(1)
Operation table of each solenoid valve
Solenoid valve name Operating condition Operating

6-spool Discharge belt Set discharge belt conveyor manual forward/reverse switch in reverse position ON
A1 conveyor reverse Set discharge belt conveyor manual forward/reverse switch in forward position OFF
Set mode selector switch in manual mode
Attachment 3 ON
6-spool Turn attachment 3 start switch ON
(Secondary belt
A2 Set mode selector switch in manual mode
conveyor) OFF
Turn attachment 3 stop switch ON
ON
6-spool Attachment 2 Turn attachment 2 start switch ON
A3 (Vibratory sieve) Set mode selector switch in manual mode
OFF
6-spool Discharge belt Set discharge belt conveyor manual forward/reverse switch in forward position ON
A4 conveyor forward Set discharge belt conveyor manual forward/reverse switch in reverse position OFF
ON
6-spool Attachment 1 Turn attachment 1 start switch ON
A5 (Aftercutter) Set mode selector switch in manual mode
OFF
6-spool Solidifying mate- Set solidifying material feeder manual forward/reverse switch in reverse position ON
A6 rial feeder reverse Set solidifying material feeder manual forward/reverse switch in forward position OFF
6-spool Set soil cutter manual forward/reverse switch in reverse position ON
Soil cutter reverse
B1 Set soil cutter manual forward/reverse switch in forward position OFF
6-spool Raking rotor Set raking rotor manual forward/reverse switch in reverse position ON
B2 reverse Set raking rotor manual forward/reverse switch in forward position OFF
6-spool Set compressor start/stop switch in start position ON
Air compressor
B3 Set compressor start/stop switch in stop position OFF
6-spool Impact hammer Set hammer rotor manual forward/reverse switch in reverse position ON
B4 reverse Set hammer rotor manual forward/reverse switch in forward position OFF
6-spool Soil feeder Set soil feeder manual forward/reverse switch in reverse position ON
B5 reverse Set soil feeder manual forward/reverse switch in forward position OFF
6-spool Set mode selector switch in travel mode ON
Travel lock
B6 Set mode selector switch in manual mode and working mode OFF
8-spool Soil feeder for- Set soil feeder manual forward/reverse switch in reverse position ON
C1 ward Set soil feeder manual forward/reverse switch in forward position OFF
8-spool Solidifying mate- Set solidifying material feeder manual forward/reverse switch in forward position ON
C2 rial feeder forward Set solidifying material feeder manual forward/reverse switch in reverse position OFF
8-spool Set soil cutter manual forward/reverse switch in forward position ON
Soil cutter forward
C3 Set soil cutter manual forward/reverse switch in reverse position OFF
Turn crane main switch ON
8-spool ON
Crane Set manual/radio control selector switch in manual position
C4
Turn crane main switch OFF OFF
8-spool No. 3 hammer Set hammer manual forward/reverse switch in forward position ON
C5 forward Set hammer manual forward/reverse switch in reverse position OFF
8-spool No.2 hammer for- Set hammer manual forward/reverse switch in forward position ON
C6 ward Set hammer manual forward/reverse switch in reverse position OFF
8-spool No.1 hammer for- Set hammer manual forward/reverse switch in forward position ON
C7 ward Set hammer manual forward/reverse switch in reverse position OFF
8-spool Raking rotor for- Set raking rotor manual forward/reverse switch in forward position ON
C8 ward Set raking rotor manual forward/reverse switch in reverse position OFF
20-130 BZ210-1
(1)
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE

a Measuring instruments for PPC valve output
pressure 3. Start the engine and raise the hydraulic oil tem-
799-101-5002 Hydraulic tester 4. While running the engine at high idling, set the
M
790-261-1204 Digital hydraulic tester control lever of the circuit to be measured in the
neutral position and stroke end and measure the
a Before measuring the PPC valve output pres- oil pressure in each position.
sure, check that the control circuit basic pres- a If the PPC valve output pressure is as fol-
sure is normal. lows, it is normal.
Lever position Oil pressure

Neutral 0 MPa {0 kg/cm2}
1. Remove plugs (1) – (6) of the circuits to be
measured. Almost same as control
Stroke end
basic pressure
No. Measured circuit
1 Left travel forward
2 Right travel forward 5. After finishing measurement, remove the meas-
3 Left travel reverse uring instruments and return the removed parts.
4 Right travel reverse
5 Mixer case open
6 Mixer case close
7 —
2. Install nipple of hydraulic tester M and con-

nect the oil pressure gauge.
kg/cm2}.
BZ210-1 20-131
(1)
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
RELEASING RESIDUAL MEASURING OIL LEAKAGE

PRESSURE IN HYDRAULIC
CIRCUIT
k When disconnecting the piping between a hy- 1. Measuring oil leakage from travel motor
draulic cylinder, hydraulic motor, and control 1) Remove the travel motor cover.
valve, release the residual pressure in the circuit 2) Start the engine and lock the travel mecha-
according to the following procedure. nism.
a Pressure is not left in a motor circuit such as the
travel motor circuit, but the pressure in the k Put pin [1] between the sprocket and
hydraulic tank affects the circuit. Accordingly, track frame to lock the travel mecha-
perform the following procedure at least up to nism securely.
opening of the hydraulic tank cap.
1. Start the engine and retract the crane.
2. Operate the mixer case open/close lever to

close the mixer case.
3. While running the engine at low idling, quickly

operate the mixer case open/close lever 2 – 3
times.
4. Stop the engine and loosen the oil filler cap of

sure from the tank. 3) Disconnect drain hose (1) of the travel
motor and fit a plug to it.
5. Turn the starting switch ON and operate the 4) Start the engine, relieve the travel circuit at
control lever several times. high idling, and measure the oil leakage.
k Wrong operation of a lever can cause

a When operating the control lever, be sure to
turn the starting switch ON, since power
must be supplied to the PPC lock valve. an accident. Accordingly, make signs
a If the control lever is operated 2 – 3 times, and checks securely.
the pressure in the accumulator is lost. a After the travel circuit is relieved for 30
seconds, measure the oil leakage for 1
6. Run the engine at low idling for about 10 sec- minute.
onds to store pressure in the accumulator, and a Measure the oil leakage several times,
then stop the engine. after moving the motor a little each time
(changing the distance between the
7. Repeat steps 5 and 6 several times. valve plate and cylinder and that be-
tween the cylinder and piston).

meas uring instruments and return the
removed parts.
20-132 BZ210-1
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
BLEEDING AIR FROM EACH PART

Air bleeding procedure
Air bleeding item 1 2 3 4 5 6 7
Bleeding air
Bleeding air
Bleeding air Bleeding air from mixer
Bleeding air Starting from soil
from raking from travel case open/ Operation
Contents of work from pump engine belt con-
rotor motor motor close cylin-
veyor motor
der
• Replacing hydraulic oil
Q Q Q Q Q
• Cleaning strainer
• Replacing return filter element Q Q
• Replacing or repairing pump
Q Q Q Q Q Q
• Removing suction piping
• Replacing or repairing control valve Q Q Q Q Q
• Replacing soil belt conveyor motor
• Removing soil belt conveyor motor Q Q Q
piping
• Replacing raking rotor motor
Q Q Q
• Removing raking rotor motor piping
• Replacing travel motor
Q Q Q
• Removing travel motor piping
• Replacing mixer case open/close
cylinder
Q Q Q
• Removing mixer case open/close
cylinder piping
Note: Bleed air from the soil belt conveyor motor, raking rotor motor, and travel motor only after the oil in the
motor cases is drained.
1. Bleeding air from hydraulic pump 2. Starting engine

1) Loosen air bleeder [1] and check that oil a Precaution for starting engine
oozes out of the bleeder. When starting the engine for the first time af-
3 Bleeder:
2) After the oil oozes out, tighten bleeder [1]. ter the above work, keep its speed at low
idling for about 10 minutes.
7.8 – 9.8 Nm {0.8 – 1.0 kgm} If the warm-up operation is started because
a If the oil does not oozes out after the air of low coolant temperature, reset it with the
bleeder [1] is loosened, remove drain hose fuel control dial.
[2] of the pump case and fill the pump case
with hydraulic oil through the drain port.
a Since oil flows out of the disconnected drain
hose, fix the hose adapter higher than the oil
level in the hydraulic tank.
BZ210-1 20-133
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
3. Bleeding air from soil belt conveyor motor 6. Bleeding air from mixer case open/close cyl-
1) Run the engine at low idling. inder
2) Disconnect hose (1) of port C. After oil flows 1) Run the engine at low idling.
out, tighten the hose. 2) Extract and retract the open/close cylinder 4
– 5 times, stopping it before the stroke end
each time (about 100 mm before the stroke
end).
3) Extract and retract the open/close cylinder 3
– 4 times to the stroke end.
4) Extract and retract the open/close cylinder 4
– 5 more times to the stroke end to bleed all
air.
4. Bleeding air from raking rotor motor

1) Run the engine at low idling.
2) Disconnect hose (1) of port C. After oil flows
out, tighten the hose.
5. Bleeding air from travel motor

1) Run the engine at low idling.
2) Disconnect hose (1) of port C. After oil flows
out, tighten the hose.
20-134 BZ210-1
(1)
TESTING AND ADJUSTING PROCEDURE FOR TESTING DIODES
PROCEDURE FOR TESTING DIODES

a Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
procedure.
a The conductive directions of the assembled-

type diode are shown in the following figure.
a The conductive direction of the single diode is

indicated on the surface of the diode.
2. When using analog circuit tester

1) Set the tester in the resistance range.
2) Apply the leads of the tester as shown
below and check the movement of the
pointer.
i) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply
the black (–) lead to the cathode (N)
side.
ii) Apply the red (+) lead of the tester to the
cathode (N) side of the diode and apply
the black (–) lead to the anode (P) side.
3) Judge the condition of the diode by the
movement of the pointer.
• The pointer does not move in i) but
moves in ii): The diode is normal (The
moving range (resistance) depends on
the type and selected range of the tester,
however).
• The pointer moves in both i) and ii): The
diode is defective (Internal short circuit).
• The pointer moves in neither of i) and ii):
The diode is defective (Internal discon-
1. When using digital circuit tester nection).
1) Set the tester in the diode range and check
the indicated value.
a When an ordinary circuit tester is used,
the voltage of the internal battery is indi-
cated.
2) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply the
black (–) lead to the cathode (N) side and
check the indicated value.
3) Judge the condition of the diode by the indi-
cated value.
• The indicated value does not change:
The diode do not have conductivity (De-
fective).
• The indicated value changes: The diode
has conductivity (Normal). (Note)
Note: In the case of a silicon diode, a value
in the range from 460 to 600 is indi-
cated.
BZ210-1 20-135
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
SPECIAL FUNCTION OF MONITOR PANEL
[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [ ] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [ ] Downward move switch
[4] Figure input switch 4 [9] Figure input switch 9 [ ] Entry confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0
20-136 BZ210-1
(1)
Monitor panel functions - conventional and special

The monitor panel is provided with conventional and special functions, and various kind of information are
shown in the multi-display. Display items consists of automatic display items that are preset in the monitor panel
and others that are shown by switch operations.
1. Conventional function: Operator's Menu

This is a function by which an operator can set or show displays by switch operations. The display contents
are those which are normally shown.
2. Special function: Service Menu

This is a function by which a service mechanic can set or show displays by special switch operations. The
display contents are those which are not normally shown. It is mainly used for inspection, adjustment, trou-
bleshooting or special setting of machines.
Operator Menu Service Menu

1 KOMATSU logo display screen 24 Monitoring [01] function
2 Startup inspection function Failure history [02] func- Electric system
25
3 Maintenance display function tion Mechanical system
4 Caution display function 26 Maintenance history [03] function
5 Normal screen display function 27 Switch maintenance mode [04] function
6 Display brightness and contrast control functions 28 Set phone number [05] function
7 Maintenance information verification function 29 Work equipment speed adjustment function
8 Service meter display function
9 Caution occurrence display function
10 User code display function
11 Service and failure code display function
12 Mixer mode setup function
13 Load setup function
14 Solidifying material setup function
15 Function for setup of other displays
16 Function for checking other displays
17 Overload and abnormal load history function
18 Function for resetting of cumulative value
19 Emergency stop verification function
20 Engine stop verification function
21 Liquid addition error verification function
22 Solidifying material CAL result verification function
23 Workload self-adjustment function
BZ210-1 20-137
(1)
Operation of Operator's Menu and

Display (Outline)
a This section introduces only the outline of the
operator's menu. For details on the contents and
operation steps of each menu, refer to the oper-
ation and maintenance manual or the chapter of
"STRUCTURE, FUNCTION AND MAINTE-
NANCE STANDARD" in this shop manual.
1. Function for showing KOMATSU logo

When the engine starting switch is turned ON,
KOMATSU logo is shown for two seconds.
2. Function for machine inspection before start-

ing day's work
Following the KOMATSU logo, the display of
machine inspection before starting day's work is
shown for 2 seconds.
3. Function for machine maintenance

Following the display of machine inspection
before starting day's work, the maintenance
mark appears for 30 seconds, if there is an oil fil-
ter whose maintenance time is approaching or
has just passed.
a This display appears only when the mainte-
nance function is set.
4. Function for showing precaution items

If there is any item of machine inspection before
starting day's work that indicates some abnor-
mality, a corresponding symbol mark is shown
after the display of machine inspection before
starting day's work.
20-138 BZ210-1
(1)
5. Normal screen display function

After the Startup Inspection screen, the normal
screen is displayed.
a If the mixer mode, travel speed setup, or
crane operation is changed or if the Eco-ac-
celerator setting is enabled on the normal
display screen, its large marking is displayed
two seconds.
a The preheating monitor is displayed during
preheating only.
a The normal screen display is switched when
the operation, manual or travel mode switch
is changed on the operation panel or when
the Mixer, Equipment or Machine switch is
used.
a If the work equipment is started or stopped,
the normal screen is displayed three sec-
onds (during Manual mode) and it is returned
to the previous screen.
6. Function for adjusting display luminance and

contrast
Luminance as well as contrast of the display can
be adjusted by operating the display adjusting
switch.
BZ210-1 20-139
(1)
7. Function for confirming maintenance infor-

mation
Detailed information on maintenance items (set
time and elapse of time) can be confirmed and
resetting after the confirmation is feasible by
operating the maintenance switch.
a Use service Menu for setting or releasing
maintenance items and setting maintenance
time.
8. Function for showing service meter reading

Only the service meter reading can be shown by
the following switching operation, when the
engine starting switch is turned OFF.
• Switching operation: [ ] + [ ] (synchro-
nized switching operation)
9. Function for showing occurrence of caution

item
If any of the caution items occurs, the magnified
corresponding symbol mark is shown for two
seconds and thereafter stays on the display as a
small symbol mark until it is dissolved.
10. Function for showing users' code No.

When a trouble occurs on the machine, the
user's code is automatically displayed depend-
ing on the magnitude of the trouble to call atten-
tion of the operator for a proper action.
a This display turns to the display of service
code and failure code, if operating the switch
(Refer to Item No. 11)
20-140 BZ210-1
(1)
a Relation between User Code and Action Directed to Operator
User
Failed System Action Directed to Operator
Code
Ordinary work may be resumed by turning the emergency pump drive switch ON, but call
E02 PC-EPC Valve
for the inspection service immediately.
The governor control has become inoperable. Operate the governor control lever manually.
E05 Governor For fixing the lever at full throttle position, use a fixing bolt provided at the bracket. In this
case, call for the inspection service immediately.
11. Function for showing service code No. and

failure code No.
If the following switching operation is made
while the users' code No. is shown, phone num-
bers (if registered), service code No. and failure
code No. are shown in turn.
• Switching operation: [ ] (keep the switch
depressed)
a The following display is repeated in turn,
while the switch is depressed.
(1) Telephone No.
(2) Service code No. and failure code No.

a The telephone No. is shown only when it is
registered in the monitor panel.
For registration, correction and deletion of
telephone No., use Service Menu.
a For details on the displayed service code No.
and failure code No., refer to the Table for
Service and Failure Code Nos.
BZ210-1 20-141
(1)
Service and Failure Code Table

User code
Service Code Failure Code
Category
Code Explanation Code Failure location Status
— E201 Conveyor FWD SOL valve disconnected 7RD1KA Conveyor FWD SOL Disconnected
— E202 Conveyor FWD SOL valve short circuited 7RD1KB Conveyor FWD SOL Short circuited
— E203 Conveyor REV SOL valve disconnected 7RD2KA Conveyor REV SOL Disconnected
— E204 Conveyor REV SOL valve short circuited 7RD2KB Conveyor REV SOL Short circuited
— E205 Hammer #1 FWD EPC SOL disconnected 7RD3KA Hammer #1 FWD EPC SOL Disconnected
— E206 Hammer #1FWD EPC SOL short circuited 7RD3KB Hammer #1 FWD EPC SOL Short circuited
— E207 Hammer #2 FWD EPC SOL disconnected 7RD4KA Hammer #2 FWD EPC SOL Disconnected
— E208 Hammer #2 FWD EPC SOL short circuited 7RD4KB Hammer #2 FWD EPC SOL Short circuited
— E209 Hammer #3FWD EPC SOL disconnected 7RD5KA Hammer #3 FWD EPC SOL Disconnected
— E210 Hammer #3FWD EPC SOL short circuited 7RD5KB Hammer #3 FWD EPC SOL Short circuited
— E211 Hammer REV SOL valve disconnected 7RD6KA Hammer REV solenoid Disconnected
— E212 Hammer REV SOL valve short circuited 7RD6KB Hammer REV solenoid Short circuited
— E213 Soil cutter FWD EPC SOL disconnected 7RD7KA Soil cutter FWD EPC SOL Disconnected
— E214 Soil cutter FWD EPC SOL short circuited 7RD7KB Soil cutter FWD EPC SOL Short circuited
— E215 Soil cutter REV SOL disconnected 7RD8KA Soil cutter REV EPC SOL Disconnected
— E216 Soil cutter REV SOL short circuited 7RD8KB Soil cutter REV EPC SOL Short circuited
Solidifying material feeder FWD EPC SOL dis- Solidifying material feeder
— E217 7RD9KA Disconnected
connected FWD EPC SOL
Electric system
Solidifying material feeder FWD EPC SOL Solidifying material feeder
— E218 7RD9KB Short circuited
short circuited FWD EPC SOL
Solidifying material feeder REV SOL discon- Solidifying material feeder
— E219 7RDAKA Disconnected
nected REV EPC SOL
Solidifying material feeder REV SOL short cir- Solidifying material feeder
— E220 7RDAKB Short circuited
cuited REV EPC SOL
— E221 Raking rotor FWD EPC SOL disconnected 7RDBKA Raking rotor FWD EPC SOL Disconnected
— E222 Raking rotor FWD EPC SOL short circuited 7RDBKB Raking rotor FWD EPC SOL Short circuited
— E223 Raking rotor REV SOL disconnected 7RDCKA Raking rotor REV EPC SOL Disconnected
— E224 Raking rotor REV SOL short circuited 7RDCKB Raking rotor REV EPC SOL Short circuited
— E225 Soil conveyor FWD EPC SOL disconnected 7RDDKA Soil conveyor FWD EPC SOL Disconnected
— E226 Soil conveyor FWD EPC SOL short circuited 7RDDKB Soil conveyor FWD EPC SOL Short circuited
— E227 Soil conveyor REV EPC SOL disconnected. 7RDEKA Soil conveyor REV EPC SOL Disconnected
— E228 Soil conveyor REV EPC SOL short circuited 7RDEKB Soil conveyor REV EPC SOL Short circuited
— E229 ATT1 solenoid disconnected 7RDFKA ATT1 solenoid Disconnected
— E230 ATT1 solenoid short circuited 7RDFKB ATT1 solenoid Short circuited
— E231 ATT2 solenoid disconnected 7RDGKA ATT2 solenoid Disconnected
— E232 ATT2 solenoid short circuited 7RDGLB ATT2solenoid Short circuited
— E233 ATT3 solenoid disconnected 7RDHKA ATT3 solenoid Disconnected
— E234 ATT3 solenoid short circuited 7RDHKB ATT3 solenoid Short circuited
— E235 Air compressor solenoid disconnected 7RDJKA Air compressor solenoid Disconnected
— E236 Air compressor solenoid short circuited 7RDJKB Air compressor solenoid Short circuited
20-142 BZ210-1
(1)
User code
Category
— E237 Crane EPC solenoid disconnected 7RDKKA Crane EPC solenoid Disconnected
— E238 Crane EPC solenoid short circuited 7RDKKB Crane EPC solenoid Short circuited
E02 E239 Pump PC-EPC solenoid disconnected DXA0KA Pump PC-EPC solenoid Disconnected
E02 E240 Pump PC-EPC solenoid short circuited DXA0KB Pump PC-EPC solenoid Short circuited
E05 E241 Governor motor A, B phase disconnected DY10KA Governor motor A, B phase Disconnected
E05 E242 Governor motor A, B phase short circuited DY10KB Governor motor A, B phase Short circuited
— E243 Governor motor abnormality DY10K4 Governor motor abnormality Loss of control
— E244 Battery relay output short circuited D110KB Battery relay output Short circuited
— E245 Monitor lamp (green) SSR short circuited DUM0KB Monitor lamp (green) SSR Short circuited
— E246 Horn relay short circuited D162KB Horn relay Short circuited
— E247 Beacon lamp (red) SSR short circuited DUB0KB Beacon lamp (red) SSR Short circuited
Electrical intake air heater
— E248 Electrical intake air heater relay disconnected 7RDMKA Disconnected
relay
Electrical intake air heater
— E249 Electrical intake air heater relay short circuited 7RDMKB Short circuited
relay
— E250 Liquid addition relay disconnected 7RDLKA Liquid addition relay Disconnected
— E251 Liquid addition relay short circuited 7RDLKB Liquid addition relay Short circuited
— E300 Emergency stop switch disconnected 7R96KA Emergency stop switch Disconnected
— E301 Engine stop switch disconnected DDA6KA Engine stop switch Disconnected
E05 E302 Fuel dial error DK10KZ Throttle potentiometer Malfunction
Electric system
Governor motor feedback
— E303 Governor potentiometer error DK58KX Malfunction
potentiometer
— E304 Conveyor ON switch short circuited 7RC1KB Belt conveyor ON switch Short circuited
— E305 Conveyor OFF switch disconnected 7RC2KA Belt conveyor OFF switch Disconnected
— E306 Mixer ON switch short circuited 7RC3KB Mixer ON switch Short circuited
— E307 Mixer OFF switch disconnected 7RC4KA Mixer OFF switch Disconnected
— E308 Feeder ON switch short circuited 7RC5KB Feeder ON switch Short circuited
— E309 Feeder OFF/REV switch disconnected 7RC6KA Feeder OFF/REV switch Disconnected
— E310 ATT1 ON switch short circuited 7RC7KB ATT1 ON switch Short circuited
— E311 ATT1 OFF switch disconnected 7RC8KA ATT1 OFF switch Disconnected
— E312 ATT2 ON switch short circuited 7RC9KB ATT2 ON switch Short circuited
— E313 ATT2 OFF switch disconnected 7RCAKA ATT2 OFF switch Disconnected
— E314 ATT3 ON switch short circuited 7RCBKB ATT3 ON switch Short circuited
— E315 ATT3 IFF switch disconnected 7RCCKA ATT3 OFF switch Disconnected
— E316 Air compressor ON switch short circuited 7RCDKB Air compressor ON switch Short circuited
— E317 Air compressor OFF switch short circuited 7RCEKA Air compressor OFF switch Short circuited
Conveyor manual FWD
— E318 Conveyor manual FWD Switch short circuited 7RCFKB Short circuited
switch
Conveyor manual REV
— E319 Conveyor manual REV switch short circuited 7RCGKB Short circuited
switch
Hammer manual FWD
— E320 Hammer manual FWD switch short circuited 7RCHKB Short circuited
switch
— E321 Hammer manual REV switch short circuited 7RCJKB Hammer manual REV switch Short circuited
BZ210-1 20-143
(1)
User code
Category
— E322 Soil cutter manual FWD switch short circuited 7RCKKB Soil cutter manual FWD switch Short circuited
— E323 Soil cutter manual REV switch short circuited 7RCLKB Soil cutter manual REV switch Short circuited
Solidifying material feeder manual FWD switch Solidifying material feeder
— E324 7RCMKB Short circuited
short circuited manual FWD switch
Solidifying material feeder manual REV switch Solidifying material feeder
— E325 7RCNKB Short circuited
short circuited manual REV switch
Raking rotor manual FWD switch short cir- Raking rotor manual FWD
— E326 7RCPKB Short circuited
cuited switch
Raking rotor manual REV switch short cir- Raking rotor manual REV
— E327 7RCQKB Short circuited
cuited switch
Soil feeder manual FWD
— E328 Soil feeder manual FWD switch short circuited 7RCRKB Short circuited
switch
Electric system
Soil feeder manual REV
— E329 Soil feeder manual REV switch short circuited 7RCSKB Short circuited
switch
— E331 Calibration switch short circuited 7RCUKB Calibration switch Short circuited
— E332 Radio control CH1 short circuited 7R9CKB Radio control receiver Short circuited
— E333 Radio control CH2 short circuited 7R9DKB Radio control receiver Short circuited
— E334 Radio control CH3 short circuited 7R9EKB Radio control receiver Short circuited
— E335 Radio control CH4 short circuited 7R9FKB Radio control receiver Short circuited
— E336 Soil cutter pressure sensor error 7R9GKB Soil cutter pressure sensor Short circuited
— E337 S-NET signal disconnected DA2SKA S-NET Disconnected
— E338 Engine speed sensor error DLE2MA Engine speed sensor Malfunction
Model selection harness disconnected, short Model selection harness, Signal mismatch-
— E339 DB79KZ
circuited or input error input ing
— E340 Crane accel. throttle signal error 7R9HKX Crane accel. throttle signal Malfunction
— E341 F pump pressure sensor error DHPAMA Pump F pressure sensor Malfunction
— E342 R pump pressure sensor error DHPBMA Pump R pressure sensor Malfunction
— None Clogged air cleaner AA10NX Air cleaner element Clogged
— None Abnormal drop of recharging voltage AB00KE Alternator Poor charging
Mechanical system
— None Abnormal drop of engine oil pressure B@BAZG Engine oil Dropped pressure
— None Abnormal drop of engine oil level B@BAZK Engine oil Dropped oil level
— None Overheated engine water temperature B@BCNS Cooling water Overheated
Dropped water
— None Abnormal drop of radiator water level B@BCZK Cooling water
level
— None Overheated hydraulic oil temperature B@HANS Hydraulic oil Overheated
a This table is arranged in the sequence of Service Code No.

a In case there is no number assigned in the column of User Code No., or in case "none" is described in
the column of Code No. of Service Code, the corresponding service code or failure code is not shown in
the display of ordinary items, even if some abnormality occurs. It is recorded only in the failure history
(either in electrical system or mechanical system) of Service Menu.
a History Classification indicates that a specific failure is classified as belonging to either electrical system
or mechanical system, when it is recorded in Service Menu.
a "E" at the head of Code No. of Service Code means the following status of a specific failure.
• With "E":The failure is yet to be dissolved and continues.
• Without "E":The failure has already been dissolved.
20-144 BZ210-1
(1)
12. Mixer mode setup function Serial No. 1001 – 1100

The mixer mode can be switched by the Mode
selector switch.
13. Load setup function

The work load and its modified coefficient can
be set by the Soil/Solidifying material set switch.
14. Solidifying material setup function

The addition amount of solidifying material, the
gravity of solidifying material, and the modified
coefficient of solidifying material can be set by
the Soil/Solidifying material set switch.
BZ210-1 20-145
(1)
15. Function for setup of other displays

The monitor panel and machine parameters can
be changed in the following steps. Use them
when necessary.
1) Check the display
Make sure that the normal (mixer, equip-
ment or machine) display is shown (see the
3 figures shown at right).
2) Switch operation
Press the Set switch.
3) Display the menu (see the figure at right bot-
tom position)
When the initial screen appears for setup of
other displays, select the desired menu. For
the menu details and their operation proce-
dure, see the "Operation & Maintenance
Manual."
No. Menu for setup of other displays
Return
00
(Exit the menu for setup of other displays)
01 Attachment setup
02 Setting cumulative value
03 Setting clock time
04 Setting kinds of solidifying material.
05 Raking rotor FWD/REV
06 Use of soil cutter
07 Eco-accelerator
08 Batch process
09 Addition of solidifying material.
10 Setting liquid addition
4) Quit the menu function

To quit the menu function from the screen
for setup of other displays or from each
menu screen, use the following steps.
: Press the [ ] switch. (This switch is
effective on all screens.)
: When the Return switch is shown, press
it.
: When the [Return] menu is displayed,
select this menu and press the [ ]
switch.
20-146 BZ210-1
(1)
16. Function for checking other displays

The options of other displays can be checked by
the Check switch of set items.
17. Overload and abnormal load history function

The number of times when the work is over-
loaded or when an abnormal load occurs can be
checked by the Clogging history switch. This
occurrence time is cleared when the function for
resetting of cumulative value (Paragraph 18) is
used.
18. Function for resetting of cumulative value

The cumulative values of workload and solidify-
ing material addition amount can be cleared if
the [ ] switch is pressed on the normal display
screen.
19. Emergency stop verification function

If the Emergency Stop switch of the machine is
pressed, the emergency stop status is indicated
after the startup inspection screen has been dis-
played. This indication is cleared when the
Emergency Stop switch is released.
BZ210-1 20-147
(1)
20. Engine stop verification function

If the Engine Stop switch is pressed or if the
Start switch is turned OFF, the engine stop is
indicated after the startup inspection screen has
been displayed.
21. Liquid addition error verification function

If the liquid addition unit (optional) has failed, the
liquid addition unit error is indicated after the
startup inspection screen has been displayed.
22. Solidifying material CAL result verification

function
After the solidifying material calibration has
completed, the calibration result is displayed.
23. Workload self-adjustment function

If the workload, its modified coefficient, harden-
ing material addition amount, or the modified
coefficient of solidifying material is changed
using the Soil/Solidifying material switch and if
its setup exceeds the operation limit, the work-
load is adjusted automatically and the modified
result is displayed.
k If "01 NO" is selected, setting is reset and

the modified value is set to the default value
again.
20-148 BZ210-1
(1)
Operation and Display of Service Menu
Way of switching to Service Menu

a When using Service Menu, change the display
to Service Menu display through the following
special operation.
1) Confirmation of display
Confirm that the display of ordinary items is
shown.
a Changing to Service Menu cannot be made
from displays other than this.
2) Switch operation
Operate the switch as instructed below.
• Switch operation: [ ] + [1] ➝ [2] ➝ [3]
(Enter a figure, depressing [ ])
BZ210-1 20-149
(1)
3) Showing Service Menu display

The display is changed to the initial display of
Service Menu program. Select an appropriate
item from among the menu.
No. Service Menu
00 Return (Termination of Service Menu)
01 Monitoring
02 Abnormality Record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
4) Termination of Service Menu function

When terminating the initial display or any sub-
sequent display of Service Menu, do that
through any one of the following methods.
Depress [ ] switch. (This method may be
used for terminating any display)
If "Return" switch is shown, depress it.
If "Return" menu is shown, call that menu
and depress [ ] switch.
20-150 BZ210-1
(1)
1. Function of monitoring [01]

The monitor panel monitors signals from an
assortment of switches, sensors and actuators
installed in various parts of the machine. Moni-
tored information can be put in display or con-
firmed on a real time basis through the following
operations.
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
2) Setting of monitoring item

Select or register an item to be monitored
through the following switch operation.
• [ ] switch: Selection
• [ ] switch: Selection
• [ ] switch: Registration
a A monitoring item can be set in any number
between the min. one to the max. four. (De-
pending upon the selected item, the max.
number is less than four)
a In case of monitoring 1 to 3 items, move to
the monitored information display through
any of the following switch operations, after
the registration work has been completed.
• Select Menu 999 and depress [ ]
switch.
a The display automatically moves to the dis-
play of monitored information, when all of the
registrable items have been duly registered.
a Monitored information are transmitted via
communication circuits. Thus the number of
selected items can impact the communica-
tion speed. If truly real time monitoring is re-
quired, reduce the selected items to the
minimum.
a For details on the monitoring items, display
unit, etc., refer to the Table for Monitoring
Items.
BZ210-1 20-151
(1)
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.
4) Monitored information holding function

If [ ] switch is depressed while monitoring,
all the monitored information are put on
hold. If [ ] switch is depressed in this con-
dition, information holding is released.
20-152 BZ210-1
(1)
Monitoring Item List

Code No. Monitoring Item Unit Remarks
000 Return (Not displayed) Exit menu
999 Display (Not displayed) Display menu
220 Raking rotor FWD current mA
221 Model code Number
222 Solidifying material feeder FWD current mA
010 Engine speed rpm
121 1st throttle command rpm
016 2nd throttle command rpm
030 Fuel dial voltage V
031 Governor potentiometer voltage V
033 Governor motor A phase current mA
034 Governor motor B phase current mA
035 Battery relay output voltage V
013 PC-EPC current mA
223 Soil feeder FWD current mA
224 Soil cutter pressure kg/cm2
225 Raking rotor target speed rpm
226 Soil cutter pressure sensor voltage V
228 Soil feeder target frequency Hz
229 Solidifying material feeder target frequency Hz
230 Soil feeder actual frequency Hz
231 Engine throttle, pump controller power voltage V
232 Solidifying material feeder actual frequency Hz
233 Program version Number
234 Crane throttle signal V
235 Soil cutter FWD current mA
236 Hammer No. 1 FWD current mA
239 Crane current mA
240 Work equipment controller power voltage V
001 Front pump pressure kg/cm2
012 Rear pump pressure kg/cm2
BZ210-1 20-153
(1)
2. Function for Abnormality Record [02]

The monitor panel records failures that occurred
on the machines in the past after classifying
them into failures in the electric system and
those in the mechanical system. Information on
them can be displayed through the following
operation.
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No. Abnormality Record Submenu
Return
00
(termination of Abnormality Record)
01 Electrical System
02 Mechanical System
3) Information shown in display of Abnormality

Record in the electrical system
: The numerator expresses sequence of
failure occurrence, counting from the
latest one. The denominator expresses
the total number of a specific failure
recorded.
: Service Code
: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
: Time elapsed since the occurrence of
the first failure
: Contents of failure
a Refer to "Table for Service Code and Ab-
normality Code" in Operator's Menu.
4) Information shown in display of Failure His-

tory in the mechanical system
: Record No.
: Contents of Abnormality
: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
: Total number of occurrence
: Service meter reading at the initial
occurrence
a Refer to "Table for Service Code and Ab-
normality Code" in Operator's Menu.
20-154 BZ210-1
(1)
5) Resetting Electrical Systems

a Resetting Electrical Systems (deletion)
is possible only with the electrical sys-
tem. The failure history in the mechani-
cal system cannot be reset.
a For resetting any specific or all informa-
tion in the Electrical Systems, follow the
operation explained below.
i) Through the following switch operation,
call the resetting display in the display of
Electrical Systems.
• Switch operation:
[ ] + [1] [2] [3]
a This is the same switch operation in
changing the display to Service
Menu.
ii) Operate the switch, following the instruc-
tions shown in the resetting display.
a When resetting specific information
only, call the display of that specific
information and reset it with either
[ ] switch or [ ] switch.
a When resetting all the information, a
display of any information will do.
BZ210-1 20-155
(1)
3. Function for Maintenance Record [03]

The monitor panel records information on the
maintenance of filters and oils. The stored infor-
mation can be displayed through the following
switch operation.
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
: Name of oils and filters
: Times of replacement to date
: Service meter reading at the latest
replacement
20-156 BZ210-1
(1)
4. Function for Maintenance Mode Change [04]

Conditions set for controlling maintenance dis-
play function can be changed in the following
manner.
• Turn the function effectual or ineffectual.
• Change the set interval for replacement.
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of item to be changed

Select an item to be changed in the display
of Maintenance Mode Change Selecting
Menu.
No. Maintenance mode change item
Return
00
(End of maintenance mode chage)
01 Maintenance Mode On/Off
02 Engine Oil Exch. Int.
03 Engine Oil Filter Exch. Int.
04 Fuel Filter Exch. Int.
05 H/Oil Filter Exch. Int.
06 H/Tank Breather Exch. Int.
07 Corro. Resis. Exch. Int.
08 PTO Oil Service Int.
09 Final Drive Oil Exch. Int.
10 Hydraulic Oil Exch. Int.
11 Soil Conv. Motor Oil Exch. Int.
12 Rotor Motor Oil Exch. Int.
13 Use Default Value
a 01 and 13 menus are provided for setting the

whole maintenance mode, while those from
02 through 12 are for setting individual items.
BZ210-1 20-157
(1)
3) Contents of Maintenance Mode On/Off

• On: The maintenance display function of
all oil and filter-related items are turned
effectual. (Irrespective of whether "On"
or "Off" set for individual items, this set-
ting prevails)
• Off: The maintenance display function of
all oil and filter-related items are turned
ineffectual. (Irrespective of whether "On"
or "Off" set for individual items, this set-
ting prevails)
4) Set contents of individual items

: Default: The maintenance time set in
the monitor (recommended by the man-
ufacturer and cannot be changed).
: Set: Maintenance time that can be
freely set. The maintenance mode pro-
gram functions based on this mainte-
nance time. (The maintenance time can
be increased or decreased by 50 hours
with [ ] or [ ] switch)
: On: Maintenance display function with
this instruction becomes effectual.
: Off: Maintenance display with this
instruction becomes ineffectual.
a The lowest maintenance time is 50 h.
5) Set contents of "Use Default Values"

When selecting this menu and depressing
the switch [ ], all individual time settings
are reduced to the initial settings.
20-158 BZ210-1
(1)
5. Function for Phone Number Entry [05]

In the display of User Code, a telephone number
and Service Code are shown alternately. Phone
number can be inputted or modified in the fol-
lowing manner.
a If there is no Phone number registered, the
display for Phone numbers does not appear.
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
2) Changing the display

Select Entry next to change the display to
the Phone Number Entry display.
a Even if a Phone number is already input-
ted, it is deleted, upon switching to the
Phone Number Entry display.
3) Entry and setting Phone number

Following the method explained below,
Entry a Phone number in the Phone Num-
ber Entry display. (Entry automatically
begins with a cursor at the left end)
i) Enter a number into a cursor at the left
end with a ten-key.
ii) Depress [ ] switch when all the num-
bers have been entered.
a Numbers can be entered up to the max.
12 digits, but omit unnecessary digits.
a When entering a wrong number, de-
press [B] switch, then the cursor goes
back by one digit.
a When input is finished, the display
changes to Entry display shown above.
If the inputted Phone number is shown in
this display, the input is normal.
BZ210-1 20-159
(1)
6. Machine speed adjustment function

This function can adjust the following parame-
ters.
• Speed of No. 1 to No. 3 hammers

• Soil cutter speed
• Raking rotor speed
a Adjust the above speeds if they greatly differ
from the standard values if the controller has
failed or after the controller has been re-
placed.
a Prepare and use the work equipment speed
measuring instruments.
Adjusting the work equipment speed

1) Set the Work/Manual/Travel mode switch to
the Work position, and start the discharging
conveyor, mixer and feeder.
Start the attachment if mounted.
a Set the solidifying material feeder to
have the soil because the feeder does
not start if the soil is not detected by its
sensor.
2) Call the Work Equipment Speed Adjustment
screen.
On the initial screen of Service Menu, enter
"91" using the monitor panel switches.
Make sure that the entry is correct and
press the [ ] switch.
3) Select the work equipment to be adjusted.
The Work Equipment Speed Adjustment
screen will be displayed.
Select the work equipment you wish to
adjust by pressing the [ ] or [ ] switch
on the monitor panel, and press the [ ]
switch.
No. Speed adjustment selection menu
00 Return (Quit the speed adjustment)
01 No. 1, No. 2 or No. 3 hammer
02 Soil cutter or raking rotor
4) Changing the No. 1, No. 2 or No. 3 hammer

speed
: From the Work Equipment Speed
Adjustment screen, select "01: #1, #2,
#3 hammer" and press the [ ] switch.
20-160 BZ210-1
(1)
: The "#1, #2, #3 Hammer Speed Adjust-

ment" screen will appear.
Locate the cursor onto "550" using the
[ ] or [ ] switch of the monitor panel,
and press the [ ] switch.
: The numeric value entry window will

appear.
A value at the selected cursor position
flashes simultaneously. Measure the
speed of the hammer you have selected
in Step , enter the measured speed
using the monitor panel switches, and
press the [ ] switch.
: The numeric value entry window will be

cleared, and the cursor will be displayed
at the position selected in Step .
: Repeat Steps to for the speed of

other hammers of Step .
5) Changing the soil cutter and raking rotor val-

ues
: From the Work Equipment Speed
Adjustment screen, select "02: Soil cut-
ter, raking rotor" and press the [ ]
switch.
BZ210-1 20-161
(1)
: The Soil Cutter, Raking Rotor Speed

Adjustment screen will be displayed.
Locate the cursor onto "Soil Cutter 75"
using the [ ] or [ ] switch of the mon-
itor panel, and press the [ ] switch.
: The numerical value input window will

be displayed.
A value at the selected cursor position
flashes simultaneously. Measure the
speed of the soil cutter selected in Step
, enter the measured speed using the
monitor panel switches, and press the
[ ] switch.
: The numeric value entry window will be

cleared, and the cursor will be displayed
at the position selected in Step .
: Repeat Steps to for the speed of
other devices and raking rotor of Step
.
6) Closing the menu and functions

To quit the operations on the Work Equip-
ment Speed Adjustment screen or each
menu, use one of the following steps.
: Press the [ ] switch. (This switch is
effective on all screens.)
: When the [Return] switch is shown,
press it.
: When the "Return" menu is displayed,
select this menu and press the [ ]
switch.
20-162 BZ210-1
(1)
7. Function of setting initial values [06]

Selection of Japanese or English display
1) Select [06].
2) Select [01].
3) Select "01 Japanese" or "02 English".
BZ210-1 20-163
(1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202

SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING......................................................... 20-213
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF
EACH SYSTEM.................................................................................................................................... 20-217
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-256
T-BRANCH BOX AND T-BRANCH TABLE................................................................................................. 20-279
TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND Error code

"MECHANICAL SYSTEM" ARE INDICATED ....................................................................................... 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ................................. 20-601
TROUBLESHOOTING OF ENGINE (S-MODE) ......................................................................................... 20-701
BZ210-1 20-201
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 BZ210-1
(1)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
BZ210-1 20-203
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 BZ210-1
(1)
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins will
be short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.
BZ210-1 20-205
(1)
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
a If the connector is twisted up and down
or to the left or right, the housing may
break.
3) Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
a If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 BZ210-1
(1)
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
a If there is any damage or breakage, re-
place the connector.
2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3) Correct any protrusion of the boot and any

misalignment of the wiring harness.
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
BZ210-1 20-207
(1)
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows:
1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
a After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 BZ210-1
(1)
3) Handling control box

1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand)
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in that circuit.
BZ210-1 20-209
(1)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger or dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt, or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210 BZ210-1
(1)
5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic tank;
also drain the oil from the filter and from the
drain plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
BZ210-1 20-211
(1)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
Value
1. Check fuel level — Add fuel
Lubricating oil, coolant
2. Check for impurities in fuel — Clean, drain

3. Check hydraulic oil level — Add oil
Checks before starting
4. Check oil level in damper case — Add oil

5. Check power train oil level — Add oil
6. Check engine oil level (engine oil pan level) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
equipment
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
mechanical
equipment
Hydraulic,
1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30 V Replace

2. Check battery electrolyte level — Add or replace
Other check items
3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wire — Repair
Electrical equipment
5. Check for water leaking on wiring (pay particularly careful attention — Disconnect con-
to water leaking on connectors or terminals) nector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After running Replace
for several
minutes:
27.5 – 29.5 V
8. Check operating sound of battery relay (starting switch ON, OFF) — Replace
20-212 BZ210-1
(1)
TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING

CLASSIFICATION OF TROUBLESHOOTING
Mode Contents
Troubleshooting when service code [Electric system] or error code [Mechanical system] is dis-
Code display
played
E Mode Troubleshooting for electrical system
H Mode Troubleshooting for hydraulic and mechanical system
S Mode Troubleshooting for engine unit
PROCEDURES FOR TROUBLESHOOTING

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to
the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when user code is displayed on monitor panel:
If a user code is displayed on the monitor panel, press the [ ] switch on the panel switch section to display
the service code.
Carry out the troubleshooting for the corresponding "Code display" according to the displayed service
code of the electrical system.
2. Procedure for troubleshooting when electrical system error code or mechanical system error code
is recorded in error history:
If a user code is not displayed on the monitor panel, check for a service code of the electrical system and an
error code of the mechanical system with the error history display function of the monitor panel.
If a code is recorded, carry out troubleshooting for the corresponding "Code display" according to the dis-
played code.
a If error codes are recorded, delete all of them and reproduce them, and then see if the trouble is still de-
tected.
a An error code of the mechanical system cannot be deleted.
a If an electrical system trouble occurs, the horn is turned ON for 1 second and OFF for 1 second 3 times.
As for mechanical system troubles, if the charge level, engine coolant temperature, or engine oil pres-
sure is abnormal, the horn continues sounding. When another mechanical system trouble occurs, the
horn does not sound.
3. Procedure for troubleshooting to be taken when user code is not displayed and error history is not
recorded:
If a user code is not displayed in the monitor panel and the error history is not recorded, a trouble that the
machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical
system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the
table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting
related to that phenomenon in the "E mode", "H mode", or "S mode".
BZ210-1 20-213
(1)
PHENOMENA LOOKING LIKE TROUBLES AND TROUBLESHOOTING NOS.

Troubleshooting
No. Phenomena looking like troubles Code
E-mode H-mode S-mode
display
Phenomena related to user code, service code, or error code
1 User code is displayed on monitor panel
When error history is checked, service code is displayed in electri- According
2
cal system to indicated
code
When error history is checked, error code is displayed in mechan-
3
ical system
Phenomena related to engine
4 Engine does not start easily (It always takes time to start) S-1
5 Engine does not crank E-1 S-2 (1)
E n g i n e Engine cranks but exhaust smoke does not come out
6 S-2 (2)
does not (Fuel is not injected)
start
Exhaust smoke comes out but engine does not start
7 S-2 (3)
(Fuel is injected)
Engine speed does not rise sharply (Follow-up performance is
8 S-3
low)
9 Engine stopped during operation E-2 H-2 S-4
10 Engine rotation is unstable (Engine hunts) E-3 S-5
11 Output is insufficient (Power is low) H-1 S-6
12 Exhaust gas is black (Incomplete combustion) S-7
13 Oil is consumed much (or exhaust gas is blue) S-8
14 Oil becomes dirty quickly S-9
15 Fuel is consumed much S-10
16 Coolant contains oil, blows back, or reduces S-11
17 Oil pressure monitor lights up (Oil pressure lowers) S-12
18 Oil level rises (Water or fuel is mixed in oil) S-13
19 Coolant temperature rises too high (Overheating) S-14
20 Abnormal sound comes out S-15
21 Vibration is excessive S-16
22 Engine does not stop E-4
23 Automatic warm-up function does not work E-5
24 The engine preheater does not operate E-5
Phenomena related to work equipment and travel system
25 Speed or power of whole work equipment and travel is low H-1 S-6
26 Engine speed lowers extremely or engine stalls H-2 S-4
27 Travel system and manual operation system do not work E-6 H-3
28 Abnormal sound comes out from around hydraulic pump H-4
While soil feeder is not loaded at all, soil feeder, solidifying mate-
29 E-21 H-5
rial feeder, and raking rotor stop
While soil feeder is overloaded, soil feeder, solidifying material
30 E-27 H-6
feeder, and raking rotor do not stop
20-214 BZ210-1
(1)
Troubleshooting
display
While solidifying material feeder is not loaded at all, soil feeder,
31 E-22 H-7
solidifying material feeder, and raking rotor stop
While solidifying material feeder is overloaded, soil feeder, solidi-
32 E-28 H-8
fying material feeder, and raking rotor do not stop
While discharge belt conveyor is not loaded at all, whole work
33 E-33 H-9
equipment stops
While discharge belt conveyor is overloaded, any work equipment
34 E-34 H-10
does not stop
While hammer is not loaded at all, soil feeder, solidifying material
35 E-29 H-11
feeder, and raking rotor stop
While hammer is overloaded, soil feeder, solidifying material
36 E-23 H-12
While soil cutter is not loaded at all, soil feeder, solidifying material
37 E-35 H-13
feeder, raking rotor, hammer, and soil cutter stop
While soil cutter is overloaded, soil feeder, solidifying material
38 E-36 H-14
feeder, raking rotor, hammer, and soil cutter do not stop
While raking rotor is not loaded at all, soil feeder, solidifying mate-
39 E-37 H-15
While raking rotor is overloaded, soil feeder, solidifying material
40 E-38 H-16
While attachment 1 is not loaded at all, whole work equipment (or
41 only front processor, when front processor is selected as attach- E-30 H-17
ment 1) stops
While attachment 1 is overloaded, any work equipment (or only
42 front processor, when front processor is selected as attachment 1) E-24 H-18
does not stop
ment 2) stops
does not stop
ment 3) stops
does not stop
47 Solidifying material level lamp (Lower) does not light up E-15
48 Solidifying material level lamp (Upper) does not light up E-16
49 Time lag of work equipment is large H-23
Phenomena related to travel
50 Machine deviates during travel H-24
51 Travel speed is low H-25
52 Machine is not steered well or steering power is low H-26
53 Travel speed does not change or it is low or high H-27
BZ210-1 20-215
(1)
Troubleshooting
display
54 Travel motor does not work (only 1 side) H-28
Phenomena related to monitor panel (Ordinary screen)
55 No items are displayed on monitor panel E-7
56 Some items are not displayed on monitor panel E-8
Radiator coolant level monitor lights red during check before start-
57 B@BCZK
ing
58 Engine oil level monitor lights red during check before starting B@BAZK
59 Maintenance hour monitor lights red during check before starting See operation manual
60 Battery charge level monitor lights red while engine is running AB00KE
61 Fuel level monitor lights red while engine is running E-9
62 Air cleaner clogging monitor lights red while engine is running AA10NX
Hydraulic oil temperature monitor lights red while engine is run-
63 B@HANS
ning
Engine coolant temperature monitor lights red while engine is run-
64 B@BCNS
ning
65 Engine coolant temperature gauge does not indicate normally E-10
66 Hydraulic oil temperature gauge does not indicate normally E-11
67 Fuel level gauge does not indicate normally E-12
68 When monitor switch is operated, nothing is displayed E-13
69 Soil presence is not displayed normally on ordinary screen E-17
70 Integrated liquid addition value is not displayed normally E-18
71 Travel/Work/Manual mode does not change E-19
Phenomena related to monitor panel (Special function screen)
72 Front pump pressure is not displayed normally E341
73 Rear pump pressure is not displayed normally E342
Other phenomena
74 Travel alarm does not sound E-20
20-216 BZ210-1
(1)
CONNECTOR LOCATION CHART AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC

CIRCUIT DIAGRAM OF EACH SYSTEM
CONNECTOR LIST
Connec- No. of Address
Type Name of device
tor No. pins Plain M circuit G circuit P circuit C circuit
A01 D 8 Short connector AJ-1 — — L-8 P-2
A02 D 6 Short connector AI-1 — — L-7 P-2
A03 D 6 Short connector BG-8 — — — U-8
A04 D 6 Short connector BG-8 — — — U-8
A05 D 6 Short connector BY-4 — — — X-8
A06 D 8 Short connector AJ-2 — — L-6 Q-2
A07 D 6 Short connector AJ-2 — — — Q-2
A08 D 8 Short connector AT-5 G-1 — — I-1
A09 D 6 Short connector AT-5 H-1 — — I-1
A10 D 6 Short connector AT-5 H-1 — — I-1
A11 — 50 Printer — — L-3 — O-9
A20 Terminal 1 Battery relay E terminal AD-7 J-4 J-6 — —
A21 Terminal 1 Battery relay BR terminal AD-9 J-4 J-6 — —
A22 Terminal 1 Battery relay M terminal AC-9 J-4 J-6 — —
A23 Terminal 1 Battery relay B terminal AC-9 J-4 J-6 — —
A24 Terminal 1 Electrical intake air heater AB-8 J-7 J-8 — —
A27 X 2 Starting motor safety relay AC-7 K-3 K-4 — —
A28 Terminal 1 Starting motor safety relay AC-9 L-3 L-4 — —
A29 Terminal 1 Starting motor safety relay AB-9 L-3 — — —
A31 D 2 Air cleaner clogging sensor K-1, AK-4 K-9 — — —
A33 X 2 Radiator coolant level sensor J-1, AK-4 K-9 — — —
A34 L 2 Fusible link AD-7 K-3 K-5 — —
A35 L 2 Fusible link AD-9 K-3 K-5 — —
A60 X 1 Fuel level sensor C-9 K-8 — — —
A61 D 2 Hydraulic oil temperature sensor AP-5 K-9 — — —
C11 MIC 13 Governor pump controller CZ-2 A-4 A-6 — A-8
C12 MIC 21 Governor pump controller DB-2 — A-5 A-6 A-7
C13 040 20 + 16 Governor pump controller CZ-5 A-4 A-5 A-5 A-7
C14 040 12 Governor pump controller DA-5 A-3 A-4 A-5 —
C15 MIC 17 Governor pump controller DB-5 — A-4 — A-6
C21 MIC 13 Work equipment controller DF-2 A-3 A-3 — A-5
C22 MIC 21 Work equipment controller DH-2 — A-3 — A-4
C23 040 20 + 16 Work equipment controller DF-5 — A-2 A-4 A-4
C24 040 12 Work equipment controller DG-5 — — — A-3
C25 MIC 17 Work equipment controller DH-5 — A-2 — A-2
CV01 X 2 Soil feeder forward EPC solenoid AG-3 — — — H-9
Solidifying material feeder forward EPC
CV02 X 2 AG-2 — — — H-9
solenoid
CV03 X 2 Soil cutter forward EPC solenoid AG-2 — — — H-9
CV04 X 2 Crane EPC solenoid AG-2 — — — H-9
BZ210-1 20-217
(1)

Type Name of device
CV05 X 2 No.3 hammer forward EPC solenoid AG-2 — — — H-9
CV06 X 2 No.2 hammer forward EPC solenoid AG-2 — — — H-9
CV07 X 2 No.1 hammer forward EPC solenoid AG-1 — — — G-9
CV08 X 2 Raking rotor forward EPC solenoid AG-1 — — — G-9
D01 D 8 Assembled-type diode AJ-4 — — L-5 L-8
D02 D 8 Assembled-type diode AJ-4 — — — K-8
D03 D 8 Assembled-type diode AJ-4 — — — J-8
D04 KES1 2 Diode AC-7 K-4 K-5 — —
D05 KES1 2 Diode — C-9 E-9 — —
D07 KES1 2 Diode — D-9 — — —
D08 KES1 2 Diode — D-9 — — —
E01 Terminal 1 Electrical intake air heater AM-8 K-7 K-8 — —
E02 Terminal 1 Engine oil pressure switch AM-8 K-8 — — —
E03 X 1 Engine oil level sensor AU-7 K-7 — — —
E04 D 2 Engine speed sensor AO-8 — — J-2 —
E05 X 2 Engine coolant temperature sensor AN-8 K-7 — — —
E07 Terminal 1 Starting motor C terminal AR-7 K-6 — — —
E08 X 1 Intermediate connector AR-8 J-5 J-7 — —
E10 D 3 Governor potentiometer AO-4 — K-8 — —
E11 D 4 Governor motor AO-4 — K-9 — —
E12 X 2 Alternator AU-8 K-5 K-7 — —
E14 IZUMI 6 Emergency stop switch CX-7 — — — A-1
E15 IZUMI 6 Horn switch CX-6 — — — A-1
E16 IZUMI 6 Discharge belt conveyor ON switch CS-4 — — — A-1
E17 IZUMI 6 Discharge belt conveyor OFF switch CS-4 — — — B-1
E18 IZUMI 6 Mixer ON switch CS-3 — — — B-1
E19 IZUMI 6 Mixer OFF switch CS-3 — — — B-1
E20 IZUMI 6 Feeder ON switch CS-2 — — — C-1
E21 IZUMI 6 Feeder OFF/reverse switch CT-2 — — — C-1
E22 IZUMI 6 ATT2 ON switch (Vibratory sieve) CS-5 — — — D-1
E23 IZUMI 6 ATT2 OFF switch (Vibratory sieve) CS-6 — — — D-1
E24 IZUMI 6 ATT1 ON switch (Aftercutter) CS-5 — — — D-1
E25 IZUMI 6 ATT1 OFF switch (Aftercutter) CS-4 — — — E-1
ATT3 ON switch (Secondary belt con-
E26 IZUMI 6 CU-2 — — — E-1
veyor)
ATT3 OFF switch (Secondary belt con-
E27 IZUMI 6 CV-2 — — — E-1
veyor)
E29 — 2 Calibration switch CS-8 — — — F-6
E30 — 4 Travel/Work/Manual mode switch CS-6 — — C-8 D-9
E31 — 4 Light switch CX-7 C-2 — — —
E32 — 3 Fuel throttle dial CX-6 — C-2 — —
E33 IZUMI 6 Horn switch DT-5 — — — N-9
E34 D 8 (Gray) Intermediate connector (Crane) V-4 — K-1 — L-6
E35 — 4 Travel speed selector switch DT-8 — — — M-9
E36 IZUMI 6 Engine stop switch DT-7 — — — M-9
E37 D 12 (Gray) Intermediate connector C-5, BH-8 — — — L-6
E38 HD 14 Intermediate connector AZ-6 — — — V-8
20-218 BZ210-1
(1)

Type Name of device
E39 — 18 Radio control receiver — — — — A-9
E40 D 6 Intermediate connector AV-3, DR-3 — — — L-7
E42 M 1 Headlamp (Right) AK-8 J-1 — — —
Emergency stop switch (Left side of
E43 IZUMI 6 Z-8 — — — K-1
chassis)
Emergency stop switch (Right side of
E44 IZUMI 6 Y-7 — — — K-1
chassis)
E45 X 2 Travel alarm AC-6 — — K-1 —
Plug Solidifying material level indicator lamp
E46 1 BW-4 — — — X-8
connector (LOW side)
E47 Terminal 1 GND BY-4 — — — X-7
Plug Solidifying material level indicator lamp
E48 1 BY-4 — — — X-8
connector (HI side)
E49 D 2 Intermediate connector AU-5 — — — J-2
Emergency stop switch (Left side of dis-
E50 D 2 — — — — J-1
charge belt conveyor)
Emergency stop switch (Both sides of
E51 IZUMI 6 AO-3, AK-3 — — — J-1
discharge belt conveyor)
Emergency stop switch (Right side of
E52 D 2 — — — — J-1
discharge belt conveyor)
E53 D 8 (Black) Crane controller V-4 — — — V-3
E54 M 1 Working lamp E-9 J-1 — — —
E55 M 1 Working lamp (Right) N-5 I-1 — — —
E56 M 2 Working lamp (OP) I-1 I-1 — — —
E57 M 2 Working lamp (OP) BH-8 — — — S8
E58 M 1 Headlamp (Left) AP-6 J-1 — — —
E59 D 6 Intermediate connector D-5 — — J-1 L-2
I n t e r m e d i a t e c o n n ec t o r ( S t a r t i n g
E60 D 8 CP-3, CS-7 E-2 C-2 — —
switch)
E61 D 12 Intermediate connector CR-3 C-6 A-6 — —
E62 D 3 Intermediate connector AP-6 — — — H1
Plug
E63 1 Operation panel lighting CN-8 D-2 — — —
connector
E70 Terminal 3 Discharge belt conveyor manual switch CX-2 — — — A-9
E71 Terminal 3 Hammer manual switch CX-3 — — — A-9
E72 Terminal 3 Soil cutter manual switch CX-4 — — — B-9
Solidifying material feeder manual
E73 Terminal 3 CX-4 — — — C-9
switch
E74 Terminal 3 Raking rotor manual switch CX-4 — — — C-9
E75 Terminal 3 Soil feeder manual switch CX-5 — — — D-9
E76 Terminal 3 Air compressor ON/OFF switch CV-2 — — — E-9
G03 X 1 — CP-5 — — — S-2
G04 X 1 — CP-5 — — — S-2
12
H01 D Intermediate connector AQ-2, CL-4 — — — F-6
(Green)
12
H02 D Intermediate connector AQ-2, CL-4 — — — F-5
(Black)
H03 D 8 (Gray) Intermediate connector AQ-2, CL-4 — — F-7 F-4
H04 D 12 (Gray) Intermediate connector AQ-3, CL-4 — — F-5 F-4
BZ210-1 20-219
(1)

Type Name of device
H05 D 1 Intermediate connector AQ-3, CK-5 F-9 G-6 — —
H06 D 1 Intermediate connector AQ-4, CK-5 F-9 — — —
H07 D 1 Intermediate connector AR-5, CK-6 F-8 G-6 — —
H08 D 12 (Gray) Intermediate connector AR-5, CK-6 F-8 G-5 — —
12
H09 D Intermediate connector AR-5, CK-6 F-4 G-5 F-4 —
(Black)
12
H10 D Intermediate connector AR-5, CK-6 F-4 — F-3 F-3
(Green)
12
H11 D Intermediate connector AS-5, CK-7 — G-4 — F-3
(Brown)
Intermediate connector (No. 1 liquid
H12 D 6 AV-3, CJ-5 — G-3 — F-2
addition unit)
AV-3, EA-3,
H13 D 3 Intermediate connector (Printer) — G-3 — F-2
CJ-6
AV-4, EA-3,
H14 D 2 Intermediate connector (Printer) — G-2 — F-2
CJ-6
Intermediate connector (No. 2 liquid
H15 D 4 AV-4, CJ-6 — G-2 — F-1
addition unit)
H16 D 3 Intermediate connector (Sensor) CR-3 — — — F-1
Intermediate connector (compensation
H17 D 6 CQ-3 — G-2 — F-1
scale signal)
Intermediate connector (compensation
H18 D 2 CQ-3 — — — F-1
scale power supply)
K01 D 8 Centralized resistor CN-3 — B-9 — F-8
K13 D 3 Resistor — A-5 A-7 — —
P01 070 12 Monitor DO-5 A-8 A-8 — —
P02 040 20 Monitor DN-5 A-7 A-7 — —
P03 040 16 Monitor DN-9 A-6 A-7 — —
R SHINA-
R01 5 Emergency stop relay CM-3 — — — F-6
GAWA
R SHINA-
R02 5 Manual/Travel mode selector relay CM-3 — D-9 — F-7
GAWA
R SHINA-
R03 5 Radio control all stop relay CM-3 — D-9 — F-7
GAWA
R SHINA-
R04 5 Horn relay CN-3 — C-9 — F-7
GAWA
R SHINA-
R05 5 Chime relay CO-4 — — — F-8
GAWA
R SHINA-
R06 5 Light relay (Optional) CO-4 D-2 — — —
GAWA
R07 — 4 Monitor lamp relay CN-3 — — — F-9
R08 — 4 Beacon lamp relay CN-3 — — — F-9
SHINA-
R09 5 — CP-6 — — — —
GAWA
S01 E 3 No. 3 hammer pressure switch AG-3 — — — O-2
S02 E 3 No. 2 hammer pressure switch AG-3 — — — O-2
S03 E 3 No. 1 hammer pressure switch AF-3 — — — M-2
S04 E 3 Vibratory sieve pressure switch AF-3 — — — P-2
S05 E 3 Aftercutter pressure switch AE-3 — — — N-2
20-220 BZ210-1
(1)

Type Name of device
Discharge belt conveyor pressure
S06 E 3 AE-3 — — — O-2
switch
S07 E 3 Soil cutter pressure sensor AE-3 — — — M-2
S08 E 3 Raking rotor pressure switch AE-4 — — — M-2
Secondary belt conveyor pressure
S09 E 3 AE-4 — — — N-2
switch
S10 X 2 Travel PPC pressure sensor H-1 — — J-3 —
S11 X 3 F pump pressure sensor AG-5 — — K-9 —
S12 X 3 R pump pressure sensor AF-5 — — K-8 —
S21 D 3 Soil feeder speed sensor switch BD-8 — — — S-8
Solidifying material feeder speed sen-
S22 D 3 BA-9 — — — T-8
sor switch
S23 D 3 Soil presence sensor switch BH-2 — — — U-8
Solidifying material level sensor paddle
S26 SWP 6 — — — — W-8
switch (LOW side)
Solidifying material level sensor paddle
S27 SWP 6 BI-6 — — — W-8
switch (HI side)
S50 X 2 Travel PPC pressure switch H-1 — — K-3 —
H-1, AA-01,
T01 Terminal 1 Revolving frame GND L-5 L-6 — —
AB-07
T02 Terminal 1 Revolving frame GND G-1, AB-07 L-5 L-6 — —
T03 Terminal 1 Revolving frame GND G-1, AB-07 L-5 — — —
T04 Terminal 1 GND AI-6 — — — I-8
Plug
T07 1 Horn (1) AA-5 — — — L-1
connector
Plug
T08 1 Horn (2) AA-5 — — — L-1
connector
Plug
T09 1 Horn (1) AA-5 — — — L-1
connector
Plug
T10 1 Horn (2) AA-5 — — — L-1
connector
Plug
T11 1 Chime AA-5 — — — L-1
connector
Plug
T12 1 Chime AA-5 — — — L-1
connector
T13 L 2 Starting motor AR-6 J-6 — — —
Plug G-1, W-
T14 1 Monitor lamp (Green) AP-7, BX-4 — — —
connector 8
T15 X 2 Beacon lamp (Red) AP-7, BY-4 — — — G-1, V-8
Plug G-1, W-
T16 1 Monitor lamp (Green) AP-7, BY-4 — — —
connector 8
T17 Terminal 1 GND AJ-6 — — — I-8
T18 Terminal 1 GND AJ-6 — — — L-8
T19 Terminal 1 GND AJ-6 — — — L-8
T21 Terminal 1 GND — — — J-3 —
T22 AI-6 — — — I-8
T31 Terminal 1 DC/DC converter DX-9 — — — P-9
T32 Terminal 1 DC/DC converter DX-9 — — — P-9
T33 Terminal 1 DC/DC converter EB-8, DX-8 — — — Q-9
T34 Terminal 1 DC/DC converter DX-7 — — — Q-9
BZ210-1 20-221
(1)

Type Name of device
Discharge belt conveyor reverse sole-
V01A X 2 AI-1 — — — I-9
noid
V01B X 2 Soil cutter reverse solenoid AJ-2 — — — K-9
V02A X 2 Secondary belt conveyor solenoid AI-1 — — — I-9
V02B X 2 Raking rotor reverse solenoid AJ-2 — — — K-9
V03A X 2 Vibratory sieve solenoid AH-1 — — — J-9
V03B X 2 Air compressor solenoid AJ-3 — — — K-9
Discharge belt conveyor forward sole-
V04A X 2 AH-4 — — — J-9
noid
V04B X 2 Impact hammer reverse solenoid AJ-3 — — — L-9
V05A X 2 Aftercutter solenoid AH-4 — — — J-9
V05B X 2 Soil feeder reverse solenoid AJ-3 — — — L-9
Solidifying material feeder reverse sole-
V06A X 2 AI-4 — — — J-9
noid
V06B X 2 Travel lock solenoid AJ-3 — — K-4 —
V21 D 2 PC-EPC valve AP-5 — — K-3 —
20-222 BZ210-1
(1)
Connector arrangement drawing (1/16)
20-224 BZ210-1
(1)
BZ210-1 20-225
(1)
20-226 BZ210-1
(1)
BZ210-1 20-227
(1)
20-228 BZ210-1
(1)
BZ210-1 20-229
(1)
20-230 BZ210-1
(1)
BZ210-1 20-231
(1)
20-232 BZ210-1
(1)
BZ210-1 20-233
(1)
20-234 BZ210-1
(1)
BZ210-1 20-235
(1)
20-236 BZ210-1
(1)
BZ210-1 20-237
(1)
Connector arrangement drawing (9/16) [Control box (1/3)]
20-238 BZ210-1
(1)
BZ210-1 20-239
(1)
20-240 BZ210-1
(1)
Connector arrangement drawing (12/16) [No.1 LX controller]
BZ210-1 20-241
(1)
Connector arrangement drawing (13/16) [No.2 LX controller]
20-242 BZ210-1
(1)
Connector arrangement drawing (14/16) [Monitor]
BZ210-1 20-243
(1)
Connector arrangement drawing (15/16) [Switch box]
20-244 BZ210-1
(1)
Connector arrangement drawing (16/16) [Printer]
BZ210-1 20-245
(1)
Circuit diagram of monitor panel system (M circuit)
20-246 BZ210-1
(1)
a This circuit diagram is made by excerpting the monitor panel system and engine starting system from the
general electric circuit diagram.
BZ210-1 20-247
(1)
Circuit diagram of governor control system of governor pump controller (G circuit)
20-248 BZ210-1
(1)
a This circuit diagram is made by excerpting the governor pump controller system (power supply, governor
control, model selection, and communication) from the general electric circuit diagram.
BZ210-1 20-249
(1)
Circuit diagram of pump control system of governor pump controller (P circuit)
20-250 BZ210-1
(1)
a This circuit diagram is made by excerpting the governor pump controller system (pump control), PPC lock
system, and backup alarm system from the general electric circuit diagram.
BZ210-1 20-251
(1)
Circuit diagram of work equipment control system of governor pump controller and work
equipment controller (C circuit) (1/2)
20-252 BZ210-1
(1)
a This circuit diagram is made by excerpting the governor pump controller system and work equipment con-
troller system from the general electric circuit diagram.
BZ210-1 20-253
(1)
Circuit diagram of work equipment control system of governor pump controller and work
equipment controller (C circuit) (2/2)
20-254 BZ210-1
(1)
a This circuit diagram is made by excerpting the governor pump controller system and work equipment con-
troller system from the general electric circuit diagram.
BZ210-1 20-255
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-256 BZ210-1
(1)
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
BZ210-1 20-257
(1)
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-258 BZ210-1
(1)
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
BZ210-1 20-259
(1)
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-260 BZ210-1
(1)
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
BZ210-1 20-261
(1)
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
20-262 BZ210-1
(1)
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
BZ210-1 20-263
(1)
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
20-264 BZ210-1
(1)
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
— Part No.: 7821-92-7330
12 799-601-7520
— Part No.: 7821-92-7340
14 799-601-7530
— Part No.: 7821-92-7350
18 799-601-7540
— Part No.: 7821-92-7350
20 799-601-7550
— Part No.: 7821-92-7360
BZ210-1 20-265
(1)
L type connector
No.of
pins T-adapter Part
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
— —
20-266 BZ210-1
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
BZ210-1 20-267
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
— —
6 799-601-7370
— —
20-268 BZ210-1
(1)
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
BZ210-1 20-269
(1)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-270 BZ210-1
(1)

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
BZ210-1 20-271
(1)

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-272 BZ210-1
(1)

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
BZ210-1 20-273
(1)

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-274 BZ210-1
(1)
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
BZ210-1 20-275
(1)
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
20-276 BZ210-1
(1)
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
BZ210-1 20-277
(1)
No.of DRC26 Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
24 799-601-9360
— Part No.:7821-93-3110
40
799-601-9350
(A)
— Part No.:7821-93-3120
40
799-601-9350
(B)
— Part No.:7821-93-3130
20-278 BZ210-1
(1)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P
BZ210-1 20-279
(1)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD24 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DRC26 40P
799-601-9360 DRC26 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 3P
press.
799-601-9430 PVC socket 2P
20-280 BZ210-1
(1)
TROUBLESHOOTING WHEN ERROR CODE
"ELECTRICAL SYSTEM" AND ERROR CODE
"MECHANICAL SYSTEM" ARE INDICATED
INFORMATION IN TROUBLESHOOTING TABLE ..................................................................................... 20-304

Electrical system service code [E201] (Disconnection in discharge belt conveyor forward SOL system) .. 20-306
Electrical system service code [E202] (Short circuit in discharge belt conveyor forward SOL system)...... 20-307
Electrical system service code [E203] (Disconnection in discharge belt conveyor reverse SOL system) .. 20-308
Electrical system service code [E204] (Short circuit in discharge belt conveyor reverse SOL system)...... 20-309
Electrical system service code [E205] (Disconnection in hammer 1 forward EPC valve system) .............. 20-310
Electrical system service code [E206] (Short circuit in hammer 1 forward EPC valve system) .................. 20- 311
Electrical system service code [E207] (Disconnection in hammer 2 forward EPC valve syste) ................. 20-312
Electrical system service code [E208] (Short circuit in hammer 2 forward EPC valve system) .................. 20-313
Electrical system service code [E209] (Disconnection in hammer 3 forward EPC valve system) .............. 20-314
Electrical system service code [E210] (Short circuit in hammer 3 forward EPC valve system) .................. 20-315
Electrical system service code [E211] (Disconnection in hammer reverse SOL system) ........................... 20-316
Electrical system service code [E212] (Short circuit in hammer reverse SOL system)............................... 20-317
Electrical system service code [E213] (Disconnection in soil cutter forward EPC valve system) ............... 20-318
Electrical system service code [E214] (Short circuit in soil cutter forward EPC valve system)................... 20-319
Electrical system service code [E215] (Disconnection in soil cutter reverse SOL system)......................... 20-320
Electrical system service code [E216] (Short circuit in soil cutter reverse SOL system) ............................ 20-321
Electrical system service code [E217] (Disconnection in solidifying material feeder forward
EPC valve system) ......................................................................... 20-322
Electrical system service code [E218] (Short circuit in solidifying material feeder forward
EPC valve system) ......................................................................... 20-323
Electrical system service code [E219] (Disconnection in solidifying material feeder reverse SOL system) 20-324
Electrical system service code [E220] (Short circuit in solidifying material feeder reverse SOL system) ... 20-325
Electrical system service code [E221] (Disconnection in raking rotor forward EPC valve system) ............ 20-326
Electrical system service code [E222] (Short circuit in raking rotor forward EPC valve system) ................ 20-327
Electrical system service code [E223] (Disconnection in raking rotor reverse SOL system) ...................... 20-328
Electrical system service code [E224] (Short circuit in raking rotor reverse SOL system).......................... 20-329
Electrical system service code [E225] (Disconnection in soil feeder forward EPC valve system) .............. 20-330
Electrical system service code [E226] (Short circuit in soil feeder forward EPC valve system).................. 20-331
Electrical system service code [E227] (Disconnection in soil feeder reverse SOL system)........................ 20-332
Electrical system service code [E228] (Short circuit in soil feeder reverse SOL system) ........................... 20-333
Electrical system service code [E229] (Disconnection in ATT1 SOL system)............................................. 20-334
Electrical system service code [E230] (Short circuit in ATT1 SOL system) ................................................ 20-335
Electrical system service code [E235] (Disconnection in compressor SOL system) .................................. 20-340
Electrical system service code [E236] (Short circuit in compressor SOL system) ...................................... 20-341
Electrical system service code [E237] (Disconnection in crane EPC valve system)................................... 20-342
Electrical system service code [E238] (Short circuit in crane EPC valve system) ...................................... 20-343
Electrical system service code [E239] (Disconnection in PC-EPC system)................................................ 20-344
Electrical system service code [E240] (Short circuit in PC-EPC system) ................................................... 20-345
BZ210-1 20-301
(1)
TROUBLESHOOTING
Electrical system service code [E241] (Disconnection in governor motor drive system) ............................ 20-346
Electrical system service code [E242] (Short circuit in governor motor drive system) ................................ 20-347
Electrical system service code [E243] (Step-out of governor motor) .......................................................... 20-349
Electrical system service code [E244] (Short circuit in battery relay system) ............................................. 20-350
Electrical system service code [E245] (Short circuit in monitor lamp relay system) ................................... 20-351
Electrical system service code [E246] (Short circuit in horn relay system) ................................................. 20-352
Electrical system service code [E247] (Short circuit in beacon lamp relay system).................................... 20-353
Electrical system service code [E248] (Disconnection in electrical intake air heater relay system)............ 20-354
Electrical system service code [E249] (Short circuit in electrical intake air heater relay system) ............... 20-355
Electrical system service code [E250] (Disconnection in liquid addition unit drive relay system) ............... 20-356
Electrical system service code [E251] (Short circuit in liquid addition unit drive relay system)................... 20-357
Electrical system service code [E300] (Disconnection in emergency stop switch system) ......................... 20-358
Electrical system service code [E301] (Disconnection in engine stop switch system) ................................ 20-360
Electrical system service code [E302] (Abnormality in fuel control dial system) ......................................... 20-362
Electrical system service code [E303] (Abnormality in governor FB potentiometer system) ...................... 20-364
Electrical system service code [E304] (Short circuit in discharge belt conveyor ON switch system).......... 20-366
Electrical system service code [E305] (Disconnection in discharge belt conveyor OFF switch system) .... 20-367
Electrical system service code [E308] (Short circuit in feeder ON switch system) ..................................... 20-368
Electrical system service code [E309] (Disconnection in feeder OFF/REVERSE switch system) .............. 20-369
Electrical system service code [E310] (Short circuit in ATT1 ON switch system) ....................................... 20-370
Electrical system service code [E311] (Disconnection in ATT1 OFF switch system) .................................. 20-371
Electrical system service code [E313] (Disconnection in ATT2 OFF switch system).................................. 20-373
Electrical system service code [E315] (Disconnection in ATT3 OFF switch system).................................. 20-375
Electrical system service code [E316] (Short circuit in air compressor ON switch system)........................ 20-376
Electrical system service code [E317] (Short circuit in air compressor OFF switch system) ...................... 20-377
Electrical system service code [E318] (Short circuit in discharge belt conveyor manual
forward switch system) ................................................................... 20-378
Electrical system service code [E319] (Short circuit in discharge belt conveyor manual
reverse switch system) ................................................................... 20-379
Electrical system service code [E320] (Short circuit in hammer manual forward switch system) ............... 20-380
Electrical system service code [E321] (Short circuit in hammer manual reverse switch system) ............... 20-381
Electrical system service code [E322] (Short circuit in soil cutter manual forward switch system) ............. 20-382
Electrical system service code [E323] (Short circuit in soil cutter manual reverse switch system) ............. 20-383
Electrical system service code [E324] (Short circuit in solidifying material feeder manual
forward switch system) ................................................................... 20-384
Electrical system service code [E325] (Short circuit in solidifying material feeder manual
reverse switch system) ................................................................... 20-385
Electrical system service code [E326] (Short circuit in raking rotor manual forward switch system) .......... 20-386
Electrical system service code [E327] (Short circuit in raking rotor manual reverse switch system) .......... 20-387
Electrical system service code [E328] (Short circuit in soil feeder manual forward switch system)............ 20-388
Electrical system service code [E329] (Short circuit in soil feeder manual reverse switch system)............ 20-389
Electrical system service code [E331] (Short circuit in calibration switch system)...................................... 20-390
Electrical system service code [E332] (Short circuit in radio control CH1 system) ..................................... 20-391
Electrical system service code [E336] (Abnormality in soil cutter pressure sensor system) ....................... 20-395
Electrical system service code [E337] (Abnormality in S_NET signal system) ........................................... 20-396
Electrical system service code [E338] (Abnormality in engine speed sensor system)................................ 20-397
Electrical system service code [E339] (Abnormality in model selection signal system).............................. 20-398
Electrical system service code [E340] (Abnormality in crane acceleration signal system) ......................... 20-399
Electrical system service code [E341] (Abnormality in F pump pressure sensor system) .......................... 20-400
Electrical system service code [E342] (Abnormality in R pump pressure sensor system).......................... 20-402
Electrical system service code [E343] (Abnormality in current flow meter signal system) .......................... 20-404
20-302 BZ210-1
(1)
TROUBLESHOOTING
Mechanical system error code [AA10NX] (Clogging of air cleaner) ............................................................ 20-405
Mechanical system error code [AB00KE] (Abnormal lowering of charge voltage)...................................... 20-406
Mechanical system error code [B@BAZG] (Abnormal lowering of engine oil pressure)............................. 20-407
Mechanical system error code [B@BAZK] (Abnormal lowering of engine oil level).................................... 20-408
Mechanical system error code [B@BCNS] (Overheating of engine coolant).............................................. 20-409
Mechanical system error code [B@BCZK] (Abnormal lowering of radiator coolant level) .......................... 20-410
Mechanical system error code [B@HANS] (Overheating of hydraulic oil) .................................................. 20- 411
BZ210-1 20-303
(1)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

aThe following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before car-
rying out troubleshooting, understand that information fully.
User Code Service code Error code

Display in Display in Display in Trouble Trouble name displayed in trouble record
monitor panel monitor panel monitor panel
Contents of
Condition at the time when the monitor panel or controller detects the trouble
trouble
Action of
The action taken by the monitor panel or controller to protect the system or devices when the monitor
monitor panel
panel or controller detects the trouble
or controller
Problem that
The problem that appears on the machine as a result of the action taken by the monitor panel or control-
appears on
ler (shown above)
machine
Related
Information related to the detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting
<Contents of description)
1
• Standard value in normal state to judge possible causes
• Remarks on judgment
Possible causes and standard value in normal state
<Troubles in wiring harness>

• Disconnection
Connector is connected imperfectly or harness is broken.
2 • Grounding fault
Wiring harness which is not connected to chassis ground circuit is in contact with
chassis ground circuit.
• Short circuit with power source
Wiring harness which is not connected to power source (24V) circuit is in contact
Possible causes of trouble
with power source (24V) circuit.
(Given numbers are refer-
3
ence numbers, which do
<Precautions for troubleshooting>
not indicate priority)
1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting, unless other-
wise specified.
• If connector No. has no marks of "male" and "female", disconnect connector and
4 insert T-adapters in both male side and female side.
• If connector No. has marks of "male" and "female", disconnect connector and
connect T-adapter to only male side or female side.
2) Entry order of pin Nos. and handling of circuit tester leads
Connect positive (+) lead and negative (–) lead of circuit tester as explained below
for troubleshooting, unless otherwise specified.
• Connect positive (+) lead to pin No. or harness entered on front side.
5
• Connect negative (–) lead to pin No. or harness entered on rear side.
20-304 BZ210-1
(1)
Related circuit diagram
This is a circuit diagram of the part related to troubleshooting.
• Connector No.: Shows the "Type-Number of pin" and "Color".

• Arrow ( ): Roughly shows the location on the machine.
BZ210-1 20-305
(1)
TROUBLESHOOTING E201
Electrical system service code [E201]

(Disconnection in discharge belt conveyor forward SOL system)
User Code Service Code Error code

Trouble Disconnection in discharge belt conveyor forward SOL system
— E201 7RD1KA
Contents of
No current flows in the solenoid.
trouble
Action of GP • None in particular.
controller • If the cause of the failure disappears, the system resets itself.
Problem that
appears on The discharge belt conveyor does not operate forward.
machine

aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
1 Defective solenoid
V04A (male) Resistance
Between (1) and (2) 20 – 60 z
starting switch.
Disconnection in wiring
2 Between C11 (female) (5) – H01 (3) – V04A (female)
harness Resistance Max. 1 z
(2)
Between V04A (female) (1) and chassis ground Resistance Max. 1 z
Short circuit with chassis starting switch.
3
ground in wiring harness Between C11 (female) (5) – H01 (3) – V04A (female)
Resistance Min. 1 Mz
(2) wiring harness and chassis ground
starting switch.
4 Defective GP controller
C11 (female) Resistance
Between (5) and chassis ground 20 – 60 z
Electric circuit diagram related to discharge belt conveyor forward SOL
20-306 BZ210-1
(1)

(Short circuit in discharge belt conveyor forward SOL system)

Trouble Short circuit in discharge belt conveyor forward SOL system
— E202 7RD1KB
Contents of
Abnormal current flowed in the solenoid.
trouble
• Turns the current OFF.
Action of GP
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
controller
turned OFF.
Problem that
appears on The discharge belt conveyor does not operate forward.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
D03 (male) Resistance
Between (1) and (8) Min. 1 Mz
3
starting switch.
Electric circuit diagram related to discharge belt conveyor forward SOL
BZ210-1 20-307
(1)

(Disconnection in discharge belt conveyor reverse SOL system)

Trouble Disconnection in discharge belt conveyor reverse SOL system
— E203 7RD2KA
Contents of
trouble
Problem that
appears on The discharge belt conveyor does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
(2)
3
starting switch.
Electric circuit diagram related to discharge belt conveyor reverse SOL
20-308 BZ210-1
(1)

(Short circuit in discharge belt conveyor reverse SOL system)

Trouble Short circuit in discharge belt conveyor reverse SOL system
— E204 7RD2KB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The discharge belt conveyor does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
3
starting switch.
Electric circuit diagram related to discharge belt conveyor reverse SOL
BZ210-1 20-309
(1)

(Disconnection in hammer 1 forward EPC valve system)

Trouble Disconnection in hammer 1 forward EPC valve system
— E205 7RD3KA
Contents of
No current flows in the EPC solenoid.
trouble
Problem that
appears on Hammer 1 stops forward operation.
machine
Related
Hammer 1 forward EPC current can be checked with the monitoring function of the monitor.
information

starting switch.
CV07 (male) Resistance
Between (1) and (2) 10 – 22 z
starting switch.
Disconnection in wiring Between C22 (female) (7) – H04 (3) – CV07 (female)
2 Resistance Max. 1 z
harness (2)
Between C22 (female) (17) – H04 (4) – CV07 (female)
Resistance Max. 1 z
(1)
aPrepare with starting switch OFF, then hold starting switch ON and carry out trou-
Short circuit with chassis bleshooting.
3
ground in wiring harness Between C22 (female) (7) – H04 (3) – CV07 (female)
Voltage Max. 1 V
Defective work equipment starting switch.
4
controller C22 (female) Resistance
Between (7) and (17) 10 – 22 z
Electric circuit diagram related to hammer 1 forward EPC valve system
20-310 BZ210-1
(1)

(Short circuit in hammer 1 forward EPC valve system)

Trouble Short circuit in hammer 1 forward EPC valve system
— E206 7RD3KB
Contents of
Abnormal current flowed in the EPC solenoid.
trouble
• Turns the EPC current OFF.
Action of GP
controller
turned OFF.
Problem that
machine
Related
information

starting switch.
standard value in normal state
Possible causes and
Between (1) and (2) 10 – 22 z

2
3
Between (7) and (17) 10 – 22 z
BZ210-1 20-311
(1)

(Disconnection in hammer 2 forward EPC valve syste)

Trouble Disconnection in hammer 2 forward EPC valve syste
— E207 7RD4KA
Contents of
trouble
Problem that
machine
Related
information

starting switch.
Between (1) and (2) 10 – 22 z
starting switch.
harness (2)
Resistance Max. 1 z
(1)
3
Voltage Max. 1 V
4
Between (8) and (18) 10 – 22 z
20-312 BZ210-1
(1)


— E208 7RD4KB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
machine
Related
information

starting switch.
Possible causes and
Between (1) and (2) 10 – 22 z

2
3
Between (8) and (18) 10 – 22 z
BZ210-1 20-313
(1)

(Disconnection in hammer 3 forward EPC valve system)

Trouble Disconnection in hammer 3 forward EPC valve system)
— E209 7RD5KA
Contents of
trouble
Problem that
machine
Related
information

starting switch.
Between (1) and (2) 10 – 22 z
starting switch.
harness (2)
Resistance Max. 1 z
(1)
3
Voltage Max. 1 V
4
Between (9) and (19) 10 – 22 z
20-314 BZ210-1
(1)


— E210 7RD5KB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
machine
Related
information

starting switch.
Possible causes and
Between (1) and (2) 10 – 22 z

2
3
Between (9) and (19) 10 – 22 z
BZ210-1 20-315
(1)

(Disconnection in hammer reverse SOL system)

Trouble Disconnection in hammer reverse SOL system
— E211 7RD6KA
Contents of
trouble
Problem that
appears on Hammer does not operate in reverse.
machine

starting switch.
V04B (male) Resistance
Between (1) and (2) 20 – 60 z
starting switch.
2 Between C21 (female) (11) – H01 (5) – V04B (female)
(2)
Between V04B (female) (1) and chassis ground Resistance Max. 1 z
Short circuit with power bleshooting.
3 source (Contact with 24V
circuit) in wiring harness Between C21 (female) (11) – H01 (5) – V04B (female)
Voltage Max. 1 V
4
Electric circuit diagram related to hammer reverse SOL system
20-316 BZ210-1
(1)

(Short circuit in hammer reverse SOL system)

Trouble Short circuit in hammer reverse SOL system
— E212 7RD6KB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on Hammer does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
3
ground in wiring harness Between C21 (female) (11) – H01 (5) – V04B (female)
4
Electric circuit diagram related to hammer reverse SOL system
BZ210-1 20-317
(1)

(Disconnection in soil cutter forward EPC valve system)

Trouble Disconnection in soil cutter forward EPC valve system
— E213 7RD7KA
Contents of
trouble
Problem that
appears on The soil cutter stops forward operation.
machine
Related
The soil cutter forward EPC current can be checked with the monitoring function of the monitor.
information

starting switch.
Between (1) and (2) 10 – 22 z
starting switch.
harness (2)
Resistance Max. 1 z
(1)
3
Voltage Max. 1 V
4
Between (10) and (20) 10 – 22 z
Electric circuit diagram related to soil cutter forward EPC valve system
20-318 BZ210-1
(1)

(Short circuit in soil cutter forward EPC valve system)

Trouble Short circuit in soil cutter forward EPC valve system
— E214 7RD7KB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The soil cutter stops forward operation.
machine
Related
The soil cutter forward EPC current can be checked with the monitoring function of the monitor.
information

starting switch.
Possible causes and
Between (1) and (2) 10 – 22 z

2
3
Between (10) and (20) 10 – 22 z
Electric circuit diagram related to soil cutter forward EPC valve system
BZ210-1 20-319
(1)

(Disconnection in soil cutter reverse SOL system)

Trouble Disconnection in soil cutter reverse SOL system
— E215 7RD8KA
Contents of
trouble
Problem that
appears on The soil cutter does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
(2)
Voltage Max. 1 V
4
Electric circuit diagram related to soil cutter reverse SOL system
20-320 BZ210-1
(1)

(Short circuit in soil cutter reverse SOL system)

Trouble Short circuit in soil cutter reverse SOL system
— E216 7RD8KB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The soil cutter does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
3
4
Electric circuit diagram related to soil cutter reverse SOL system
BZ210-1 20-321
(1)

(Disconnection in solidifying material feeder forward EPC valve system)
User Code Service Code Error code Disconnection in solidifying material feeder forward EPC
Trouble
— E217 7RD9KA valve system
Contents of
trouble
Problem that
appears on The solidifying material feeder stops forward operation.
machine
Related The solidifying material feeder forward EPC current can be checked with the monitoring function of the
information monitor.

starting switch.
Between (1) and (2) 10 – 22 z
starting switch.
harness (2)
Resistance Max. 1 z
(1)
3
starting switch.
Between (10) and (20) 10 – 22 z
Electric circuit diagram related to solidifying material feeder forward EPC valve system
20-322 BZ210-1
(1)

(Short circuit in solidifying material feeder forward EPC valve system)
User Code Service Code Error code Short circuit in solidifying material feeder forward EPC valve
Trouble
— E218 7RD9KB system
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The solidifying material feeder stops forward operation.
machine
Related The solidifying material feeder forward EPC current can be checked with the monitoring function of the
information monitor.

starting switch.
Possible causes and
Between (1) and (2) 10 – 22 z

2
starting switch.
Between (10) and (20) 10 – 22 z
Electric circuit diagram related to solidifying material feeder forward EPC valve system
BZ210-1 20-323
(1)

(Disconnection in solidifying material feeder reverse SOL system)
User Code Service Code Error code Disconnection in solidifying material feeder reverse SOL sys-
Trouble
— E219 7RDAKA tem
Contents of
trouble
Problem that
appears on The solidifying material feeder does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
(2)
3
starting switch.
Related electric circuit diagram
20-324 BZ210-1
(1)

(Short circuit in solidifying material feeder reverse SOL system)

Trouble Short circuit in solidifying material feeder reverse SOL system
— E220 7RDAKB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The solidifying material feeder does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
3
starting switch.
BZ210-1 20-325
(1)

(Disconnection in raking rotor forward EPC valve system)

Trouble Disconnection in raking rotor forward EPC valve system
— E221 7RDBKA
Contents of
trouble
Problem that
appears on The raking rotor stops forward operation.
machine
Related
The raking rotor forward EPC current can be checked with the monitoring function of the monitor.
information

starting switch.
Between (1) and (2) 10 – 22 z
starting switch.
harness (2)
Resistance Max. 1 z
(1)
3
starting switch.
Between (8) and (18) 10 – 22 z
Electric circuit diagram related to raking rotor forward EPC valve system
20-326 BZ210-1
(1)

(Short circuit in raking rotor forward EPC valve system)

Trouble Short circuit in raking rotor forward EPC valve system
— E222 7RDBKB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The raking rotor stops forward operation.
machine
Related
The raking rotor forward EPC current can be checked with the monitoring function of the monitor.
information

starting switch.
Possible causes and
Between (1) and (2) 10 – 22 z

2
starting switch.
Between (8) and (18) 10 – 22 z
Electric circuit diagram related to raking rotor forward EPC valve system
BZ210-1 20-327
(1)

(Disconnection in raking rotor reverse SOL system)

Trouble Disconnection in raking rotor reverse SOL system
— E223 7RDCKA
Contents of
trouble
Problem that
appears on The raking rotor does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
(2)
3
starting switch.
Electric circuit diagram related to raking rotor reverse SOL system
20-328 BZ210-1
(1)

(Short circuit in raking rotor reverse SOL system)

Trouble Short circuit in raking rotor reverse SOL system
— E224 7RDCKB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The raking rotor does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
3
starting switch.
Electric circuit diagram related to raking rotor reverse SOL system
BZ210-1 20-329
(1)

(Disconnection in soil feeder forward EPC valve system)

Trouble Disconnection in soil feeder forward EPC valve system
— E225 7RDDKA
Contents of
trouble
Problem that
appears on The soil feeder stops forward operation.
machine
Related
The soil feeder forward EPC current can be checked with the monitoring function of the monitor.
information

starting switch.
Between (1) and (2) 10 – 22 z
starting switch.
harness (2)
Resistance Max. 1 z
(1)
3
starting switch.
Between (9) and (19) 10 – 22 z
Electric circuit diagram related to soil feeder forward EPC valve system
20-330 BZ210-1
(1)

(Short circuit in soil feeder forward EPC valve system)

Trouble Short circuit in soil feeder forward EPC valve system
— E226 7RDDKB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The soil feeder stops forward operation.
machine
Related
The soil feeder forward EPC current can be checked with the monitoring function of the monitor.
information

starting switch.
Possible causes and
Between (1) and (2) 10 – 22 z

2
starting switch.
Between (9) and (19) 10 – 22 z
Electric circuit diagram related to soil feeder forward EPC valve system
BZ210-1 20-331
(1)

(Disconnection in soil feeder reverse SOL system)

Trouble Disconnection in soil feeder reverse SOL system
— E227 7RDEKA
Contents of
trouble
Problem that
appears on The soil feeder does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
(2)
3
starting switch.
Electric circuit diagram related to soil feeder reverse SOL system
20-332 BZ210-1
(1)
Electrical system service code [E228] (Short circuit in soil feeder reverse SOL system)

Trouble Short circuit in soil feeder reverse SOL system
— E228 7RDEKB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The soil feeder does not operate in reverse.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
3
starting switch.
BZ210-1 20-333
(1)
Electrical system service code [E229] (Disconnection in ATT1 SOL system)

Trouble Disconnection in ATT1 SOL system
— E229 7RDFKA
Contents of
trouble
Problem that
appears on ATT1 does not operate.
machine
Related
Set the devices connected to ATT1 – ATT3 with the monitor.
information

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
(2)
circuit) in wiring harness Between C21 (female) (2) – H01 (2) – V05A (female)
Voltage Max. 1 V
4
Electric circuit diagram related to ATT1 SOL system
20-334 BZ210-1
(1)
Electrical system service code [E230] (Short circuit in ATT1 SOL system)

Trouble Short circuit in ATT1 SOL system
— E230 7RDFKB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
machine
Related
information

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
3
4
Electric circuit diagram related to ATT1 SOL system
BZ210-1 20-335
(1)

— E231 7RDGKA
Contents of
trouble
Problem that
machine
Related
information

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
(2)
Voltage Max. 1 V
4
20-336 BZ210-1
(1)

— E232 7RDGKB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
machine
Related
information

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
3
4
BZ210-1 20-337
(1)

— E233 7RDHKA
Contents of
trouble
Problem that
machine
Related
information

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
(2)
Voltage Max. 1 V
4
20-338 BZ210-1
(1)

— E234 7RDHKB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
machine
Related
information

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
3
4
BZ210-1 20-339
(1)
Electrical system service code [E235] (Disconnection in compressor SOL system)

Trouble Disconnection in compressor SOL system
— E235 7RDJKA
Contents of
trouble
Problem that
appears on The compressor does not operate.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
(2)
Voltage Max. 1 V
4
20-340 BZ210-1
(1)
Electrical system service code [E236] (Short circuit in compressor SOL system)

Trouble Short circuit in compressor SOL system
— E236 7RDJKB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The compressor does not operate.
machine

starting switch.
Between (1) and (2) 20 – 60 z
starting switch.
2 Defective diode
3
4
BZ210-1 20-341
(1)
Electrical system service code [E237] (Disconnection in crane EPC valve system)

Trouble Disconnection in crane EPC valve system
— E237 7RDKKA
Contents of
trouble
Problem that
appears on The crane stops.
machine
Related
The crane EPC current can be checked with the monitoring function of the monitor.
information

starting switch.
Between (1) and (2) 10 – 22 z
starting switch.
harness (2)
Resistance Max. 1 z
(1)
3
Voltage Max. 1 V
4
Between (2) and (13) 10 – 22 z
20-342 BZ210-1
(1)
Electrical system service code [E238] (Short circuit in crane EPC valve system)

Trouble Short circuit in crane EPC valve system
— E238 7RDKKB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The crane stops.
machine
Related
information

starting switch.
Possible causes and
Between (1) and (2) 10 – 22 z

2
3
Between (2) and (13) 10 – 22 z
BZ210-1 20-343
(1)
Electrical system service code [E239] (Disconnection in PC-EPC system)

Trouble Disconnection in PC-EPC system
E02 E239 DXA0KA
Contents of
trouble
Problem that
appears on If the pump load is increased, the engine speed lowers largely and the engine may stall.
machine
Related
The PC-EPC current can be checked with the monitoring function of the monitor.
information

starting switch.
V21 (male) Resistance
Between (1) and (2) 10 – 22 z
starting switch.
2 Between C12 (female) (7) – H10 (5) – V21 (female) (1) Resistance Max. 1 z
harness
Between C12 (female) (17) – H10 (6) – V21 (female)
Resistance Max. 1 z
(2)
3
ground in wiring harness Between C12 (female) (7) – H10 (5) – V21 (female) (1)
wiring harness and chassis ground
starting switch.
Between (7) and (17) 10 – 22 z
Electric circuit diagram related to PC-EPC system
20-344 BZ210-1
(1)
Electrical system service code [E240] (Short circuit in PC-EPC system)

Trouble Short circuit in PC-EPC system
E02 E240 DXA0KB
Contents of
trouble
Action of GP
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned
controller
OFF.
Problem that
appears on If the pump load is increased, the engine speed lowers largely and the engine may stall.
machine
Related
The PC-EPC current can be checked with the monitoring function of the monitor.
information

starting switch.
V21 (male) Resistance
Possible causes and
Between (1) and (2) 10 – 22 z

2
ground in wiring harness Between C12 (female) (7) – H10 (5) – V21 (female) (1)
starting switch.
Between (7) and (17) 10 – 22 z
Electric circuit diagram related to PC-EPC system
BZ210-1 20-345
(1)

(Disconnection in governor motor drive system)

Trouble Disconnection in governor motor drive system)
E05 E241 DY10KA
Contents of
No current flows in the governor motor.
trouble
• The engine speed is fixed to low idling.
Problem that
• The engine hunts.
appears on
• The engine does not stop.
machine
• The governor motor steps out.
Related
The governor motor current can be checked with the monitoring function of the monitor.
information

starting switch.
1 Defective governor motor E11 (male) Resistance
Between (1) and (2) 2.5 – 7.5 z
Between (3) and (4) 2.5 – 7.5 z
starting switch.
Disconnection in wiring Between C12 (female) (2) – H09 (1) – E11 (female) (1) Resistance Max. 1 z
2
harness Between C12 (female) (3) – H09 (2) – E11 (female) (2) Resistance Max. 1 z
Between C12 (female) (4) – H09 (3) – E11 (female) (3) Resistance Max. 1 z
Between C12 (female) (5) – H09 (4) – E11 (female) (4) Resistance Max. 1 z
starting switch.
3 Defective GP controller C12 (female) Resistance
Between (2) and (3) 2.5 – 7.5 z
Between (4) and (5) 2.5 – 7.5 z
Electric circuit diagram related to governor motor drive system
20-346 BZ210-1
(1)
Electrical system service code [E242] (Short circuit in governor motor drive system)

Trouble Short circuit in governor motor drive system
E05 E242 DY10KB
Contents of
Abnormal current flowed in the governor motor.
trouble
• The engine speed is fixed to low idling.
Problem that
appears on
• The engine does not stop.
machine
• The governor motor steps out.
Related
The governor motor current can be checked with the monitoring function of the monitor.
information

starting switch.
E11 (male) Resistance
1 Defective governor motor Between (1) and (2) 2.5 – 7.5 z
Between (3) and (4) 2.5 – 7.5 z
Between (1) and chassis ground Min. 1 Mz

starting switch.
Between C12 (female) (2) – H09 (1) – E11 (female) (1)
Short circuit with chassis Between C12 (female) (3) – H09 (2) – E11 (female) (2)
2 Resistance Min. 1 Mz
ground in wiring harness wiring harness and chassis ground
starting switch.
Between (2) and (3) 2.5 – 7.5 z
3 Defective GP controller Between (4) and (5) 2.5 – 7.5 z
BZ210-1 20-347
(1)
Electric circuit diagram related to governor motor drive system
20-348 BZ210-1
(1)
Electrical system service code [E243] (Step-out of governor motor)

Trouble Step-out of governor motor
— E243 DY10K4
Contents of
The difference between the input signal of the potentiometer and the set value in the controller is large.
trouble
• Repeats the control operation.
Action of GP
controller
turned OFF.
Problem that • The engine speed cannot be controlled.
appears on • The engine hunts.
machine • The engine does not stop.

Defective fuel control dial
1 If service code [E302] is displayed, carry out troubleshooting for it first.
system
Defective governor poten-

Possible causes and
tiometer
Disconnection in gover-
nor motor drive system
Short circuit in governor
motor drive system
Defective engine fuel con-
5 See Shop Manual for engine.
trol system
Troubleshooting cannot be carried out since the defect is in the GP controller.
6 Defective GP controller (If none of causes 1 – 5 is the cause of the trouble, the GP controller is judged
defective.)
BZ210-1 20-349
(1)
Electrical system service code [E244] (Short circuit in battery relay system)

Trouble Short circuit in battery relay system
— E244 D110KB
Contents of
Abnormal current flowed in the relay coil.
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The engine cannot be stopped and the whole work equipment stops.
machine

starting switch. Disconnect BR terminal.
1 Defective battery relay

Battery relay Resistance
Possible causes and
Between BR and E 45 – 65 z
Short circuit with chassis starting switch. Disconnect BR terminal.
2
ground in wiring harness Between C11 (female) (1) – H09 (6) – BR terminal wir-
ing harness and chassis ground
starting switch.
Electric circuit diagram related to battery relay system
20-350 BZ210-1
(1)
Electrical system service code [E245] (Short circuit in monitor lamp relay system)

Trouble Short circuit in monitor lamp relay system
— E245 DUM0KB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The monitor lamp does not light up.
machine

aPrepare with starting switch OFF and replace relay R07 and relay R08. Then, start
Defective monitor lamp engine and operate feeder.

1
relay While feeder is in operation Condition of monitor lamp
Monitor lamp Lighting or flashing
aPrepare with starting switch OFF and remove C11, R07 (8) and K01, then carry out
Short circuit with chassis troubleshooting without turning starting switch.
2
ground in wiring harness Between C11 (female) (3) – H07 (8) terminal wiring
harness and chassis ground
starting switch.
Defective assembled-type K01 (male) Resistance
3
diode
Between (3) and (6) 2 – 2.4 kz
troubleshooting without turning starting switch.
BZ210-1 20-351
(1)
Electrical system service code [E246] (Short circuit in horn relay system)

Trouble Short circuit in horn relay system
— E246 D162KB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The horn does not sound.
machine

starting switch.
1 Defective relay
R04 (male) Resistance
Possible causes and
Between (1) and (2) 250 – 350 z

Short circuit with chas- starting switch.
2 sis ground in wiring har-
ness Between C11 (female) (11) – R04 (female) (1) wiring
starting switch.
CN11 (female) Resistance
Electric circuit diagram related to horn relay system
20-352 BZ210-1
(1)
Electrical system service code [E247] (Short circuit in beacon lamp relay system)

Trouble Short circuit in beacon lamp relay system
— E247 DUB0KB
Contents of
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The beacon lamp does not light up.
machine

aPrepare with starting switch OFF and replace relay R08 and relay R07, then start
Defective beacon lamp engine.

1
relay Press emergency stop switch Condition of beacon lamp
Beacon lamp Lighting
Short circuit with chassis troubleshooting without turning starting switch.
2
ground in wiring harness Between C11 (female) (4) – H07 (7) terminal wiring
starting switch.
Defective assembled-type K01 (male) Resistance
3
diode
troubleshooting without turning starting switch.
Electric circuit diagram related to beacon lamp relay system
BZ210-1 20-353
(1)

(Disconnection in electrical intake air heater relay system)

Trouble Disconnection in electrical intake air heater relay system
— E248 7RDLKA
Contents of
No current flows in the electrical intake air heater relay.
trouble
Problem that
appears on The engine is not warmed up automatically.
machine

starting switch.
1 Defective relay
Electrical intake air heater relay Resistance
Between A25 (relay side) and chassis ground 25 – 40 z
starting switch.
2 Between D07 (female) (1) – H08 (3) – relay (female)
A25
Between C21 (female) (5) – D07 (female) (2) Resistance Max. 1 z
circuit) in wiring harness Between C21 (female) (5) – H08 (3) – relay A25 wiring
Voltage Max. 1 V
4 Defective diode bleshooting.
Replace with diode D08. Normal
Defective work equipment
5 When none of causes 1 – 4 is the cause of the trouble
controller
20-354 BZ210-1
(1)

(Short circuit in electrical intake air heater relay system)

Trouble Short circuit in electrical intake air heater relay system
— E249 7RDLKB
Contents of
Abnormal current flowed in the electrical intake air heater relay.
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The engine is not warmed up automatically.
machine

starting switch.
1 Defective relay
Electrical intake air heater relay Resistance
Between A25 (relay side) and chassis ground 25 – 40 z

Possible causes and
2 Defective diode starting switch.
Replace with diode D08. Normal
starting switch.
Short circuit with chassis Between D07 (female) (1) – H08 (3) – relay A25 wiring
3 Resistance Min. 1 Mz
ground in wiring harness harness and chassis ground
Between C21 (female) (5) – D07 (female) (2) wiring
Defective work equip-
4 When none of causes 1 – 3 is the cause of the trouble
ment controller
BZ210-1 20-355
(1)

(Disconnection in liquid addition unit drive relay system)

Trouble Disconnection in liquid addition unit drive relay system
— E250 7RDLKA
Contents of
No current flows in the liquid addition unit drive relay.
trouble
Problem that
appears on The liquid addition unit does not operate.
machine

starting switch.
1 Defective relay
Liquid addition unit drive relay (male) Resistance
Between (1) and (2) 250 – 350 z
Possible causes and
starting switch.
2 Between C21 (female) (10) – H12 (2) – relay (female)
(1)
Between relay (female) (2) and chassis ground Resistance Max. 1 z
circuit) in wiring harness Between C21 (female) (10) – H12 (2) – relay (female)
Voltage Max. 1 V
4
20-356 BZ210-1
(1)

(Short circuit in liquid addition unit drive relay system)

Trouble Short circuit in liquid addition unit drive relay system
— E251 7RDLKB
Contents of
Abnormal current flowed in the liquid addition unit drive relay.
trouble
Action of GP
controller
turned OFF.
Problem that
appears on The liquid addition unit does not operate.
machine

starting switch.
1 Defective relay
Liquid addition unit drive relay (male) Resistance
Possible causes and
Between (1) and (2) 250 – 350 z

2
ground in wiring harness Between C21 (female) (10) – H12 (2) – relay (female)
Defective work equip- starting switch.
3
ment controller C21 (female) Resistance
BZ210-1 20-357
(1)

(Disconnection in emergency stop switch system)

Trouble Disconnection in emergency stop switch system
— E300 7R96KA
Contents of When the starting switch is turned ON, the emergency stop switch system is disconnected or the emer-
trouble gency stop switch is pressed.
Action of GP
None in particular.
controller
Problem that
appears on The work equipment does not start.
machine

1 Defective fuse No.7 If the fuse is broken, the circuit probably has a grounding fault, etc.
aPrepare with starting switch OFF, then hold starting switch ON (turn only power
ON) and carry out troubleshooting.
2 Defective relay R01
R01 Voltage
Between (5) and chassis ground 20 – 30 V
bleshooting.
3 Defective GP controller C13A Emergency stop switch Voltage
Pressed Max. 1 V
Between (9) and chassis ground
Released 20 – 30 V
starting switch.
Between C13A (female) (9) and R01 (female) (5) Resistance Max. 1 z
Between R01 (female) (2) and R03 (female) (6) Resistance Max. 1 z
Between R03 (female) (3) and H10 (male) (4) Resistance Max. 1 z
Between H10 (female) (4) – E49 (2) – D52 (2) – E51
Resistance Max. 1 z
Disconnection in wiring (female) (1)
4
harness Between E51 (female) (3) – E52 (1) – E50 (2) – E51
Resistance Max. 1 z
(female) (1)
Between E51 (female) (3) – E50 (1) – E49 (1) – E44
Resistance Max. 1 z
(female) (1)
Between E44 (female) (3) and E43 (female) (1) Resistance Max. 1 z
Between E43 (female) (3) – H10 (8) – E14 (female) (4) Resistance Max. 1 z
Between E14 (female) (6) and chassis ground Resistance Max. 1 z
starting switch.
Defective emergency stop Between E43 (male) (1) and (3) Resistance Max. 1 z
5
switch Between E44 (male) (1) and (3) Resistance Max. 1 z
Between E51 (male) (1) and (3) (2 pieces) Resistance Max. 1 z
Between E14 (male) (4) and (6) Resistance Max. 1 z
20-358 BZ210-1
(1)
Electric circuit diagram related to emergency stop switch system
BZ210-1 20-359
(1)
Electrical system service code [E301] (Disconnection in engine stop switch system)

Trouble Disconnection in engine stop switch system
— E301 DDA6KA
Contents of When the starting switch is turned ON, the engine stop switch system is disconnected or the engine stop
trouble switch is pressed.
Action of GP
None in particular.
controller
Problem that
appears on The engine does not start.
machine

Defective engine stop starting switch.
1
switch E34 (male) Resistance
Between (1) and (3) Max. 1 z

Possible causes and
starting switch.
2 Defective GP controller C13B (female) Engine stop switch Resistance
Pressed Min. 1 Mz
Released Max. 1 z
starting switch.
Disconnection in wiring Between C13B (female) (9) – H02 (11) – E40 (4) –
harness E34 (female) (3)
Between E34 (female) (1) – E40 (5) – H02 (12) – H06
Resistance Max. 1 z
Electric circuit diagram related to engine stop switch system
20-360 BZ210-1
(1)
Electrical system service code [E302] (Abnormality in fuel control dial system)

Trouble Abnormality in fuel control dial system
E05 E302 DK10KZ
Contents of
The fuel control dial signal is disconnected or shorted.
trouble
Action of GP • Calculates the fuel control dial position from voltage just before the trouble and controls with it.
• If the output was set in the full mode before occurrence of the failure, it is not set in the partial mode.
Problem that
• If the output was set in the partial mode before occurrence of the failure, it is not set in the full mode.
appears on
• The high idling speed is not obtained and the output is insufficient.
machine
Related
The fuel control dial signal can be checked with the monitoring function of the monitor.
information

Defective sensor power bleshooting.
1
supply system E32 Voltage
Between (1) and (3) 5 V ± 0.5 V
starting switch.
2 Defective fuel control dial
Between (1) and (3) 4.0 – 6.0 kz
Between (2) and (1) 0.25 – 5.0 kz
Between (2) and (3) 0.25 – 5.0 kz
starting switch.
Disconnection in wiring Between C13A (female) (2) and E32 (female) (2) Resistance Max. 1 z
3
harness
Between C13A (female) (7) and E32 (female) (1) Resistance Max. 1 z
4
ground in wiring harness Between C13A (female) (2) – E32 (female) (2) wiring
bleshooting.
5 Defective GP controller C13A Voltage
Between (7) and (17) 4.5 – 5.5 V
Between (2) and (17) 0.5 – 4.5V
20-362 BZ210-1
(1)
Electric circuit diagram related to fuel control dial system
BZ210-1 20-363
(1)

(Abnormality in governor FB potentiometer system)

Trouble Abnormality in governor FB potentiometer system
— E303 DK58KX
Contents of
The governor FB potentiometer signal is disconnected or shorted.
trouble
• Calculates the motor position from voltage just before the trouble and controls with it.
Action of GP
controller
turned OFF.
Problem that • The high idling speed is not obtained (a little low). • The engine does not stop.
appears on • The low idling speed is not obtained (a little high). • The engine stops.
machine • The engine hunts.
Related
The governor FB potentiometer signal can be checked with the monitoring function of the monitor.
information

Defective sensor power bleshooting.
1
supply system E10 Voltage
Between (A) and (C) 5V ± 0.5V
starting switch.
Defective governor FB E32 (male) Resistance

2
potentiometer Between (A) and (C) 4.0 – 6.0 kz
Between (B) and (A) 0.25 – 5.0 kz
Between (B) and (C) 0.25 – 5.0 kz
starting switch.
Between C13 (female) (12) – H09 (9) – E10 (female)
Disconnection in wiring Resistance Max. 1 z
3 (B)
harness
Between C13 (female) (7) – H09 (8) – E10 (female) (A) Resistance Max. 1 z
Resistance Max. 1 z
(C)
4
ground in wiring harness Between C13 (female) (12) – H09 (9) – E10 (female)
(B) wiring harness and chassis ground
bleshooting.
5 Defective GP controller C13 Voltage
Between (7) and (17) 4.5 – 5.5 V
Between (12) and (17) 0.5 – 4.5V
20-364 BZ210-1
(1)
Electric circuit diagram related to governor FB potentiometer system
BZ210-1 20-365
(1)

(Short circuit in discharge belt conveyor ON switch system)

Trouble Short circuit in discharge belt conveyor ON switch system
— E304 7RC1KB
Contents of When the starting switch is turned ON, the discharge belt conveyor ON switch system is shorted or the dis-
trouble charge belt conveyor ON switch is pressed.
Action of GP
Stops the discharge belt conveyor.
controller
Problem that
appears on The discharge belt conveyor is not turned ON.
machine

starting switch.
E16 (male) ON switch Resistance
1 Defective ON switch
Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
ground in wiring harness Between C13B (female) (5) – E16 (female) (2) wiring
starting switch.
3 Defective GP controller C13B (female) ON switch Resistance
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to discharge belt conveyor ON switch system
20-366 BZ210-1
(1)

(Disconnection in discharge belt conveyor OFF switch system)

Trouble Disconnection in discharge belt conveyor OFF switch system
— E305 7RC2KA
Contents of When the starting switch is turned ON, the discharge belt conveyor OFF switch system is disconnected or
trouble the discharge belt conveyor OFF switch is pressed.
Action of GP
controller
Problem that
appears on The discharge belt conveyor is not turned ON.
machine

starting switch.
1 Defective OFF switch E17 (male) ON switch Resistance
Pressed Min. 1 Mz
Possible causes and
Between (1) and (3)

Released Max. 1 z
Disconnection in wiring starting switch.
2
harness Between C15 (female) (9) and E17 (female) (3)
Resistance Max. 1 z
Between E17 (female) (1) – H06 (1) – chassis ground
starting switch.
3 Defective GP controller C15 (female) OFF switch Resistance
Pressed Min. 1 Mz
Released Max. 1 z
Electric circuit diagram related to discharge belt conveyor OFF switch system
BZ210-1 20-367
(1)
Electrical system service code [E308] (Short circuit in feeder ON switch system)

Trouble Short circuit in feeder ON switch system
— E308 7RC5KB
Contents of When the starting switch is turned ON, the feeder ON switch system is shorted or the feeder ON switch is
trouble pressed.
Action of GP
Stops the feeder.
controller
Problem that
appears on The feeder is not turned ON.
machine

starting switch.
Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
3 Defective GP controller C13B (female) ON switch Resistance
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to feeder ON switch
20-368 BZ210-1
(1)

(Disconnection in feeder OFF/REVERSE switch system)

Trouble Disconnection in feeder OFF/REVERSE switch system
— E309 7RC6KA
Contents of When the starting switch is turned ON, the feeder OFF/REVERSE switch system is disconnected or the
trouble feeder OFF/REVERSE switch is pressed.
Action of GP
Stops the feeder.
controller
Problem that
appears on The feeder is not turned ON.
machine

starting switch.
Pressed Min. 1 Mz
Between (1) and (3)
Possible causes and
Released Max. 1 z
starting switch.
2 Between C13B (female) (15) and E21 (female) (3)
harness
Between E21 (female) (1) – H06 (1) wiring harness Resistance Max. 1 z
and chassis ground
starting switch.
3 Defective GP controller C13B (female) OFF switch Resistance
Pressed Min. 1 Mz
Released Max. 1 z
Electric circuit diagram related to feeder OFF/REVERSE switch
BZ210-1 20-369
(1)
Electrical system service code [E310] (Short circuit in ATT1 ON switch system)

Trouble Short circuit in ATT1 ON switch system
— E310 7RC7KB
Contents of When the starting switch is turned ON, the ATT1 ON switch system is shorted or the ATT1 ON switch is
trouble pressed.
Action of GP
Stops the output to ATT1.
controller
Problem that
appears on The ATT1 is not turned ON.
machine

starting switch.
Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
ground in wiring harness Between C25 (female) (6) – E24 (female) (2) wiring
starting switch.
Defective work equipment C25 (female) ON switch Resistance
3
controller
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to ATT1 ON switch system
20-370 BZ210-1
(1)
Electrical system service code [E311] (Disconnection in ATT1 OFF switch system)

Trouble Disconnection in ATT1 OFF switch system
— E311 7RC8KA
Contents of When the starting switch is turned ON, the ATT1 OFF switch system is disconnected or the ATT1 OFF
Action of GP
controller
Problem that
machine

starting switch.
Pressed Min. 1 Mz
Between (1) and (3)
Possible causes and
Released Max. 1 z
starting switch.
2 Between C23B (female) (8) and E25 (female) (3)
harness
Between E25 (female) (1) – H06 (1) wiring harness Resistance Max. 1 z
and chassis ground
starting switch.
Defective work equipment C23B (female) OFF switch Resistance
3
controller
Pressed Min. 1 Mz
Released Max. 1 z
Electric circuit diagram related to ATT1 OFF switch
BZ210-1 20-371
(1)

— E312 7RC9KB
trouble pressed.
Action of GP
controller
Problem that
machine

starting switch.
Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
Defective work equipment C25 (female) ON switch Resistance
3
controller
Pressed Max. 1 z
Released Min. 1 Mz
20-372 BZ210-1
(1)

— E313 7RCAKA
Action of GP
controller
Problem that
machine

starting switch.
Pressed Min. 1 Mz
Between (1) and (3)
Possible causes and
Released Max. 1 z
starting switch.
2 Between C25 (female) (17) and E23 (female) (3) Resistance Max. 1 z
harness
Between E23 (female) (1) – H06 (1) wiring harness
Resistance Max. 1 z
and chassis ground
starting switch.
Defective work equipment C25 (female) OFF switch Resistance
3
controller
Pressed Min. 1 Mz
Released Max. 1 z
BZ210-1 20-373
(1)

— E314 7RCBKB
trouble pressed.
Action of GP
controller
Problem that
machine

starting switch.
Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
Defective work equipment C23B (female) ON switch Resistance
3
controller
Pressed Max. 1 z
Released Min. 1 Mz
20-374 BZ210-1
(1)

— E315 7RCCKA
Action of GP
controller
Problem that
machine

starting switch.
Pressed Min. 1 Mz
Between (1) and (3)
Possible causes and
Released Max. 1 z
starting switch.
2 Between C23B (female) (13) and E27 (female) (3) Resistance Max. 1 z
harness
Between E27 (female) (1) – H06 (1) wiring harness
Resistance Max. 1 z
and chassis ground
starting switch.
3
controller
Pressed Min. 1 Mz
Released Max. 1 z
BZ210-1 20-375
(1)

(Short circuit in air compressor ON switch system)

Trouble Short circuit in air compressor ON switch system
— E316 7RCDKB
Contents of When the starting switch is turned ON, the compressor ON switch system is shorted or the compressor ON
Action of GP
Stops the output to the compressor.
controller
Problem that
appears on The compressor is not turned ON.
machine

starting switch.
Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
Defective work equipment C23B (female) ON switch Resistance
3
controller
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to compressor ON switch system
20-376 BZ210-1
(1)

(Short circuit in air compressor OFF switch system)

Trouble Short circuit in air compressor OFF switch system
— E317 7RCEKB
Contents of When the starting switch is turned ON, the compressor OFF switch system is shorted or the compressor
trouble OFF switch is pressed.
Action of GP
Stops the output to the compressor.
controller
Problem that
appears on The compressor is not turned ON.
machine

starting switch.
1 Defective OFF switch

Pressed Max. 1 z
Possible causes and
Between (2) and (3)

Released Min. 1 Mz
2
starting switch.
3
controller
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to compressor OFF switch system
BZ210-1 20-377
(1)

(Short circuit in discharge belt conveyor manual forward switch system)
User Code Service Code Error code Short circuit in discharge belt conveyor manual forward switch
Trouble
— E318 7RCFKB system
Contents of When the starting switch is turned ON, the discharge belt conveyor manual forward switch system is
trouble shorted or the discharge belt conveyor manual forward switch is pressed.
Action of GP
controller
Problem that
appears on The manual discharge belt conveyor is not turned ON.
machine

starting switch.
E70 (male) Forward switch Resistance
1 Defective forward switch

Pressed Max. 1 z
Possible causes and
Between (2) and (3)

Released Min. 1 Mz
2
starting switch.
3 Defective GP controller C15 (female) Forward switch Resistance
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to discharge belt conveyor manual forward switch system
20-378 BZ210-1
(1)

(Short circuit in discharge belt conveyor manual reverse switch system)
User Code Service Code Error code Short circuit in discharge belt conveyor manual reverse switch
Trouble
— E319 7RCGKB system
Contents of When the starting switch is turned ON, the discharge belt conveyor manual reverse switch system is
trouble shorted or the discharge belt conveyor manual reverse switch is pressed.
Action of GP
Stops reverse operation of the discharge belt conveyor.
controller
Problem that
appears on Manual operation of the discharge belt conveyor is not turned ON.
machine

starting switch.
E70 (male) Reverse switch Resistance
1 Defective reverse switch

Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
3 Defective GP controller C15 (female) Reverse switch Resistance
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to discharge belt conveyor manual reverse switch system
BZ210-1 20-379
(1)

(Short circuit in hammer manual forward switch system)

Trouble Short circuit in hammer manual forward switch system
— E320 7RCHKB
Contents of When the starting switch is turned ON, the hammer manual forward switch system is shorted or the ham-
trouble mer manual forward switch is pressed.
Action of GP
Stops forward operation of the hammer.
controller
Problem that
appears on The hammer is not operated forward.
machine

starting switch.

Pressed Max. 1 z
Possible causes and
Between (2) and (3)

Released Min. 1 Mz
2
starting switch.
Defective work equipment C25 (female) Forward switch Resistance
3
controller
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to hammer manual forward switch system
20-380 BZ210-1
(1)

(Short circuit in hammer manual reverse switch system)

Trouble Short circuit in hammer manual reverse switch system
— E321 7RCJKB
Contents of When the starting switch is turned ON, the hammer manual reverse switch system is shorted or the ham-
trouble mer manual reverse switch is pressed.
Action of GP
Stops the manual reverse output to the hammer.
controller
Problem that
appears on The hammer is not operated manually in reverse.
machine

starting switch.

Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
Defective work equipment C25 (female) Reverse switch Resistance
3
controller
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to hammer manual reverse switch system
BZ210-1 20-381
(1)

(Short circuit in soil cutter manual forward switch system)

Trouble Short circuit in soil cutter manual forward switch system
— E322 7RCKKB
Contents of When the starting switch is turned ON, the soil cutter manual forward switch system is shorted or the soil
trouble cutter manual forward switch is pressed.
Action of GP
Stops forward operation of the soil cutter.
controller
Problem that
appears on The soil cutter is not operated forward.
machine

starting switch.

Pressed Max. 1 z
Possible causes and
Between (2) and (3)

Released Min. 1 Mz
2
starting switch.
Defective work equipment C25 (female) Forward switch Resistance
3
controller
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to soil cutter manual forward switch system
20-382 BZ210-1
(1)

(Short circuit in soil cutter manual reverse switch system)

Trouble Short circuit in soil cutter manual reverse switch system
— E323 7RCLKB
Contents of When the starting switch is turned ON, the soil cutter manual reverse switch system is shorted or the soil
trouble cutter manual reverse switch is pressed.
Action of GP
Stops reverse operation of the soil cutter.
controller
Problem that
appears on The soil cutter is not operated manually in reverse.
machine

starting switch.

Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
Defective work equipment C25 (female) Reverse switch Resistance
3
controller
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to soil cutter manual reverse switch system
BZ210-1 20-383
(1)

(Short circuit in solidifying material feeder manual forward switch system)
User Code Service Code Error code Short circuit in solidifying material feeder manual forward
Trouble
— E324 7RCFKB switch system
Contents of When the starting switch is turned ON, the solidifying material feeder manual forward switch system is
trouble shorted or the solidifying material feeder manual forward switch is pressed.
Action of GP
Stops forward operation of the solidifying material feeder.
controller
Problem that
appears on The solidifying material feeder is not operated forward.
machine

starting switch.

Pressed Max. 1 z
Possible causes and
Between (2) and (3)

Released Min. 1 Mz
2
starting switch.
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to solidifying material feeder manual forward switch system
20-384 BZ210-1
(1)

(Short circuit in solidifying material feeder manual reverse switch system)
User Code Service Code Error code Short circuit in solidifying material feeder manual reverse
Trouble
— E325 7RCNKB switch system
Contents of When the starting switch is turned ON, the solidifying material feeder manual reverse switch system is
trouble shorted or the solidifying material feeder manual reverse switch is pressed.
Action of GP
Stops reverse operation of the solidifying material feeder.
controller
Problem that
appears on The solidifying material feeder is not operated manually in reverse.
machine

starting switch.

Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to solidifying material feeder manual reverse switch system
BZ210-1 20-385
(1)

(Short circuit in raking rotor manual forward switch system)

Trouble Short circuit in raking rotor manual forward switch system
— E326 7RCPKB
Contents of When the starting switch is turned ON, the raking rotor manual forward switch system is shorted or the rak-
trouble ing rotor manual forward switch is pressed.
Action of GP
Stops forward operation of the raking rotor.
controller
Problem that
appears on The raking rotor is not operated forward.
machine

starting switch.

Pressed Max. 1 z
Possible causes and
Between (2) and (3)

Released Min. 1 Mz
2
starting switch.
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to raking rotor manual forward switch system
20-386 BZ210-1
(1)

(Short circuit in raking rotor manual reverse switch system)

Trouble Short circuit in raking rotor manual reverse switch system
— E327 7RCQKB
Contents of When the starting switch is turned ON, the raking rotor manual reverse switch system is shorted or the rak-
trouble ing rotor manual reverse switch is pressed.
Action of GP
Stops reverse operation of the raking rotor.
controller
Problem that
appears on The raking rotor is not operated manually in reverse.
machine

starting switch.

Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to raking rotor manual reverse switch system
BZ210-1 20-387
(1)

(Short circuit in soil feeder manual forward switch system)

Trouble Short circuit in soil feeder manual forward switch system
— E328 7RCRKB
Contents of When the starting switch is turned ON, the soil feeder manual forward switch system is shorted or the soil
trouble feeder manual forward switch is pressed.
Action of GP
Stops forward operation of the soil feeder.
controller
Problem that
appears on The soil feeder is not operated forward.
machine

starting switch.

Pressed Max. 1 z
Possible causes and
Between (2) and (3)

Released Min. 1 Mz
2
starting switch.
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to soil feeder manual forward switch system
20-388 BZ210-1
(1)

(Short circuit in soil feeder manual reverse switch system)

Trouble Short circuit in soil feeder manual reverse switch system
— E329 7RCSKB
Contents of When the starting switch is turned ON, the soil feeder manual reverse switch system is shorted or the soil
trouble feeder manual reverse switch is pressed.
Action of GP
Stops reverse operation of the soil feeder.
controller
Problem that
appears on The soil feeder is not operated manually in reverse.
machine

starting switch.

Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to soil feeder manual reverse switch system
BZ210-1 20-389
(1)
Electrical system service code [E331] (Short circuit in calibration switch system)

Trouble Short circuit in calibration switch system
— E331 7RCUKB
Contents of When the starting switch is turned ON, the calibration switch system is shorted or the calibration switch is
trouble pressed.
Action of GP
Stops calibration.
controller
Problem that
appears on Calibration is not performed.
machine

starting switch.
Pressed Max. 1 z
Possible causes and
Between (1) and (2)

Released Min. 1 Mz
2
starting switch.
3 Defective GP controller C15 (female) ON switch Resistance
Pressed Max. 1 z
Released Min. 1 Mz
Electric circuit diagram related to calibration switch system
20-390 BZ210-1
(1)
Electrical system service code [E332] (Short circuit in radio control CH1 system)

Trouble Short circuit in radio control CH1 system
— E332 7R9CKB
Contents of When the starting switch is turned ON, the radio control CH1 system is shorted or the radio control CH1
Action of GP • In manual mode: Stops forward operation of the solidifying material feeder.
controller • In work mode: Stops turning the feeder ON.
Problem that
appears on The above operation is not performed.
machine

Defective radio control starting switch.
1
Possible causes and
receiver
Between E39 (male) (A2) and (B2) Resistance Min. 1 Mz
2
ground in wiring harness Between C13B (female) (2) – E39 (female) (A2) wiring
3 Defective GP controller starting switch.
Between C13B (female) (2) and chassis ground Resistance Min. 1 Mz
Electric circuit diagram related to radio control CH1 system
BZ210-1 20-391
(1)

— E333 7R9DKB
Action of GP • In manual mode: Stops reverse operation of the solidifying material feeder.
controller • In work mode: Stops turning the feeder OFF or in reverse.
Problem that
machine

1
Possible causes and
receiver
2
ground in wiring harness Between C13B (female) (3) – E39 (female) (A3) wir-
20-392 BZ210-1
(1)

— E334 7R9EKB
Action of GP • In manual mode: Stops forward operation of the soil feeder
controller • In work mode: Stops the horn.
Problem that
machine

1
Possible causes and
receiver
2
BZ210-1 20-393
(1)

— E335 7R9FKB
Action of GP • In manual mode: Stops reverse operation of the soil feeder
controller • In work mode: Stops all stop operation.
Problem that
machine

1
Possible causes and
receiver
2
20-394 BZ210-1
(1)

(Abnormality in soil cutter pressure sensor system)
Trouble Abnormality in soil cutter pressure sensor system
— E336 7R9GKB
Contents of
The pressure sensor output voltage is below 0.3 V or above 4.7 V.
trouble
Action of GP • Assumes the pressure to be 0 MPa {0 kg/cm2}.
Problem that
appears on If the pressure rises, relief is continued.
machine
Related
The soil cutter pressure can be checked with the monitoring function of the monitor.
information

aPrepare with starting switch OFF, then start engine and carry out troubleshoot-
ing.
2 Defective pressure sensor S07 Voltage
Between (1) and (3) 0.5 – 4.5V
starting switch.
3 Between C13A (female) (16) – H03 (6) – A07 (1) or
(6) – A06 (1) or (6) – S07 (female) (1)
Between C13A (11) – H02 (6) – S07 (female) (3) Resistance Max. 1 z
4
ground in wiring harness Between C13 (female) (11) – S07 (female) (3) wiring
aPrepare with starting switch OFF, then start engine and carry out troubleshoot-
ing.
C13A Voltage
Between (11) and (16) 0.5 – 4.5V
Electric circuit diagram related to soil cutter pressure sensor system
BZ210-1 20-395
(1)
Electrical system service code [E337] (Abnormality in S_NET signal system)

Trouble Abnormality in S_NET signal system
— E337 DB6SKR
Contents of
The network data are not updated.
trouble
Action of GP
controller
Problem that
appears on
machine

starting switch.
Possible causes and
Between C14 (female) (11) and P02 (female) (10) Resistance Max. 1 z
Between P02 (female) (9) and C23B (female) (12) Resistance Max. 1 z
Between C23B (female) (4) and C14 (female) (12) Resistance Max. 1 z
1 Between C11 (female) (6) or (12) – H06 (1) – chassis
ground
Between C21 (female) (6) or (12) – H06 (1) – chassis
Resistance Max. 1 z
ground
Between P02 (female) (20) – H06 (1) – chassis
Resistance Max. 1 z
ground
Electric circuit diagram related to S_NET signal system
20-396 BZ210-1
(1)
Electrical system service code [E338] (Abnormality in engine speed sensor system)

Trouble Abnormality in engine speed sensor system
— E338 DLE2KA
Contents of
Normal pulse signals are not input to the signal circuit of the engine speed sensor.
trouble
Action of GP • Assumes the engine speed to be 0.
Problem that
appears on The engine output is lowered.
machine
Related
The engine speed can be checked with the monitoring function of the monitor.
information

starting switch.
1 Defective sensor E04 (male) Resistance
Between (1) and (2) 500 – 1000 z

Defective adjustment of
2 See TESTING AND ADJUSTING (Adjusting engine speed sensor).
engine speed sensor
starting switch.
Disconnection in wiring Between C14 (female) (1) – H08 (11) – E04 (female)
harness (1)
Resistance Max. 1 z
(2)
4
ground in wiring harness Between C14 (female) (1) – H08 (11) – E04 (female)
starting switch.
5 Defective GP controller C14 (female) Resistance
Between (1) and (9) 500 – 1000 z
Electric circuit diagram related to engine speed sensor system
BZ210-1 20-397
(1)
Electrical system service code [E339] (Abnormality in model selection signal system)

Trouble Abnormality in model selection signal system
— E339 DB79KZ
Contents of
An improper model is selected.
trouble
Action of GP
Assumes the model to be BZ210.
controller
Problem that
appears on None in particular.
machine

Possible causes and
starting switch.

1 Defective wiring harness
Electric circuit diagram related to model selection signal system
20-398 BZ210-1
(1)

(Abnormality in crane acceleration signal system)

Trouble Abnormality in crane acceleration signal system
— E340 7R9HKX
Contents of
The crane acceleration signal is shorted to power source.
trouble
Problem that
appears on When the speed lever of the crane transmitter is operated, the crane and engine do not stop.
machine
Related
information

Defective sensor power aPrepare with starting switch OFF, then hold starting switch ON and carry out trou-
Possible causes and
supply system bleshooting.

1 Short circuit with power
source (Contact with 24V Between C23A (female) (14) – H11 (2) – E34 (female)
Voltage Max. 1 V
circuit) in wiring harness (2) wiring harness and chassis ground
Defective work equipment bleshooting.
2
controller C23A Voltage
Between (14) and chassis ground 0 – 4.5 V
Electric circuit diagram related to crane acceleration signal system
BZ210-1 20-399
(1)

(Abnormality in F pump pressure sensor system)

Trouble Abnormality in F pump pressure sensor system
— E341 DHPAMA
Contents of
trouble
Action of GP
If the cause of the failure disappears, the system resets itself.
controller
Problem that
machine
Related
The F pump pressure can be checked with the monitoring function of the monitor.
information

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
S11 Voltage
2 Defective pressure sensor
Between (3) and (1) 0.5 – 4.5 V
starting switch.
Between C23A (female) (16) – H03 (6) – A07 (female)
Disconnection in wiring Resistance Max. 1 z
3 (1)
harness
Between A07 (female) (6) and A06 (female) (1) Resistance Max. 1 z
Between A06 (female) (7) and S11 (female) (1) Resistance Max. 1 z
Between C23 (female) (5) – H03 (7) – S11 (female) (3) Resistance Max. 1 z
4
ground in wiring harness Between C23A (female) (5) – H03 (7) – S11 (female)
5 C23A Voltage
controller
Between (5) and (16) 0.5 – 4.5 V
20-400 BZ210-1
(1)
Electric circuit diagram related to F pump pressure sensor system
BZ210-1 20-401
(1)

(Abnormality in R pump pressure sensor system)

Trouble Abnormality in R pump pressure sensor system
— E342 DHPAMA
Contents of
trouble
Action of GP
controller
Problem that
machine
Related
The R pump pressure can be checked with the monitoring function of the monitor.
information

S12 Voltage
2 Defective pressure sensor
Between (3) and (1) 0.5 – 4.5 V
starting switch.
Resistance Max. 1 z
Disconnection in wiring (1)
3
harness Between A07 (female) (6) and A06 (female) (1) Resistance Max. 1 z
Between C23A (female) (15) – H03 (8) – S12 (female)
Resistance Max. 1 z
(3)
4
5 C23A Voltage
controller
Between (15) and (16) 0.5 – 4.5V
20-402 BZ210-1
(1)
Electric circuit diagram related to R pump pressure sensor system
BZ210-1 20-403
(1)

(Abnormality in current flow meter signal system)

Trouble Abnormality in current flow meter signal system
— E343 7RCVKX
Contents of
The pressure sensor output voltage is below 0.3 V.
trouble
Action of GP
controller
Problem that
appears on The current flow meter does not indicate normally.
machine

1
harness Between C23A (female) (13) – H12 (5) – terminal I+ Resistance Max. 1 z
Possible causes and
Between C23A (female) (17) – H12 (6) – terminal I Resistance Max. 1 z

2
ground in wiring harness Between C23A (female) (13) – H12 (5) – terminal I+
wiring harness and C23A (female) (17)
aDisconnect flowmeter terminals I+ and I.
3
controller
C23A (female) Resistance
Between (13) and (17) 220 – 270 z
Related electric circuit diagrams
20-404 BZ210-1
(1)
TROUBLESHOOTING AA10NX
Mechanical system error code [AA10NX] (Clogging of air cleaner)

Trouble Clogging of air cleaner
— — AA10NX
Contents of While the engine is running, the signal circuit of the air cleaner clogging switch is disconnected (from the
trouble chassis ground).
Action of GP
None in particular.
controller
Problem that
appears on If the machine is used as it is, the engine may be damaged.
machine
Related If the air cleaner clogging caution symbol is displayed on the monitor panel while the engine is running, this
information error code is recorded.

Clogging of air cleaner

1 aCheck air cleaner. If it is clogged, clean or replace it.
(When system is normal)
Defective air cleaner clog- A31 (male) Air cleaner Resistance
2 ging switch (Internal discon-
nection) When normal Max. 1 z
Between (1) and (2)
When clogged Min. 1 Mz
3 Between P02 (female) (5) – H08 (9) – A31 (female) (1) Resistance Max. 1 z
harness
Between A31 (female) (2) and chassis ground Resistance Max. 1 z
P02 Air cleaner Voltage
4 Defective monitor panel When normal Max. 1 V
When clogged 20 – 30 V
Electric circuit diagram related to air cleaner clogging switch
BZ210-1 20-405
(1)
TROUBLESHOOTING AB00KE
Mechanical system error code [AB00KE] (Abnormal lowering of charge voltage)

Trouble Abnormal lowering of charge voltage
— — AB00KE
Contents of
While the engine is running, the generating signal is not input from the alternator.
trouble
Action of GP
None in particular.
controller
Problem that
appears on If the machine is used as it is, the battery may not be charged.
machine
Related If the charge level caution symbol is displayed on the monitor panel while the engine is running, this error
information code is recorded.

Defective alternator
1 E12 (male) Engine speed Voltage
(Insufficient generation)
Between (1) and chassis ground Above middle speed 27.5 – 29.5 V
2
harness Between P02 (female) (11) – H08 (2) – E08 (2) – E12
Resistance Max. 1 z
(female) (1)
3
ground in wiring harness Between P02 (female) (11) – H08 (2) – E08 (2) – E12
(female) (1) wiring harness and chassis ground
4 Defective monitor panel P02 Engine speed Voltage
Between (11) and chassis ground Above middle speed 27.5 – 29.5 V
Electric circuit diagram related to charge voltage system
20-406 BZ210-1
(1)
TROUBLESHOOTING B@BAZG
Mechanical system error code [B@BAZG] (Abnormal lowering of engine oil pressure)

Trouble Abnormal lowering of engine oil pressure
— — B@BAZG
Contents of While the engine is running, the signal circuit of the engine oil pressure switch is connected (to the chassis
trouble ground).
Action of GP
None in particular.
controller
Problem that
appears on If the machine is used as it is, the engine may be seized.
machine
Related If the engine oil pressure caution symbol is displayed on the monitor panel while the engine is running, this

Lowering of engine oil pres-

1 sure aCheck for the cause and damage of the engine, then repair.
Defective engine oil pres- E02 (Switch side) Engine oil pressure Resistance
2
sure switch When normal Min. 1 Mz
Between terminal and chassis ground
When low Max. 1 z
3
ground in wiring harness Between P02 (female) (7) – H08 (6) – E02 (terminal)
bleshooting.
4 Defective monitor panel P02 Engine oil pressure Voltage
When normal 20 – 30 V
When low Max. 1 V
Electric circuit diagram related to engine oil pressure switch system
BZ210-1 20-407
(1)
TROUBLESHOOTING B@BAZK
Mechanical system error code [B@BAZK] (Abnormal lowering of engine oil level)

Trouble Abnormal lowering of engine oil level
— — B@BAZK
Contents of While the engine is stopped (with the starting switch ON), the signal circuit of the engine oil level switch is
trouble disconnected (from the chassis ground).
Action of GP
None in particular.
controller
Problem that
machine
Related If the engine oil level caution symbol is displayed on the monitor panel while the engine is stopped (with
information the starting switch ON), this error code is recorded.

Lowering of engine oil level

1 aCheck the oil level.
starting switch.
Defective engine oil level E03 (male) Engine oil level Resistance
2
switch
When normal Min. 1 Mz
When low Max. 1 z
3
ground in wiring harness Between P02 (female) (8) – H08 (8) – E03 (female) (1)
bleshooting.
4 Defective monitor panel P02 Engine oil level Voltage
When normal Max. 1 V
When low 20 – 30 V
Electric circuit diagram related to engine oil level sensor system
20-408 BZ210-1
(1)
TROUBLESHOOTING B@BCNS
Mechanical system error code [B@BCNS] (Overheating of engine coolant)

Trouble Overheating of engine coolant
— — B@BCNS
Contents of
While the engine is running, the signal of the engine coolant temperature sensor rises above 102°C.
trouble
Action of GP
None in particular.
controller
Problem that
machine
Related If the engine coolant temperature gauge becomes red on the monitor panel while the engine is running,
information this error code is recorded.

Overheating of engine
1 aCheck for the cause and damage of the engine, then repair.
starting switch.
Defective engine coolant Engine coolant
2 E05 (male) Resistance
temperature sensor temperature
Between (1) and (2) 90 – 3.5 kz
0 – 100ºC
Short circuit with chassis
3 Between P02 (female) (1) – H08 (7) – E05 (female) (1)
ground in wiring harness Resistance Min. 1 Mz
starting switch.
Engine coolant
4 Defective monitor panel P02 (female) Resistance
temperature
Between (1) and (13) 90 – 3.5 kz
0 – 100ºC
Electric circuit diagram related to engine coolant temperature system
BZ210-1 20-409
(1)
TROUBLESHOOTING B@BCZK
Mechanical system error code [B@BCZK]

(Abnormal lowering of radiator coolant level)

Trouble Abnormal lowering of radiator coolant level
— — B@BCZK
Contents of While the engine is running, the signal circuit of the radiator coolant level switch is disconnected (from the
trouble chassis ground).
Action of GP
None in particular.
controller
Problem that
appears on If the machine is used as it is, the engine overheats.
machine
Related If the radiator coolant level caution symbol is displayed on the monitor panel while the engine is running,
information this error code is recorded.

Lowering of radiator cool-

1 ant level aCheck the coolant level.
starting switch.
Defective radiator coolant A33 (male) Radiator coolant level Resistance
2
level switch
When normal Max. 1 z
Between (1) and (2)
When low Min. 1 Mz
3
harness
Between P02 (female) (3) – H08 (10) – A33 (1) Resistance Min. 1 Mz
bleshooting.
4 Defective monitor panel P02 Radiator coolant level Voltage
When normal Max. 1 V
When low 20 – 30 V
Electric circuit diagram related to radiator coolant level switch system
20-410 BZ210-1
(1)
TROUBLESHOOTING B@HANS
Mechanical system error code [B@HANS] (Overheating of hydraulic oil)

Trouble Overheating of hydraulic oil
— — B@HANS
Contents of
While the engine is running, the signal of the hydraulic oil temperature sensor rises above 102°C.
trouble
Action of GP
None in particular.
controller
Problem that
appears on If the machine is used as it is, the hydraulic equipment is damaged.
machine
Related If the hydraulic oil temperature gauge becomes red on the monitor panel while the engine is running, this

Overheating of hydraulic oil

1 aCheck for the cause and repair.
starting switch.
Defective hydraulic oil tem- A61 (male) Hydraulic oil temperature Resistance
2
perature sensor
Between (1) and (2) 90 – 3.5 kz
10 – 100ºC
3
ground in wiring harness Between P02 (female) (12) – H08 (12) – A61 (female)
bleshooting.
4 Defective monitor panel P02 Hydraulic oil temperature Resistance
Between (12) and (13) 90 – 3.5 kz
10 – 100ºC
Electric circuit diagram related to hydraulic oil temperature sensor system
BZ210-1 20-411
(1)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)

E-1 Engine does not start (Engine does not crank)................................................................................. 20-504
E-2 Engine stops during operation .......................................................................................................... 20-507
E-3 Engine rotation is unstable or engine hunts...................................................................................... 20-508
E-4 Engine does not stop ........................................................................................................................ 20-510
E-5 Engine preheater does not operate .................................................................................................. 20-512
E-6 Travel system and manual operation system do not work................................................................ 20-514
E-7 No items are displayed on monitor panel.......................................................................................... 20-516
E-8 Some items are not displayed on monitor panel............................................................................... 20-517
E-9 Fuel level monitor lights red while engine is running ........................................................................ 20-517
E-10 Engine coolant temperature gauge does not indicate normally ........................................................ 20-518
E-11 Hydraulic oil temperature gauge does not indicate normally ............................................................ 20-519
E-12 Fuel level gauge does not indicate normally..................................................................................... 20-520
E-13 When monitor switch is operated, nothing is displayed .................................................................... 20-521
E-14 Printer does not print ........................................................................................................................ 20-522
E-15 Solidifying material level lamp (Lower) does not light up .................................................................. 20-526
E-16 Solidifying material level lamp (Upper) does not light up .................................................................. 20-528
E-17 Soil presence is not displayed normally on ordinary screen ............................................................. 20-530
E-18 Integrated liquid addition value is not displayed normally................................................................. 20-531
E-19 Travel/Work/Manual mode does not change .................................................................................... 20-532
E-20 Travel alarm does not sound ............................................................................................................ 20-534
E-21 While soil feeder is not loaded at all, it senses overload and stops.................................................. 20-536
E-22 While solidifying material feeder is not loaded at all, it senses overload and stops.......................... 20-537
E-23 While hammer is overloaded, soil feeder does not stop ................................................................... 20-538
E-24 While attachment 1 is overloaded, any work equipment (or only front processor,
when front processor is selected as attachment 1) does not stop .................................................... 20-540
E-27 While soil feeder is overloaded, soil feeder, solidifying material feeder,
and raking rotor do not stop .............................................................................................................. 20-546
E-28 While solidifying material feeder is overloaded, soil feeder, solidifying material feeder,
E-29 While hammer is not loaded at all, soil feeder, solidifying material feeder,
and raking rotor, hammer, and soil cutter stop.................................................................................. 20-548
E-30 While attachment 1 is not loaded at all, whole work equipment (or only front processor,
when front processor is selected as attachment 1) stops ................................................................. 20-550
E-33 While discharge belt conveyor is not loaded at all, whole work equipment stops............................. 20-556
E-34 While discharge belt conveyor is overloaded, any work equipment does not stop........................... 20-557
E-35 While soil cutter is not loaded at all, soil feeder, solidifying material feeder, raking rotor,
hammer, and soil cutter stop............................................................................................................. 20-558
BZ210-1 20-501
(1)
TROUBLESHOOTING
E-36 While soil cutter is overloaded, soil feeder, solidifying material feeder, raking rotor,
hammer, and soil cutter stop............................................................................................................. 20-560
E-37 While raking rotor is not loaded at all, soil feeder, solidifying material feeder,
and raking rotor stop ......................................................................................................................... 20-562
E-38 While raking rotor is overloaded, soil feeder, solidifying material feeder,
20-502 BZ210-1
(1)

Trouble Trouble which occurred in the machine

Related
Information related to the detected trouble or troubleshooting
information
Cause Standard value in normalcy and references for troubleshooting
<Contents of description)
1 • Standard value in normal state to judge possible causes
Presumed cause and standard value in normalcy
<Troubles in wiring harness>

• Disconnection
Connector is connected imperfectly or harness is broken.
2 • Grounding fault
Wiring harness which is not connected to chassis ground circuit is in contact with chas-
sis ground circuit.
• Short circuit with power source
Possible causes of trou- Wiring harness which is not connected to power source (24V) circuit is in contact with
ble power source (24V) circuit.
3 (Given numbers are ref-
erence numbers, which <Precautions for troubleshooting>
do not indicate priority) 1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting, unless otherwise
specified.
• If connector No. has no marks of "male" and "female", disconnect connector and in-
4 sert T-adapters in both male side and female side.
• If connector No. has marks of "male" and "female", disconnect connector and con-
nect T-adapter to only male side or female side.
2) Entry order of pin Nos. and handling of circuit tester leads
Connect positive (+) lead and negative (–) lead of circuit tester as explained below
for troubleshooting, unless otherwise specified.
5 • Connect positive (+) lead to pin No. or harness entered on front side.
• Connect negative (–) lead to pin No. or harness entered on rear side.
Related circuit diagram
This is a circuit diagram of the part related to troubleshooting.
• Connector No.: Shows the "Type-Number of pin" and "Color".

• Arrow ( ): Roughly shows the location on the machine.
BZ210-1 20-503
(1)
TROUBLESHOOTING E-1
E-1 Engine does not start (Engine does not crank)
Trouble Engine does not start (Engine does not crank)

Insufficient charge level of Battery voltage Electrolyte specific gravity
1
battery Min. 24 V Min. 1.26
aPrepare with starting switch OFF.
E60 (male) Starting switch Resistance
2 Defective starting switch
OFF Min. 1 Mz
Between (1) and (6)
START Max. 1 z
If the fuse or the fusible link is broken, the circuit probably has a grounding fault, etc.
Defective fuse No.1 or fus-
3 If the monitor panel does not light up, check the power supply circuit between the
ible link A35
battery and fuse, too.
(If power supply, GND, generation signal, and starting input are normal but starting
output is abnormal, starting motor relay is defective.)
Safety relay Starting switch Voltage

Power supply: Between B terminal and
20 – 30 V
chassis ground
GND: Between E terminal and chassis
4 Defective safety relay Connected
ground
Generation signal: R terminal (A27 (2))
START Max. 1 V
and chassis ground
Starting input: C terminal and chassis
20 – 30 V
ground
Starting output: S terminal (A27 (1)) and
20 – 30 V
chassis ground
(If power supply and starting input are normal but starting motor does not rotate,
starting motor relay is defective.)
Starting motor Starting switch Voltage
5 Defective monitor panel
Power supply: Between B terminal and
20 – 30 V
chassis ground
START
Starting input: C terminal and chassis
20 – 30 V
ground
6 Defective alternator E12 (male) Voltage
Between (1) and chassis ground Max. 1 V
starting switch.
Disconnection in wiring Between FB (fuse) (1) and E60 (female) (1) Resistance Max. 1 z
7
harness Between E60 (female) (6) – H08 (1) – A27 (female) (1) Resistance Max. 1 z
Between safety relay C terminal – T13 (1) – starting
Resistance Max. 1 z
motor C terminal
20-504 BZ210-1
(1)
TROUBLESHOOTING E-1

starting switch.
Between battery relay B terminal – A35 (1) or (2) – H07
(1) – FB (fuse) (1) or (2) wiring harness and chassis Resistance Min. 1 Mz
ground
8 Between FB (fuse) (1) – E60 (female) (1) wiring har-
ground in wiring harness Resistance Min. 1 Mz
ness and chassis ground
Between starting motor relay C terminal – starting
motor C terminal wiring harness and chassis ground
Between E60 (female) (6) – A27 (female) (1) wiring
circuit) in wiring harness Between A27 (female) (2) – E08 (2) – E12 (female) (1)
Voltage Max. 1 V
BZ210-1 20-505
(1)
TROUBLESHOOTING E-1
Electric circuit diagram related to starting, stopping, and charging of engine
20-506 BZ210-1
(1)
TROUBLESHOOTING E-2
E-2 Engine stops during operation
Trouble Engine stopped suddenly during operation.

starting switch.

1 Defective fuel control dial
Between (1) and (3) 4.0 – 6.0 kz
Between (2) and (1) 0.25 – 5.0 kz
Between (2) and (3) 0.25 – 5.0 kz
2
harness
3
ground in wiring harness Between C13A (female) (2) – E32 (female) (2) wiring
bleshooting.
4 Defective GP controller C13A Voltage
Between (7) and (17) 4.5 – 5.5V
Between (2) and (17) 0.5 – 4.5V
Electric circuit diagram related to fuel control dial system
BZ210-1 20-507
(1)
TROUBLESHOOTING E-3
E-3 Engine rotation is unstable or engine hunts
• Low idling speed is unstable.

Trouble • Engine hunts.
• High idling speed is insufficient.
Related
The engine speed can be checked with the monitoring function.
information

Defective adjustment of
1 Adjust the governor lever.

governor lever
When the following operation is performed, if the governor motor lever moves
Malfunction of governor smoothly, the governor motor is normal.
2
motor • Change speed between low idling and high idling with fuel control dial.
• Stop engine with starting switch.
Defective engine fuel control
3 See Shop Manual for engine.
system
4
harness
Between C13 (female) (8) and E60 (female) (3) Resistance Max. 1 z
5
6 Defective GP controller (If none of causes 1 – 5 is the cause of the trouble, the GP controller is judged
defective.)
20-508 BZ210-1
(1)
TROUBLESHOOTING E-3
BZ210-1 20-509
(1)
TROUBLESHOOTING E-4
E-4 Engine does not stop
Trouble Engine does not stop.

Related The GP (Governor Pump) controller controls the battery relay for 4 seconds at shorted and 7 seconds at
information longest after the starting switch is turned OFF until the engine stops completely.

When the starting switch is operated, if the contacts of the battery relay make operat-
1 Defective battery relay ing sounds, the battery relay is normal.
• Turn the starting switch OFF, ON, and OFF.
aPrepare with starting switch OFF, then carry out troubleshooting without turning start-
Disconnection in wiring ing switch.
2
harness Between C11 (female) (1) – H09 (6) – battery relay BR
Resistance Max. 1 z
terminal
aPrepare with starting switch OFF, then carry out troubleshooting without turning start-
Short circuit with chassis ing switch.
3
ground in wiring harness Between C11 (female) (1) – H09 (6) – battery relay BR
terminal wiring harness and chassis ground
aPrepare with starting switch OFF, then hold starting switch ON and carry out trouble-
shooting.
4 Defective GP controller C11 Starting switch Voltage
20 – 30 V
Between (1) and chassis ground ON o OFF
(For 4 – 7 sec)
20-510 BZ210-1
(1)
TROUBLESHOOTING E-4
BZ210-1 20-511
(1)
TROUBLESHOOTING E-5
E-5 Engine preheater does not operate
Trouble (1) When starting switch is set in PREHEAT position, preheating monitor does not light up.

Defective starting switch If the engine is not preheated (the heater does not become hot), carry out trouble-
1
system shooting for trouble (2).
Possible causes and
2
harness
Between P02 (female) (18) and E60 (female) (4) Resistance Max. 1 z
P02 Starting switch Voltage
OFF Max. 1 V
HEAT 20 – 30 V
Trouble (2) When starting switch is set in PREHEAT position, heater does not become hot.
Related When the temperature is low (coolant temperature is below 30ºC), GP (Governor Pump) controller drives
information the heater relay for 100 seconds to preheat automatically after the engine is started.

Defective starting switch E60 (male) Starting switch Resistance
1
system OFF Min. 1 Mz
Between (1) and (4)
HEAT Max. 1 z
starting switch.
Defective electrical intake Electrical intake air heater relay Continuity and resistance
2
air heater relay
Between coil terminal and chassis ground There is continuity
Between contact terminals Min. 1 Mz
Defective electrical intake aPrepare with starting switch OFF.
3
air heater Between heater terminals If there is continuity, heater is normal.
starting switch.
Between E60 (female) (4) – H08 (3) – electrical intake
Resistance Max. 1 z
Disconnection in wiring air heater relay terminal
4
harness Between battery relay M terminal and electrical intake
Resistance Max. 1 z
air heater relay terminal
Between C21 (female) (5) and D07 (female) (2) Resistance Max. 1 z
Between D07 (female) (1) and E60 (female) (4) Resistance Max. 1 z
starting switch.
5 Defective diode D07 (male) Digital circuit tester Continuity
There is
Between (2) and (1) Diode mode
continuity
20-512 BZ210-1
(1)
TROUBLESHOOTING E-5
BZ210-1 20-513
(1)
TROUBLESHOOTING E-6
E-6 Travel system and manual operation system do not work
Trouble Travel system does not work

starting switch.
Defective travel/work/man- E30 (female) Mode selector switch Resistance
2
ual mode selector switch
Travel Max. 1 z
Between (2) and (4)
Other position Min. 1 Mz
3
harness Between V06B (female) (2) – H04 (11) – E30 (male) (2) Resistance Max. 1 z
starting switch.
4 Defective solenoid valve
Between (1) and (2) 20 – 45 z
Trouble Manual mode cannot be selected

starting switch.
E30 (female) Mode selector switch Resistance
Defective travel/work/man- Travel Max. 1 z
2
ual mode selector switch Between (2) and (4)
Other position Min. 1 Mz
Work Min. 1 Mz
Between (3) and (4)
Other position Max. 1 z
starting switch.
Disconnection in wiring Between V06B (female) (2) – H04 (11) – E30 (male) (2) Resistance Max. 1 z
3
harness Between V06B (female) (1) and chassis ground Resistance Max. 1 z
Between C13A (female) (19) and E30 (male) (3) Resistance Max. 1 z
Between C13A (female) (18) and E30 (male) (2) Resistance Max. 1 z
starting switch.
4 Defective solenoid valve
Between (1) and (2) 20 – 45 z
20-514 BZ210-1
(1)
TROUBLESHOOTING E-6
Electric circuit diagram related to travel and manual mode system
BZ210-1 20-515
(1)
TROUBLESHOOTING E-7
E-7 No items are displayed on monitor panel
Trouble When starting switch is turned ON, no items are displayed on monitor panel.

2
harness Between P01 (female) (1) or (2) and fuse No.3 Resistance Max. 1 z
Between P01 (female) (6) or (7) and chassis ground Resistance Max. 1 z
3
ground in wiring harness Between P01 (female) (1) or (2) – fuse No.3 wiring har-
bleshooting.
Voltage and
4 Defective GP controller C11
resistance
Between (7) or (13) and chassis ground Voltage: 20 – 30 V
Between (6) or (12) and chassis ground Resistance: Max. 1 z
Electric circuit diagram related to monitor panel power supply system
20-516 BZ210-1
(1)
TROUBLESHOOTING E-8, E-9
E-8 Some items are not displayed on monitor panel
Trouble When starting switch is turned ON, some items are not displayed on monitor panel.

When the following switches are operated, if all the LCD of the panel light up (the
Defective monitor
Possible causes and
1 front side becomes white), the LCD is normal.

panel LCD
• Operation of switches: [ ] + [A] (Operate simultaneously)
Troubleshooting cannot be carried out since the defect is in the monitor panel.
(If cause 1 is not the cause of the trouble, the monitor panel is judged defective.)
E-9 Fuel level monitor lights red while engine is running
Trouble Fuel level monitor lights red while engine is running.

Related
If the fuel level gauge of the monitor panel enters the red range, the fuel level monitor becomes red.
information

Low fuel level

1 aAdd fuel.
starting switch.
2 Defective fuel level sensor A60 (male) Fuel level Resistance
FULL (Upper limit) Approx. 12 z
EMPTY (Lower limit) 85 – 110 z
3
harness
Between P02 (female) (2) – H08 (4) – A60 (female) (1) Resistance Max. 1 z
shooting.
4 Defective monitor panel P02 (male) Fuel level Resistance
Electric circuit diagram related to fuel level sensor system
BZ210-1 20-517
(1)
TROUBLESHOOTING E-10
E-10 Engine coolant temperature gauge does not indicate normally
• While coolant temperature rises normally, gauge does not rise above white range (C).
Trouble
• While coolant temperature is stabilized normally, gauge does not rise to red range (H).

starting switch.
Defective engine coolant Engine coolant tempera-
1 E05 Resistance
temperature sensor ture
Between (1) and (2) 90 – 3.5 kz
10 – 100ºC
starting switch.
2 Between P02 (female) (1) – H08 (7) – E05 (female) (1) Resistance Max. 1 z
harness
Between P02 (female) (13) – H08 (2) – E05 (female)
Resistance Max. 1 z
(2)
3
ground in wiring harness Between P02 (female) (1) – H08 (7) – E05 (female) (1)
4 source in wiring harness
between Between P02 (female) (1) – H08 (7) – E05 (female) (1)
Voltage Max. 1 V
starting switch.
Engine coolant tempera-
5 Defective monitor panel P02 (male) Resistance
ture
Between (1) and (13) 90 – 3.5 kz
10 – 100ºC
Electric circuit diagram related to engine coolant temperature system
20-518 BZ210-1
(1)
E-11 Hydraulic oil temperature gauge does not indicate normally
• While hydraulic oil temperature rises normally, gauge does not rise above white range (C).
Trouble
• While hydraulic oil temperature is stabilized normally, gauge does not rise to red range (H).

starting switch.
Defective hydraulic oil tem- A61 Hydraulic oil temperature Resistance
1
perature sensor
Between (1) and (2) 90 – 3.5 kz
10 – 100ºC

starting switch.
Disconnection in wiring Between P02 (female) (13) – H08 (11) – A61 (female)
harness (1)
Between P02 (female) (12) – H08 (12) – A61 (female)
Resistance Max. 1 z
(2)
3
ground in wiring harness Between P02 (female) (12) – H08 (12) – A61 (female)
4 source in wiring harness
between Between P02 (female) (12) – H08 (12) – A61 (female)
Voltage Max. 1 V
starting switch.
5 Defective monitor panel P02 (male) Starting switch Voltage
Between (12) and (13) 90 – 3.5 kz
10 – 100ºC
Electric circuit diagram related to hydraulic oil temperature sensor system
BZ210-1 20-519
(1)
E-12 Fuel level gauge does not indicate normally
• After fuel is added, gauge does not rise above red range (E).
Trouble
• After fuel level lowers, gauge does not lower from green range (F).

starting switch.
1 Defective fuel level sensor A60 (male) Fuel level Resistance

2
harness
Between P02 (female) (2) – H08 (4) – A60 (female) (1) Resistance Max. 1 z
3
ground in wiring harness Between P02 (female) (2) – H08 (4) – A60 (female) (1)
Short circuit with power shooting.
4
source in wiring harness Between P02 (female) (2) – H08 (4) – A60 (female) (1)
Voltage Max. 1 V
starting switch.
5 Defective monitor panel P02 (male) Fuel level Resistance
Electric circuit diagram related to fuel level sensor system
20-520 BZ210-1
(1)
E-13 When monitor switch is operated, nothing is displayed
Trouble (1) When mix mode switch is pressed, mix mode setting screen is not displayed.

Possible causes and
in tenormal state
standard value
1 Defective monitor panel Troubleshooting cannot be carried out since the defect is in the monitor panel.
When soil/solidifying material switch is pressed, soil and solidifying material setting screen is not dis-
Trouble (2)
played.

Possible causes and
in normal state
standard value
Trouble (3) When other item setting switch is pressed, other item setting screen is not displayed.

Possible causes and
standard value
in normal state
BZ210-1 20-521
(1)
E-14 Printer does not print
Trouble Printer does not print data.

Related
You can see if the printer can be set and can print by test printing.
information

Defective input voltage of bleshooting.
1
DC/DC converter DC/DC converter Voltage
Between T31 and T32 20 – 30 V
Defective output voltage of bleshooting.
2
DC/DC converter DC/DC converter Voltage
Between T33 and T34 4.7 – 7.0 V
bleshooting.
A11 (female) Voltage
Between (41) and (31) 4.7 – 7.0 V
Between (41) and (32) 4.7 – 7.0 V
Between (41) and (33) 4.7 – 7.0 V
Between (41) and (34) 4.7 – 7.0 V
Between (41) and (35) 4.7 – 7.0 V
Between (41) and (36) 4.7 – 7.0 V
Between (41) and (37) 4.7 – 7.0 V
Defective printer power Between (41) and (38) 4.7 – 7.0 V

3
supply system Between (41) and (39) 4.7 – 7.0 V
Between (41) and (40) 4.7 – 7.0 V
Between (42) and (31) 4.7 – 7.0 V
Between (43) and (31) 4.7 – 7.0 V
Between (44) and (31) 4.7 – 7.0 V
Between (45) and (31) 4.7 – 7.0 V
Between (46) and (31) 4.7 – 7.0 V
Between (47) and (31) 4.7 – 7.0 V
Between (48) and (31) 4.7 – 7.0 V
Between (49) and (31) 4.7 – 7.0 V
Between (50) and (31) 4.7 – 7.0 V
20-522 BZ210-1
(1)

starting switch.
Defective RS232C commu- Between C14 (female) (3) – H13 (1) – H13-A (1) – A11
Resistance Max. 1 z
nication wiring harness (female) (29)
4
(Disconnection or defective Between C14 (female) (4) – H13 (3) – H13-A (3) – A11
contact of connector) Resistance Max. 1 z
(female) (27)
Between C14 (female) (10) – H13 (2) – H13-A (2) –
Resistance Max. 1 z
A11 (female) (18), (20)
Defective printing unit of bleshooting.
5
printer Data must be printed nor-
Perform test printing
mally.
Troubleshooting cannot be carried out since the defect is in the printer.
6 Defective printer
(If none of causes 1 – 5 is the cause of the trouble, the printer is judged defective.)
7 Defective GP controller (If none of causes 1 – 6 is the cause of the trouble, the GP (Governor Pump) con-
troller is judged defective.)
BZ210-1 20-523
(1)
Electric circuit diagram related to operation of printer
20-524 BZ210-1
(1)
E-15 Solidifying material level lamp (Lower) does not light up
Trouble While there is solidifying material, solidifying material level lamp (Lower) does not light up.

Defective power supply sys- bleshooting.
1 tem of solidifying material
S26 (female) Voltage
sensor paddle switch
Between (1) and (4) 20 – 30 V
level lamp (Lower)
Between (2) and (4) 20 – 30 V
bleshooting.
Defective solidifying mate- Solidifying material
3 S26 Voltage
rial sensor paddle switch paddle switch
When rotated Max. 0.5 V
Between (5) and (4)
When stopped 20 – 30 V
Disconnection in wiring aPrepare with starting switch OFF, then carry out troubleshooting without turning
harness (Disconnection or starting switch.
4
defective contact of connec-
tor) Between S26 (female) (5) and E46 (female) Resistance Max. 1 z
5 ground in wiring harness
(Contact with ground circuit) Between S26 (female) (5) – E46 (female) wiring har-
Defective solidifying mate- If none of causes 1 – 5 is the cause of the trouble, the solidifying material level lamp
6
rial level lamp is judged defective.
20-526 BZ210-1
(1)
Electric circuit diagram related to solidifying material level lamp (Lower)
BZ210-1 20-527
(1)
E-16 Solidifying material level lamp (Upper) does not light up
Trouble While there is solidifying material, solidifying material level lamp (Upper) does not light up.

sensor paddle switch
Between (1) and (4) 20 – 30 V
level lamp (Upper)
Between (2) and (4) 20 – 30 V
bleshooting.
Defective solidifying mate- Solidifying material
3 S27 Voltage
rial sensor paddle switch paddle switch
When rotated Max. 0.5 V
Between (5) and (4)
When stopped 20 – 30 V
4
defective contact of connec-
tor) Between S27 (female) (5) and E48 (female) Resistance Max. 1 z
(Contact with ground circuit) Between S27 (female) (5) – E48 (female) wiring har-
Defective solidifying mate- If none of causes 1 – 5 is the cause of the trouble, the solidifying material level lamp
6
rial level lamp is judged defective.
20-528 BZ210-1
(1)
Electric circuit diagram related to solidifying material level lamp (Upper)
BZ210-1 20-529
(1)
E-17 Soil presence is not displayed normally on ordinary screen
• Soil presence is not displayed normally on ordinary screen.

Trouble • While there is soil, solidifying material feeder does not operate.
• While there is not soil, solidifying material feeder operates.


1 tem of soil presence sensor
proximity switch
Between (1) and (3) 20 – 30 V
2
defective contact of connec- Between C13B (female) (7) – H10 (7) – E37 (6) – S23
tor) Resistance Max. 1 z
(female) (2)
(Contact with ground circuit) Between C13B (female) (7) – H10 (7) – E37 (6) – S23
Defective soil presence Replace with the solidifying material feeder speed sensor switch or soil feeder
4
sensor proximity switch speed sensor proximity switch.
Troubleshooting cannot be carried out since the defect is in the governor pump con-
troller.
(If none of causes 1 – 4 is the cause of the trouble, the governor pump controller is
judged defective.)
Electric circuit diagram related to soil presence sensor
20-530 BZ210-1
(1)
E-18 Integrated liquid addition value is not displayed normally
Trouble Integrated liquid addition value is not displayed normally on ordinary screen

1
defective contact of connec- Between C23B (female) (10) – H12 (1) – flowmeter P
terminal (terminal on chassis side)
2 ground in wiring harness Between C23B (female) (10) – H12 (1) – flowmeter P
(Contact with ground circuit) terminal (terminal on chassis side) wiring harness and Resistance Min. 1 Mz
chassis ground
Troubleshooting cannot be carried out since the defect is in the flowmeter.
3 Defective flowmeter (If either of causes 1 – 2 is not the cause of the trouble, the flowmeter is judged
defective.)
Troubleshooting cannot be carried out since the defect is in the work equipment
Defective work equipment controller.
4
controller (If none of causes 1 – 3 is the cause of the trouble, the work equipment controller is
judged defective.)
Electric circuit diagram related to liquid addition unit drive system
BZ210-1 20-531
(1)
E-19 Travel/Work/Manual mode does not change
• When travel/work/manual mode selector switch is changed, mode does not change.
• Machine cannot be operated in work mode.
Trouble
• Machine cannot be operated manually in manual mode.
• Machine cannot travel in travel mode.
Defective power supply for aPrepare with starting switch OFF, then hold starting switch ON and carry out trou-
selecting model (Discon- bleshooting.
1
nection or defective contact E30 Voltage
of connector) Between (4) and chassis ground 20 – 30 V
starting switch.
E30 (female) Mode selector switch Resistance

Defective travel/work/man- Work
2 Between (2) and (4) Min. 1 Mz
ual mode selector switch
Manual
Travel
3
defective contact of connec- Between E30 (male) (3) and C13A (male) (19) Resistance Max. 1 z
tor) Between E30 (male) (2) and C13A (male) (18) Resistance Max. 1 z
starting switch. (Disconnect manual/travel ON mode selector relay R02.)
Between E30 (male) (3) and C13A (male) (19) wiring
4 ground in wiring harness Resistance Min. 1 Mz
(Contact with ground circuit)
Between E30 (male) (2) and C13A (male) (18) wiring
5 Defective GP controller (If none of causes 1 – 4 is the cause of the trouble, the GP (Governor Pump) con-
20-532 BZ210-1
(1)
Electric circuit diagram related to selection of travel/work/manual mode
BZ210-1 20-533
(1)
E-20 Travel alarm does not sound
• While machine is traveling, alarm does not sound.

Trouble
• While machine is stopped, alarm sounds.

starting switch.
2 Defective pressure switch
S10 (male) Resistance

starting switch.
Between fuse No.4 and E30 (male) (4) Max. 1 z
3 Between E30 (male) (2) – H10 (12) – E59 (6) – E45
harness Max. 1 z
(female) (2) Resistance
Between E45 (female) (1) – E59 (5) – S10 (female) (1) Max. 1 z
Between S10 (female) (2) and chassis ground Max. 1 z
starting switch.
Short circuit with chassis Between E30 (male) (2) – H10 (12) – E59 (6) – E45
4 Min. 1 Mz
ground in wiring harness (female) (2) wiring harness and chassis ground
Resistance
Between fuse No.4 – E30 (male) (4) wiring harness
Min. 1 Mz
and chassis ground
starting switch.
Defective work/travel/man- E30 (female) Selector switch Resistance
5
ual selector switch
Travel Max. 1 z
Between (4) and (2)
Other than above Min. 1 Mz
20-534 BZ210-1
(1)
Electric circuit diagram related to travel alarm
BZ210-1 20-535
(1)
E-21 While soil feeder is not loaded at all, it senses overload and stops
Trouble While soil feeder is not loaded at all, soil feeder stops.
Related When the actual soil feeder speed is kept below 50% of the command speed for 0.5 seconds, the soil
information feeder is judged to be overloaded.


1 tem of soil feeder speed
sensor proximity switch
Between (1) and (3) 20 – 30 V
2
defective contact of connec- Between C13A (female) (20) – H10 (3) – E37 (8) – S21
(female) (2)
(Contact with ground circuit) Between C13A (female) (20) – H10 (3) – E37 (8) – S21
Defective soil feeder speed Replace with the solidifying material feeder speed sensor switch or soil presence
4
sensor proximity switch sensor proximity switch.
Troubleshooting cannot be carried out since the defect is in the GP (Governor
Pump) controller.
(If none of causes 1 – 4 is the cause of the trouble, the governor pump controller is
judged defective.)
Electric circuit diagram related to soil feeder speed sensor
20-536 BZ210-1
(1)
E-22 While solidifying material feeder is not loaded at all, it senses overload and
stops
Trouble While solidifying material feeder is not loaded at all, solidifying material feeder stops.
Related When the actual solidifying material feeder speed is kept below 50% of the command speed for 5 seconds,
information the solidifying material feeder is judged to be overloaded.
Defective power supply aPrepare with starting switch OFF, then hold starting switch ON and carry out trou-
system of solidifying mate- bleshooting.

1
rial feeder speed sensor S22 (female) Voltage
proximity switch Between (1) and (3) 20 – 30 V
2
defective contact of connec- Between C13A (female) (10) – H10 (9) – E37 (7) – S22
(female) (2)
(Contact with ground circuit) Between C13A (female) (10) – H10 (9) – E37 (7) – S22 Resistance Min. 1 Mz
Defective solidifying mate-
Replace with the soil feeder speed sensor switch or soil presence sensor proximity
4 rial feeder speed sensor
switch.
proximity switch
Pump) controller.
(If none of causes 1 – 4 is the cause of the trouble, the GP (Governor Pump) con-
Electric circuit diagram related to solidifying material feeder speed sensor
BZ210-1 20-537
(1)
E-23 While hammer is overloaded, soil feeder does not stop
Trouble While hammer is overloaded, soil feeder does not stop

Related
When the hammer pressure switch is kept turned ON for 20 seconds, it is judged to be overloaded.
information
Defective power supply sys- aPrepare with starting switch OFF, then hold starting switch ON and carry out trou-
tem of solidifying No.1 ham- bleshooting.
1
mer overload sensor S03 (female) Voltage
pressure switch Between (3) and (1) 20 – 30 V
2

3
starting switch.
Disconnection in wiring Between C23B (female) (15) – H02 (1) – S03 (female)
Resistance Max. 1 z
harness (Disconnection or (2)
4
defective contact of connec- Between C23B (female) (15) – H02 (1) – S02 (female)
(2)
Between C23B (female) (15) – H02 (1) – S01 (female)
Resistance Max. 1 z
(2)
starting switch.
Short circuit with chassis Resistance Min. 1 Mz
(Contact with ground circuit) Between C23B (female) (15) – H02 (1) – S02 (female) Resistance Min. 1 Mz
Troubleshooting cannot be carried out since the defect is in the pressure switch.
Defective No.1/No.2/No.3
6 (If none of causes 1 – 5 is the cause of the trouble, the pressure switch is judged
hammer pressure switch
defective.)
7
judged defective.)
20-538 BZ210-1
(1)
Electric circuit diagram related to No.1/No.2/No.3 hammer overload sensor
BZ210-1 20-539
(1)
when front processor is selected as attachment 1) does not stop
While attachment 1 is overloaded, any work equipment (or only front processor, when front processor is
Trouble
selected as attachment 1) does not stop.
Condition for judging overload on attachment
• When vibratory sieve is used: Pressure switch is kept turned ON for 30 seconds
Related
• When aftercutter is used: Pressure switch is kept turned ON for 1 second
information
• When belt conveyor is used: Pressure switch is kept turned ON for 1 second
• When front processor is used: Pressure switch is kept turned ON for 6 seconds
Defective power supply aPrepare with starting switch OFF, then hold starting switch ON and carry out trou-
system of attachment 1 bleshooting.

1
overload sensor pressure S05 (female) Voltage
switch Between (1) and (3) 20 – 30 V
2
(2)
Defective attachment 1 Troubleshooting cannot be carried out since the defect is in the pressure switch.
4 overload sensor pressure (If none of causes 1 – 3 is the cause of the trouble, the pressure switch is judged
switch defective.)
5
judged defective.)
20-540 BZ210-1
(1)
Electric circuit diagram related to attachment 1 overload sensor
BZ210-1 20-541
(1)
Trouble
Related
information

Defective power supply sys-
bleshooting.
1 tem of attachment 2 over-
load sensor pressure switch
Between (1) and (3) 20 – 30 V
2
(2)
switch defective.)
5
judged defective.)
20-542 BZ210-1
(1)
BZ210-1 20-543
(1)
Trouble
Related
information

Defective power supply sys-
bleshooting.
Between (1) and (3) 20 – 30 V
2
(2)
switch defective.)
5
judged defective.)
20-544 BZ210-1
(1)
BZ210-1 20-545
(1)
E-27 While soil feeder is overloaded, soil feeder, solidifying material feeder, and rak-
ing rotor do not stop
Trouble While soil feeder is overloaded, soil feeder, solidifying material feeder, and raking rotor do not stop.
Related When the actual soil feeder speed is kept below 50% of the command speed for 0.5 seconds, the soil
information feeder is judged to be overloaded.


Possible causes and
(Contact with ground circuit) Between C13A (female) (20) – H10 (3) – E37 (8) –
S21 (female) (2) wiring harness and chassis ground
Defective soil feeder speed Replace with the solidifying material feeder speed sensor switch or soil presence
2
sensor proximity switch sensor proximity switch.
Pump) controller.
(If none of causes 1 – 3 is the cause of the trouble, the GP (Governor Pump)
controller is judged defective.)
Electric circuit diagram related to soil feeder speed sensor
20-546 BZ210-1
(1)
E-28 While solidifying material feeder is overloaded, soil feeder, solidifying material
Trouble While soil feeder is overloaded, soil feeder, solidifying material feeder, and raking rotor do not stop.
Related When the actual solidifying material feeder speed is kept below 50% of the command speed for 5 sec-
information onds, the solidifying material feeder is judged to be overloaded.

Short circuit with chassis aPrepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch.

1
(Contact with ground cir-
Possible causes and
Between C13A (female) (10) – H10 (9) – E37 (7) –

cuit) Resistance Min. 1 Mz
S22 (female) (2) wiring harness and chassis ground
Defective solidifying mate-
Replace with the soil feeder speed sensor switch or soil presence sensor proxim-
2 rial feeder speed sensor
ity switch.
proximity switch
Pump) controller.
(If none of causes 1 – 3 is the cause of the trouble, the GP (Governor Pump) con-
Electric circuit diagram related to solidifying material feeder speed sensor
BZ210-1 20-547
(1)
E-29 While hammer is not loaded at all, soil feeder, solidifying material feeder, and
raking rotor, hammer, and soil cutter stop
While hammer is not loaded at all, soil feeder, solidifying material feeder, and raking rotor, hammer, and
Trouble
soil cutter stop.
Related
When the hammer pressure switch is kept turned ON for 20 seconds, it is judged to be overloaded.
information
1
2
bleshooting.
tem of solidifying No.3 ham-

3
starting switch.
Disconnection in wiring Between C23B (female) (15) – H02 (1) – S03 (female)
Resistance Max. 1 z
harness (Disconnection or (2)
5
(2)
Resistance Max. 1 z
(2)
starting switch.
Short circuit with chassis Resistance Min. 1 Mz
Troubleshooting cannot be carried out since the defect is in the pressure switch.
Defective No.1/No.2/No.3
7 (If none of causes 1 – 6 is the cause of the trouble, the pressure switch is judged
hammer pressure switch
defective.)
8
judged defective.)
20-548 BZ210-1
(1)
Electric circuit diagram related to No.1/No.2/No.3 hammer overload sensor
BZ210-1 20-549
(1)
E-30 While attachment 1 is not loaded at all, whole work equipment (or only front pro-
cessor, when front processor is selected as attachment 1) stops
While attachment 1 is not loaded at all, whole work equipment (or only front processor, when front proces-
Trouble
sor is selected as attachment 1) stops.
Related
information

Between (1) and (3) 20 – 30 V
switch defective.)
5
judged defective.)
20-550 BZ210-1
(1)
Electric circuit diagram related to attachment 1 unload sensor
BZ210-1 20-551
(1)
Trouble
Related
information

Between (1) and (3) 20 – 30 V
switch defective.)
5
judged defective.)
20-552 BZ210-1
(1)
BZ210-1 20-553
(1)
Trouble
Related
information

Between (1) and (3) 20 – 30 V
switch defective.)
5
judged defective.)
20-554 BZ210-1
(1)
BZ210-1 20-555
(1)
E-33 While discharge belt conveyor is not loaded at all, whole work equipment stops
Trouble While discharge belt conveyor is not loaded at all, whole work equipment stops.

starting switch.

Resistance Max. 1 z
(2)
Disconnection in wiring Between C13A (female) (16) – H03 (6) – A07 (female)
harness (1)
Between fuse (12) and A02 (female) (1) Resistance Max. 1 z
3
ground in wiring harness Between C13B (female) (13) – H02 (4) – S06 (female)
bleshooting.
Voltage and
resistance
Electric circuit diagram related to discharge belt conveyor pressure switch system
20-556 BZ210-1
(1)
E-34 While discharge belt conveyor is overloaded, any work equipment does not stop
Trouble While discharge belt conveyor is overloaded, any work equipment does not stop.

starting switch.

Resistance Max. 1 z
(2)
Disconnection in wiring Between C13A (female) (16) – H03 (6) – A07 (female)
harness (1)
Between fuse (12) and A02 (female) (1) Resistance Max. 1 z
3
ground in wiring harness Between C13B (female) (13) – H02 (4) – S06 (female)
bleshooting.
Voltage and
resistance
Electric circuit diagram related to discharge belt conveyor pressure switch system
BZ210-1 20-557
(1)
E-35 While soil cutter is not loaded at all, soil feeder, solidifying material feeder, rak-
ing rotor, hammer, and soil cutter stop
While soil cutter is not loaded at all, soil feeder, solidifying material feeder, raking rotor, hammer, and soil
Trouble
cutter stop.

starting switch.

Resistance Max. 1 z
(1)
Disconnection in wiring Between A07 (female) (2) and S07 (female) (1) Resistance Max. 1 z
2
harness Between C13A (female) (11) – H02 (6) – S07 (female)
Resistance Max. 1 z
(3)
Between fuse (12) – H01 (11) – A02 (female) (1) Resistance Max. 1 z
3
bleshooting.
Voltage and
resistance
20-558 BZ210-1
(1)
BZ210-1 20-559
(1)
E-36 While soil cutter is overloaded, soil feeder, solidifying material feeder, raking
rotor, hammer, and soil cutter stop
While soil cutter is overloaded, soil feeder, solidifying material feeder, raking rotor, hammer, and soil cutter
Trouble
do not stop.
starting switch.

Resistance Max. 1 z
(1)
2
harness Between C13A (female) (11) – H02 (6) – S07 (female)
Resistance Max. 1 z
(3)
3
bleshooting.
Voltage and
resistance
20-560 BZ210-1
(1)
BZ210-1 20-561
(1)
E-37 While raking rotor is not loaded at all, soil feeder, solidifying material feeder, and
raking rotor stop
Trouble While raking rotor is not loaded at all, soil feeder, solidifying material feeder, and raking rotor stop.

starting switch.

Resistance Max. 1 z
(1)
2
harness Between C15 (female) (16) – H02 (7) – S08 (female)
Resistance Max. 1 z
(2)
3
ground in wiring harness Between C15 (female) (16) – H02 (7) – S08 (female)
bleshooting.
Voltage and
resistance
Electric circuit diagram related to raking rotor pressure switch system
20-562 BZ210-1
(1)
E-38 While raking rotor is overloaded, soil feeder, solidifying material feeder, and raking
rotor do not stop
Trouble While raking rotor is overloaded, soil feeder, solidifying material feeder, and raking rotor do not stop.

starting switch.

Resistance Max. 1 z
(1)
2
harness Between C15 (female) (16) – H02 (7) – S08 (female)
Resistance Max. 1 z
(2)
3
ground in wiring harness Between C15 (female) (16) – H02 (7) – S08 (female)
bleshooting.
Voltage and
resistance
Electric circuit diagram related to raking rotor pressure switch system
BZ210-1 20-563
(1)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)

H-1 Speed or power of whole work equipment and travel is low ............................................................. 20-603
H-2 Engine speed lowers extremely or engine stalls............................................................................... 20-604
H-3 Work equipment and travel system do not move.............................................................................. 20-605
H-4 Abnormal sound comes out from around hydraulic pump ................................................................ 20-605
H-5 While soil belt conveyor is not loaded at all, soil belt conveyor, solidifying material feeder,
H-6 While soil belt conveyor is overloaded, soil belt conveyor, solidifying material feeder,
H-7 While solidifying material feeder is not loaded at all, soil belt conveyor,
solidifying material feeder, and raking rotor stop .............................................................................. 20-608
H-8 While solidifying material feeder is overloaded, soil belt conveyor,
solidifying material feeder, and raking rotor do not stop ................................................................... 20-609
H-9 While discharge belt conveyor is not loaded at all, whole work equipment stops............................. 20-610
H-10 While discharge belt conveyor is overloaded, any work equipment does not stop........................... 20- 611
H-11 While rotary hammer is not loaded at all, soil belt conveyor, solidifying material feeder,
H-12 While rotary hammer is overloaded, soil belt conveyor, solidifying material feeder,
H-13 While soil cutter is not loaded at all, soil belt conveyor, solidifying material feeder,
raking rotor, rotary hammer, and soil cutter stop............................................................................... 20-614
H-14 While soil cutter is overloaded, soil belt conveyor, solidifying material feeder,
raking rotor, rotary hammer, and soil cutter do not stop.................................................................... 20-615
H-15 While raking rotor is not loaded at all, soil belt conveyor, solidifying material feeder,
H-16 While raking rotor is overloaded, soil belt conveyor, solidifying material feeder,
H-17 While attachment 1 is not loaded at all, whole work equipment (or only front processor,
H-18 While attachment 1 is overloaded, whole work equipment (or only front processor,
H-23 Time lag of work equipment is large ................................................................................................. 20-623
H-24 Machine deviates during travel ......................................................................................................... 20-624
H-25 Travel speed is low ........................................................................................................................... 20-625
H-26 Machine is not steered well or steering power is low........................................................................ 20-626
H-27 Travel speed does not change or it is low or high............................................................................. 20-627
H-28 Travel motor does not work (only one side)...................................................................................... 20-627
BZ210-1 20-601
(1)
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE

Trouble Trouble which occurred in the machine

Related information Information related to the detected trouble or troubleshooting
Cause Standard value in normalcy and references for troubleshooting

Possible causes of trouble

<Contents of description>
(Given numbers are reference
3 • Standard value in normal state to judge possible causes
numbers, which do not indi-
cate priority)
20-602 BZ210-1
(1)
TROUBLESHOOTING H-1
H-1 Speed or power of whole work equipment and travel is low
Trouble Speed or power of whole work equipment and travel is low.

Related information When carrying out troubleshooting, reset the ECO-accelerator.

aPrepare with engine stopped, then run engine at high idling and carry out
troubleshooting.
Control lever Unload pressure (Reference value)
1 Malfunction of unload valve
Whole work equipment control
3.38 ± 1.0 MPa
stopped
{34.5 ± 10 kg/cm2}
All levers in neutral
troubleshooting.
Control lever Main relief pressure
7-spool valve: Start soil belt conveyor 16.2 – 20.1 MPa
Defective adjustment or * (Note 1) {165 – 205 kg/cm2}
2
malfunction of main relief valve 32.9 – 36.8 MPa
8-spool valve: Travel * (Note 2)
{335 – 375 kg/cm2}
If the oil pressure does not become normal after adjustment, the main relief
valve may have a malfunction or a defect in it. Check the main relief valve
directly.
troubleshooting.
Malfunction of self-reducing Control lever Control circuit basic pressure
3
pressure valve Whole work equipment control
2.83 – 3.43 MPa
stopped
{29 – 35 kg/cm2}
Defective adjustment or If the oil pressure does not become normal after adjustment, the PC valve may
4
malfunction of PC valve have a malfunction or a defect in it. Check the PC valve directly.
troubleshooting.
Travel speed Travel lever LS-EPC output pressure
5 Malfunction of LS-EPC valve
Approx. 2.5 MPa
Lo Neutral
{Approx. 25 kg/cm2}
Hi Idling 0 MPa {0 kg/cm2}
troubleshooting.
Oil pressure ratio
Measured oil pressure Traveling idle
(Lever at half)
Defective adjustment or
6 Pump discharge
malfunction of LS valve 1
pressure
Almost same pressure
LS valve output
Approx. 3/5
pressure
If the oil pressure does not become normal after adjustment, the LS valve may
have a malfunction or a defect in it. Check the LS valve directly.
7 Malfunction of servo piston The servo piston may have a malfunction. Check it directly.
If none of the above causes is the cause of the trouble, the cause of the trou-
8 Defective piston pump ble may be lowering of performance, malfunction, or internal defect of the pis-
ton pump.
* Note 1. Put a wood block, etc. in the sprocket of the soil belt conveyor to relieve the circuit.
* Note 2. Set the travel speed selector switch in the Lo position and put a wood block, etc. in the sprocket to relieve the cir-
cuit.
BZ210-1 20-603
(1)
TROUBLESHOOTING H-2
H-2 Engine speed lowers extremely or engine stalls
Trouble Engine speed lowers extremely or engine stalls.


troubleshooting.
Control lever Main relief pressure
7-spool valve: Start soil belt conveyor 16.2 – 20.1 MPa
Defective adjustment or * (Note 1) {165 – 205 kg/cm2}
1
malfunction of main relief valve
32.9 – 36.8 MPa

8-spool valve: Travel * (Note 2)
{335 – 375 kg/cm2}
If the oil pressure does not become normal after adjustment, the main relief
valve may have a malfunction or a defect in it. Check the main relief valve
directly.
Defective adjustment or If the oil pressure does not become normal after adjustment, the PC valve may
2
malfunction of PC valve have a malfunction or a defect in it. Check the PC valve directly.
troubleshooting.
Oil pressure ratio
Measured oil pressure Traveling idle
(Lever at half)
Defective adjustment or
3 Pump discharge
malfunction of LS valve 1
pressure
Almost same pressure
LS valve output pres-
Approx. 3/5
sure
If the oil pressure does not become normal after adjustment, the LS valve may
have a malfunction or a defect in it. Check the LS valve directly.
Clogging of orifices or filters in Orifices or filters in the pump servo devices may be clogged. Check them
4
servo devices directly.
5 Malfunction of servo piston The servo piston may have a malfunction. Check it directly.
cuit.
20-604 BZ210-1
(1)
TROUBLESHOOTING H-3, H-4
H-3 Work equipment and travel system do not move
Trouble Work equipment and travel system do not move.


troubleshooting.
Malfunction of PPC travel lock Position of mode selector switch Main relief pressure
1
solenoid valve Manual 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Travel
{29 – 35 kg/cm2}
troubleshooting.
Malfunction of self-reducing
2 Control lever Control circuit basic pressure
pressure valve
2.83 – 3.43 MPa
{29 – 35 kg/cm2}
The piston pump may have a malfunction or a defect in it. Check it by the fol-
lowing method.
3 Defective piston pump
• Remove the oil pressure pickup plug and crank the engine o If oil flows out,
the piston pump is normal.
The pump shaft may not revolve because of a defect in the damper. Check the
4 Defective damper
damper directly.
H-4 Abnormal sound comes out from around hydraulic pump
Trouble Abnormal sound comes out from around hydraulic pump.

Related information —

standard value in normalcy
Presumed cause and
1 Lowering of hydraulic oil level Check directly.

2 Air in hydraulic oil Air may be in the hydraulic oil. Check the oil directly.
Negative pressure may be generated in the tank because of clogging of
3 Clogging of hydraulic tank cap
the hydraulic tank cap. Check the cap directly.
Clogging of hydraulic tank Negative pressure may be generated in the suction circuit because of clog-
4
strainer ging of the hydraulic tank strainer. Check the strainer directly.
5 Defective piston pump The piston pump may have a defect in it. Check it directly.
BZ210-1 20-605
(1)
TROUBLESHOOTING H-5
H-5 While soil belt conveyor is not loaded at all, soil belt conveyor, solidifying mate-
While soil belt conveyor is not loaded at all, soil belt conveyor, solidifying material feeder, and raking
Trouble
rotor stop.

Defective soil belt conveyor
1
motor
The final drive may have a defect in it. Check it directly.
2 Defective final drive a(It can be judged by abnormal sound, abnormal heating, quantity of metal
dust in drained oil, etc.)
troubleshooting.
Malfunction of soil belt conveyor aCarry out troubleshooting in manual mode.
3
forward EPC valve Operation EPC valve output pressure
Approx. 2.6 MPa
Manual forward operation
{Approx. 26 kg/cm2}
Malfunction of soil belt conveyor The spool of the soil belt conveyor control valve may have a malfunction.
4
control valve (spool) Check it directly.
Malfunction of soil belt conveyor
The pressure compensation valve of the soil belt conveyor control valve may
5 control valve (pressure compen-
have a malfunction. Check it directly.
sation valve)
troubleshooting.
Defective adjustment or aCarry out troubleshooting in manual mode.
6
malfunction of main relief valve Operation Main relief pressure
16.2 – 20.1 MPa
Manual forward operation * (Note 1)
{165 – 205 kg/cm2}
20-606 BZ210-1
(1)
TROUBLESHOOTING H-6
H-6 While soil belt conveyor is overloaded, soil belt conveyor, solidifying material
While soil belt conveyor is overloaded, soil belt conveyor, solidifying material feeder, and raking
Trouble
rotor do not stop.

troubleshooting.
Presumed cause and
Malfunction of soil belt conveyor aCarry out troubleshooting in manual mode.

1
Approx. 2.6 MPa
{Approx. 26 kg/cm2}
2
The pressure compensation valve of the soil belt conveyor control valve
may have a malfunction. Check it directly.
sation valve)
BZ210-1 20-607
(1)
TROUBLESHOOTING H-7
H-7 While solidifying material feeder is not loaded at all, soil belt conveyor, solidify-
ing material feeder, and raking rotor stop
While solidifying material feeder is not loaded at all, soil belt conveyor, solidifying material feeder,
Trouble
and raking rotor stop.

Something caught in rotary parts A stone, cement block, etc. may be caught in the rotary parts of the solidifying
1
of solidifying material feeder material feeder. Check the feeder directly.
A stone, cement block, etc. may be caught in the circle and pinion. Check the
2 Defective circle or pinion
circle and pinion directly.
Defective solidifying material
3
feeder motor
troubleshooting.
Malfunction of solidifying mate- aCarry out troubleshooting in manual mode.
4
rial feeder forward EPC valve Operation EPC valve output pressure
Approx. 2.6 MPa
{Approx. 26 kg/cm2}
Malfunction of solidifying mate- The spool of the solidifying material feeder control valve may have a malfunc-
5
rial feeder control valve (spool) tion. Check it directly.
Malfunction of solidifying mate-
The pressure compensation valve of the solidifying material feeder control
6 rial feeder control valve
valve may have a malfunction. Check it directly.
(pressure compensation valve)
troubleshooting.
7
malfunction of port relief valve Operation Port relief pressure
16.7 – 20.6 MPa
{170 – 210 kg/cm2}
troubleshooting.
Defective adjustment or aCarry out troubleshooting in travel mode.
8
32.9 – 36.8 MPa
Travel * (Note 2)
{335 – 375 kg/cm2}
* Note 1. Put a wood block, etc. in the 4 blades of the solidifying material feeder to relieve the circuit.
cuit.
20-608 BZ210-1
(1)
TROUBLESHOOTING H-8
H-8 While solidifying material feeder is overloaded, soil belt conveyor, solidifying
material feeder, and raking rotor do not stop
While solidifying material feeder is overloaded, soil belt conveyor, solidifying material feeder, and
Trouble
raking rotor do not stop.

troubleshooting.
Malfunction of solidifying mate- aCarry out troubleshooting in manual mode.
1
rial feeder forward EPC valve Operation EPC valve output pressure
Approx. 2.6 MPa
{Approx. 26 kg/cm2}
Malfunction of solidifying mate- The spool of the solidifying material feeder control valve may have a malfunc-
2
rial feeder control valve (spool) tion. Check it directly.
Malfunction of solidifying mate-

The pressure compensation valve of the solidifying material feeder control
3 rial feeder control valve
BZ210-1 20-609
(1)
TROUBLESHOOTING H-9
H-9 While discharge belt conveyor is not loaded at all, whole work equipment stops
Trouble While discharge belt conveyor is not loaded at all, whole work equipment stops.

Soil, stones, etc. may be sticking to the tail pulley of the discharge belt con-
1 Much soil sticking to tail pulley
veyor. Check the pulley directly.
The discharge belt conveyor bearing may be defective. Check it directly.
Defective discharge belt
2 aRemove the discharge belt conveyor motor and set its shaft free. Rotate the
conveyor bearing
shaft with the hand to check that it revolves smoothly.
Defective discharge belt
3
conveyor motor
troubleshooting.
Malfunction of discharge belt aCarry out troubleshooting in manual mode.
4
conveyor forward ON/OFF valve Operation ON/OFF valve output pressure
2.83 – 3.43 MPa
{29 – 35 kg/cm2}
Malfunction of discharge belt The spool of the discharge belt conveyor control valve may have a malfunc-
5
conveyor control valve (spool) tion. Check it directly.
Malfunction of discharge belt
The pressure compensation valve of the discharge belt conveyor control valve
6 conveyor control valve
troubleshooting.
7
15.2 – 19.16 MPa
{155 – 195 kg/cm2}
troubleshooting.
8
32.9 – 36.8 MPa
Travel * (Note 2)
{335 – 375 kg/cm2}
* Note 1. Put a wood block, etc. in the sprocket of the discharge belt conveyor to relieve the circuit.
cuit.
20-610 BZ210-1
(1)
TROUBLESHOOTING H-10
H-10 While discharge belt conveyor is overloaded, any work equipment does not stop
Trouble While discharge belt conveyor is overloaded, any work equipment does not stop.

troubleshooting.
Presumed cause and
Malfunction of discharge belt aCarry out troubleshooting in manual mode.

1
conveyor forward ON/OFF valve Operation ON/OFF valve output pressure
2.83 – 3.43 MPa
{29 – 35 kg/cm2}
Malfunction of discharge belt The spool of the discharge belt conveyor control valve may have a mal-
2
conveyor control valve (spool) function. Check it directly.
Malfunction of discharge belt
The pressure compensation valve of the discharge belt conveyor control
3 conveyor control valve
BZ210-1 20-611
(1)
H-11 While rotary hammer is not loaded at all, soil belt conveyor, solidifying material
While rotary hammer is not loaded at all, soil belt conveyor, solidifying material feeder, and raking
Trouble
rotor stop.

Much soil sticking to inside wall of
1 Soil may be sticking to the inside wall of the mixer. Check the mixer directly.
mixer
2 Defective rotary hammer motor
3 Defective rotary hammer coupling The rotary hammer coupling may be defective. Check it directly.
The rotary hammer bearing may be defective. Check it directly.
4 Defective rotary hammer bearing aRemove the rotary hammer motor and set its shaft free. Rotate the shaft with
the hand to check that it revolves smoothly.
The rotary hammer spline may be defective. Check it directly.
5 Defective rotary hammer spline
aRemove the rotary hammer motor and check its spline.

troubleshooting.
Malfunction of rotary hammer aCarry out troubleshooting in manual mode.
6
Approx. 2.2 MPa
{Approx. 22 kg/cm2}
Malfunction of rotary hammer The spool of the rotary hammer control valve may have a malfunction. Check
7
control valve (spool) it directly.
Malfunction of rotary hammer
The pressure compensation valve of the rotary hammer control valve may
sation valve)
troubleshooting.
9
15.2 – 19.16 MPa
{155 – 195 kg/cm2}
troubleshooting.
1 Defective adjustment or aCarry out troubleshooting in manual mode.
0 malfunction of main relief valve Operation Main relief pressure
16.2 – 20.1 MPa
{165 – 205 kg/cm2}
* Note 1. Put a wood block, etc. in the rotary hammer to relieve the circuit.
20-612 BZ210-1
(1)
H-12 While rotary hammer is overloaded, soil belt conveyor, solidifying material feeder,
and raking rotor do not stop
While rotary hammer is overloaded, soil belt conveyor, solidifying material feeder, and raking rotor
Trouble
do not stop.

troubleshooting.
Presumed cause and
Malfunction of rotary hammer aCarry out troubleshooting in manual mode.

1
forward EPC valve Operation ON/OFF valve output pressure
Approx. 2.2 MPa
{Approx. 22 kg/cm2}
Malfunction of rotary hammer The spool of the rotary hammer control valve may have a malfunction.
2
Malfunction of rotary hammer
The pressure compensation valve of the rotary hammer control valve may
sation valve)
BZ210-1 20-613
(1)
H-13 While soil cutter is not loaded at all, soil belt conveyor, solidifying material
feeder, raking rotor, rotary hammer, and soil cutter stop
While soil cutter is not loaded at all, soil belt conveyor, solidifying material feeder, raking rotor,
Trouble
rotary hammer, and soil cutter stop.

1 Gravel in side of soil cutter shaft Gravel may be caught in side of the soil cutter shaft. Check the shaft directly.
If a round stone not higher than 200 mm but long (about 350 mm) is supplied,
Automatic stop because of large
2 it may not pass the soil cutter, although it is rare.
stone
In this case, set the production to the maximum (101 m3/H).
3 Defective soil cutter motor
4 Defective soil cutter coupling The soil cutter coupling may be defective. Check it directly.
The soil cutter bearing may be defective. Check it directly.
5 Defective soil cutter bearing aRemove the soil cutter motor and set its shaft free. Rotate the shaft with the
hand to check that it revolves smoothly.
The soil cutter spline may be defective. Check it directly.

6 Defective soil cutter spline
aRemove the soil cutter motor and check its spline.
troubleshooting.
Malfunction of soil cutter forward aCarry out troubleshooting in manual mode.
7
EPC valve Operation EPC valve output pressure
Approx. 1.8 MPa
{Approx. 18 kg/cm2}
Malfunction of soil cutter control The spool of the soil cutter control valve may have a malfunction. Check it
8
valve (spool) directly.
Malfunction of soil cutter control
The pressure compensation valve of the soil cutter control valve may have a
9 valve (pressure compensation
malfunction. Check it directly.
valve)
troubleshooting.
10
15.2 – 19.16 MPa
{155 – 195 kg/cm2}
troubleshooting.
11
32.9 – 36.8 MPa
Travel * (Note 2)
{335 – 375 kg/cm2}
* Note 1. Put a wood block, etc. in the soil cutter to relieve the circuit.
cuit.
20-614 BZ210-1
(1)
H-14 While soil cutter is overloaded, soil belt conveyor, solidifying material feeder,
raking rotor, rotary hammer, and soil cutter do not stop
While soil cutter is overloaded, soil belt conveyor, solidifying material feeder, raking rotor, rotary
Trouble
hammer, and soil cutter do not stop.

troubleshooting.
Presumed cause and
Malfunction of soil cutter forward aCarry out troubleshooting in manual mode.

1
EPC valve Operation ON/OFF valve output pressure
Approx. 1.8 MPa
{Approx. 18 kg/cm2}
Malfunction of soil cutter control The spool of the soil cutter control valve may have a malfunction. Check it
2
Malfunction of soil cutter control
The pressure compensation valve of the soil cutter control valve may have
a malfunction. Check it directly.
valve)
BZ210-1 20-615
(1)
H-15 While raking rotor is not loaded at all, soil belt conveyor, solidifying material
While raking rotor is not loaded at all, soil belt conveyor, solidifying material feeder, and raking rotor
Trouble
stop.

1 Gravel in side of raking rotor Gravel may be caught in side of the raking rotor. Check the shaft directly.
The raking rotor bearing may be defective. Check it directly.
2 Defective raking rotor bearing aRemove the raking rotor bearing and rotate it with the hand to check that it
revolves smoothly.
3 Defective raking rotor motor
4 Defective final drive aIt can be judged by abnormal sound, abnormal heating, quantity of metal dust
in drained oil, etc.
troubleshooting.
Malfunction of raking rotor aCarry out troubleshooting in manual mode.
5
Approx. 2.6 MPa
{Approx. 26 kg/cm2}
Malfunction of raking rotor control The spool of the raking rotor control valve may have a malfunction. Check it
6
Malfunction of raking rotor control
The pressure compensation valve of the raking rotor control valve may have a
malfunction. Check it directly.
valve)
troubleshooting.
8
9.8 – 13.7 MPa
{100 – 140 kg/cm2}
troubleshooting.
9
32.9 – 36.8 MPa
Travel * (Note 2)
{335 – 375 kg/cm2}
* Note 1. Put a wood block, etc. in the raking rotor to relieve the circuit.
cuit.
20-616 BZ210-1
(1)
H-16 While raking rotor is overloaded, soil belt conveyor, solidifying material feeder, and
raking rotor do not stop
While raking rotor is overloaded, soil belt conveyor, solidifying material feeder, raking rotor, rotary
Trouble
hammer, and raking rotor do not stop.

troubleshooting.
Presumed cause and
Malfunction of raking rotor aCarry out troubleshooting in manual mode.

1
Approx. 2.6 MPa
{Approx. 26 kg/cm2}
Malfunction of raking rotor control The spool of the raking rotor control valve may have a malfunction. Check
2
valve (spool) it directly.
Malfunction of raking rotor control
The pressure compensation valve of the raking rotor control valve may
valve)
BZ210-1 20-617
(1)
H-17 While attachment 1 is not loaded at all, whole work equipment (or only front pro-
While attachment 1 is not loaded at all, whole work equipment (or only front processor, when front
Trouble
processor is selected as attachment 1) stops.

Condition for judging overload is set specially for each device. Accordingly, if
Setting of attachment 1 is differ- the actually installed device is different from the setting, the system may mis-
1
ent from actually installed device judge the installed device overloaded.
Match the setting of attachment 1 to the actually installed device.
Wrong connection of attachment The attachment hoses may be connected wrongly (through the quick cou-
2
hoses plers). Connect them correctly.
The device installed to attachment 1 may be defective.
aFor a device other than the aftercutter, carry out troubleshooting according to
instruction manual attached to the device.
aWhen the aftercutter is installed, check the following points.
• Soil may be sticking to inside of the aftercutter case. Check the case direct-
ly.
• Gravel may be caught in the aftercutter blades. Check the blades directly.
3 Defect in device of attachment 1
• The aftercutter coupling may be defective. Check it directly.
• The aftercutter bearing may be defective. Check it directly.

aRemove the aftercutter motor and set its shaft free. Rotate the shaft with the
• The aftercutter spline may be defective. Check it directly.
aRemove the aftercutter motor and check its spline.
• Defective aftercutter motor
troubleshooting.
Malfunction of attachment 1 ON/ aCarry out troubleshooting in work mode and operate only attachment 1.
4
OFF valve Operation ON/OFF valve output pressure
2.83 – 3.43 MPa
ON
{29 – 35 kg/cm2}
Malfunction of attachment 1 con- The spool of the attachment 1 control valve may have a malfunction. Check it
5
trol valve (spool) directly.
Malfunction of attachment 1 con-
The pressure compensation valve of the attachment 1 control valve may have
6 trol valve (pressure compensa-
tion valve)
troubleshooting.
Defective adjustment or aCarry out troubleshooting in work mode and operate only attachment 1.
7
15.2 – 19.16 MPa
ON * (Note 1)
{155 – 195 kg/cm2}
troubleshooting.
8
32.9 – 36.8 MPa
Travel * (Note 2)
{335 – 375 kg/cm2}
* Note 1. Put a wood block, etc. in the device of attachment 1 to relieve the circuit.
cuit.
20-618 BZ210-1
(1)
H-18 While attachment 1 is overloaded, whole work equipment (or only front proces-
sor, when front processor is selected as attachment 1) does not stop
While attachment 1 is overloaded, whole work equipment (or only front processor, when front pro-
Trouble
cessor is selected as attachment 1) does not stop.

1
2
aCarry out troubleshooting in work mode and operate only attachment 1.
Malfunction of attachment 1 ON/
3 Operation ON/OFF valve output pressure
OFF valve
2.83 – 3.43 MPa
ON
{29 – 35 kg/cm2}
4
tion valve)
BZ210-1 20-619
(1)
Trouble

1
2
ly.

troubleshooting.
4
2.83 – 3.43 MPa
ON
{29 – 35 kg/cm2}
5
tion valve)
troubleshooting.
7
15.2 – 19.16 MPa
ON * (Note 1)
{155 – 195 kg/cm2}
troubleshooting.
8
32.9 – 36.8 MPa
Travel * (Note 2)
{335 – 375 kg/cm2}
cuit.
20-620 BZ210-1
(1)
Trouble

1
2
OFF valve
2.83 – 3.43 MPa
ON
{29 – 35 kg/cm2}
4
tion valve)
BZ210-1 20-621
(1)
Trouble

1
2
ly.

troubleshooting.
4
2.83 – 3.43 MPa
ON
{29 – 35 kg/cm2}
5
tion valve)
troubleshooting.
7
15.2 – 19.16 MPa
ON * (Note 1)
{155 – 195 kg/cm2}
troubleshooting.
8
16.2 – 20.1 MPa
{165 – 205 kg/cm2}
20-622 BZ210-1
(1)
Trouble

1
2
OFF valve
2.83 – 3.43 MPa
ON
{29 – 35 kg/cm2}
4
tion valve)
H-23 Time lag of work equipment is large
Trouble Time lag of work equipment is large.


Presumed cause and
1

The pressure compensation valve of the soil belt conveyor control valve
2 control valve (pressure compensa-
tion valve)
BZ210-1 20-623
(1)
H-24 Machine deviates during travel
Trouble Machine deviates during travel.

Related information When carrying out troubleshooting, set the mode selector switch in the travel mode.

aPrepare with engine stopped, then run engine at high idling and carry out trou-
bleshooting.
1 Malfunction of travel PPC valve Travel lever PPC valve output pressure
Output difference between right and
Max. 0.4 MPa {Max. 4 kg/cm2}
left
bleshooting.
pressure valve
2.83 – 3.43 MPa
{29 – 35 kg/cm2}
bleshooting.
Oil pressure ratio
Defective adjustment or Measured oil pressure Traveling idle
3 All levers in neutral
malfunction of LS valve (Lever at half)
Pump discharge
1
pressure Almost same pressure
LS valve output pressure Approx. 3/5
Malfunction of travel junction sole- bleshooting.
4
noid valve Travel lever Solenoid output pressure
One side operated 0 MPa {0 kg/cm2}
Malfunction of travel junction
5 The travel junction valve may have a malfunction. Check it directly.
valve
Malfunction of travel control valve
6 The spool of the travel control valve may have a malfunction. Check it directly.
(spool)
bleshooting.
7 Defective travel motor
Travel lever Leakage through travel motor
Travel circuit relieved Approx. 10 l/min
20-624 BZ210-1
(1)
H-25 Travel speed is low
Trouble Travel speed is low.


troubleshooting.
1 Malfunction of travel PPC valve Travel lever PPC valve output pressure
Output difference between right and
Max. 0.4 MPa {Max. 4 kg/cm2}
left and between front and rear
troubleshooting.
pressure valve
2.83 – 3.43 MPa
{29 – 35 kg/cm2}
troubleshooting.
Travel speed Travel lever LS-EPC output pressure
3 Malfunction of LS-EPC valve
Approx. 2.5 MPa
Lo Neutral
{Approx. 25 kg/cm2}
Hi Travel lever 0 MPa {0 kg/cm2}
(spool)
Malfunction of travel control valve The pressure compensation valve of the travel control valve may have a mal-
5
(pressure compensation valve) function. Check it directly.
Malfunction of travel control valve The suction valve of the travel control valve may have a malfunction. Check it
6
(suction valve) directly.
troubleshooting.
7 Defective travel motor
Travel lever Leakage through travel motor
Travel circuit relieved 10 l/min
BZ210-1 20-625
(1)
H-26 Machine is not steered well or steering power is low
Trouble Machine is not steered


Malfunction of travel PPC valve troubleshooting.
1
(steering spool) Travel lever PPC valve output pressure (steering)
Both sides in neutral 0 MPa {0 kg/cm2}
Malfunction of travel junction troubleshooting.

2
solenoid valve Travel lever Solenoid output pressure
One side operated 0 MPa {0 kg/cm2}
Malfunction of travel junction
3 The travel junction valve may have a malfunction. Check it directly.
valve
(spool)
Malfunction of travel control valve The pressure compensation valve of the travel control valve may have a mal-
5
(pressure compensation valve) function. Check it directly.
Malfunction of travel control valve The suction valve of the travel control valve may have a malfunction. Check it
6
(suction valve) directly.
Defective seal of LS oil pressure The seal of the LS oil pressure pickup check valve may be defective. Check it
7
pickup check valve directly.
The safety valve seal of the travel motor may be defective. Check it directly.
Malfunction of travel motor aThe sealing condition can be judged by replacing the same front and rear
8
(safety valve) motors or the same right and left motors with each other and checking the
change of the phenomenon.
The check valve seal of the travel motor may be defective. Check it directly.
Malfunction of travel motor aThe sealing condition can be judged by replacing the same front and rear
9
(check valve) motors or the same right and left motors with each other and checking the
change of the phenomenon.
20-626 BZ210-1
(1)
H-27 Travel speed does not change or it is low or high
Trouble Travel speed does not change or it is low or high.


troubleshooting.
LS-EPC output
Presumed cause and
Travel speed Travel lever

1 Malfunction of LS-EPC valve pressure
Approx. 2.5 MPa
Lo Neutral
{Approx. 25 kg/cm2}
Hi Operation 0 MPa {0 kg/cm2}
troubleshooting.
Malfunction of travel speed
2 Solenoid output
solenoid valve Travel speed Travel lever
pressure
Lo Neutral 0 MPa {0 kg/cm2}
H-28 Travel motor does not work (only one side)
Trouble Travel motor does not work (only one side).


Defective seat of travel control The suction valve seat of the travel control valve may be defective. Check
1
valve (suction valve) it directly.
Presumed cause and
Defective seat of travel motor The safety valve seat of the travel motor may be defective. Check it
2
(safety valve) directly.
Defective seat of travel motor The check valve seat of the travel motor may be defective. Check it
3
(check valve) directly.
4 Lowering of travel motor
5 Defective final drive aIt can be judged by abnormal sound, abnormal heating, quantity of metal
dust in drained oil, etc.
BZ210-1 20-627
(1)
TROUBLESHOOTING OF ENGINE
(S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-702

S-1 Starting performance is poor (Starting always takes time)................................................................ 20-706
S-2 Engine does not start ........................................................................................................................ 20-708
(1) Engine does not turn ................................................................................................................... 20-708
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) ............................... 20-709
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)............................. 20-710
S-3 Engine does not pick up smoothly (Follow-up is poor) ..................................................................... 20- 711
S-4 Engine stops during operations ........................................................................................................ 20-712
S-5 Engine does not rotate smoothly (Hunting)....................................................................................... 20-713
S-6 Engine lacks output (or lacks power) ................................................................................................ 20-714
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................................ 20-715
S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-716
S-9 Oil becomes contaminated quickly ................................................................................................... 20-717
S-10 Fuel consumption is excessive ......................................................................................................... 20-718
S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-719
S-12 Oil pressure monitor lights up (Drop in oil pressure)......................................................................... 20-720
S-13 Oil level rises (Water, fuel in oil)........................................................................................................ 20-721
S-14 Water temperature becomes too high (Overheating)........................................................................ 20-722
S-15 Abnormal noise is made ................................................................................................................... 20-723
S-16 Vibration is excessive ....................................................................................................................... 20-724
BZ210-1 20-701
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in [B] are items that can be
obtained from the user, depending on the user’s
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under [C] in the
chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the user
and the results of [C] that he has obtained from his
own inspection.
[Troubleshooting] Causes
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check
items].
(1) (2) (3)
(a)
Questions
[A] (b)
(c)
(d)
(e)
[B]
Check items
[C]
i
shooting
Trouble-
ii
iii
20-702 BZ210-1
(1)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and
mark the Cause column with E to use Causes
as reference for locating the cause of
tion)
the failure. However, do not use this
injec
when making calculations to narrow
down the causes.
fuel
2. Use the E in the Cause column as ref-
sive
erence for [Degree of use (Operated for
zzle
xces
nce
long period)] in the [Questions] section
n no
p (e
fere
g
as reference. As a rule, do not use it
jectio
men
pum
timin
inter
r
nde
when calculating the points for locating
le
uel in
tion
ction
er e
ger,
, cyli
the cause, but it can be included if nec-
injec
lean
ed f
l inje
char
ring
essary to determine the order for trou-
, seiz
fuel
air c
r fue
bleshooting. urbo
ton
ctive
n pis
ged
ged
rope
ed t
Defe
Clog
Clog
Seiz
Wor
Imp
Confirm recent repair history
Degree of use Operatred for long period
BZ210-1 20-703
(1)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
Causes
d
hea
tion)
)
ized
der
injec
r se
cylin
fuel
n ge
e, va rger and
sive
k, plu
eat
ozzle
xces
lve s
(rac
leme nce
a
boc h
p (e
on n
re
ump
g
nt
terfe
timin
pum
jecti
r
n tu
der
ance
ler
on p
valv
er, in
el in
ff
tion
e
n
ction
er e
u
etwe
, cyli
jecti
lear
dm
ct of
injec
d fu
harg
lean
l inje
lve c
el in
ring
gge
b
conta
eize
Legend
f air
rboc
fuel
air c
r fue
, clo
e fu
n
r va
: Possible causes (judging from Questions and check items)
to
s
o
ed tu
ctive
ctive
,
n pis
ectiv
: Most probable causes (judging from Questions and Check items)
kage
hed
ged
ged
rope
rope
: Possible causes due to length of use (used for a long period) Defe
Crus
Defe
Clog
Clog
Seiz
Wor
Deff
Imp
Imp
Lea
: Items to confirm the cause.
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after starting
Check items
engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment
Seal on fuel injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and cylinder head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating on
reduced cylinders
Troubleshooting
When check is made using delivery method, fuel injection timing

is found to be incorrect
Fuel injection pump test shows that fuel injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does not
return
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-704 BZ210-1
(1)
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cylinder head:
(3) Clogged, seized fuel injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item
marked . The Remedy is given as [Clean], so
carry out cleaning, and the exhaust gas color
should return to normal.
BZ210-1 20-705
(1)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)
General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of –10°C or below,
ASTM D975 No. 2 diesel fuel is used)
a Battery charging rate
Charging rate
Ambient 100 % 90 % 80 % 75 % 70 %
temperature
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
–10°C 1.30 1.28 1.26 1.25 1.24
• The specific gravity should exceed the value for the

charging rate of 70% in the above table.
• In cold areas the specific gravity must exceed the value
for the charging rate of 75% in the above table.
20-706 BZ210-1
(1)
Replace Defe
ctive
Replace Defe regu
lator
ctive
Replace
BZ210-1
Defe alter
nato
ctive r
Replace Defe or de
terio
ctive rated
Adjust Defe injec
tion batte
tive nozz ry
Replace Defe
injec
tion le
tive timin
Correct injec g
Leak tion
age, pum
Clean c lo p
TROUBLESHOOTING
Clog ggin (rack

ged g, air , plu
nger
Replace Defe
air b
reath
in fu
el pip stuc
ctive er ho ing k)
Replace Defe feed
p
le in
f
Causes
ctive ump uel t

boos ank
t com
pens
ator
canc
el
(1)
20-707
S-1
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn
General causes why engine does not turn Causes
• Internal parts of engine seized

a If internal parts of the engine are seized, car-
ry out troubleshooting for "Engine stops dur-
ing operations".
n
ectio
it
• Failure in hydraulic pump system
ery
circu
conn
batt
• Defective electrical system
ting
inal
ted
ch
tor
star
y
term
swit
iora
lay
rela
m o
y re
g of
eter
ting
rting
ery
ery
ear
afet
wirin
or d
star
batt
batt
ing g
t a
s
s
ctive
ctive
ctive
ctive
ctive
ctive
ctive
en r
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
Questions
Degree of use of machine Operated for long period

Condition of horn when Horn sounds
starting switch is turned ON
Horn volume is low
Speed of rotation is low
When starting switch is Makes grating noise
turned to START, pinion Soon disengages pinion again
moves out, but
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not
Check items
move out
When starting switch is turned to ON, there is no clicking

Troubleshooting of defective wiring in starting circuit
sound
Battery terminal is loose
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 4), turn the starting switch
OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
Troubleshooting
connected, engine starts

2) When terminal B and terminal C of starting motor are
connected, engine starts
3) When terminal B and terminal C of safety relay are connected,
engine starts
4) There is no 24V between battery relay terminal b and terminal
E
When ring gear is inspected directly, tooth surface is found to be
chipped
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-708 BZ210-1
(1)
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust

smoke comes out
• Supply of fuel impossible Causes

• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
)
ized
a Standards for use of fuel
r se
nge
y
nk
t, ke
el ta
k, plu
ton
shaf
in fu
p pis
c
p (ra
iner
g
drive
pipin
r
hole
e
pum
rain
a
pum
r
ank
ump
s t
fuel
her
r, st
eed
ump
d
l in t
tion
on p
l use
reat
king
l filte
en f
p
injec
t fue
air b
jecti
feed
r fue
, lea
brok
u e
n
f
ctive
en in
fficie
ged
ged
ged
rope
ged
ed,
Defe
Clog
Clog
Clog
Clog
Brok
Seiz
Insu
Imp
Questions

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
Mud is stuck to fuel tank cap
When fuel filter is drained, fuel does not come out
Check items
When engine is cranked with starting motor,

1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pump piping sleeve
nut is loosened
Rust and water are found when fuel tank is drained
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Troubleshooting
Inspect feed pump directly

When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Repair
Repair
Remedy
Clean
Clean
Add
BZ210-1 20-709
(1)
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine

does not start (Fuel is being injected)
General causes why exhaust smoke comes out but Causes
engine does not start
etc.)
• Lack of rotating force due to defective electrical
ck)
k, plu er lever,
system
r stu
ap
y
spra
nk c
nge
rock
em
ctive
el ta
syst
alve,
ttery
• Improper selection of fuel
in fu
r
e
r line
m (v
(rac
fuel
e f
t
d ba
r
men
aine
le, d
ater
iner
syste
hole
mp
ir in
rate
d
e
p str
nozz
stra
ir he
n
l
n pu
er e
g, a
i
her
, cyl
alve
erio
d
pum
ter,
ke a
l use
lean
tion
reat
ggin
io
ken v
ring
t
t
e
el fil
c
or d
a
injec
je
feed
air b
air c
, clo
r fue
t
, bro
ton
n
in
i
f
ctive
ctive
ctive
n pis
kage
ged
ged
ged
ged
ged
rope
ctive
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Lea
Imp
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

around cylinder head
Non-specified fuel is being used
Operation Manual
Air cleaner clogging monitor lights up
Preheating monitor does not light up
Starting motor cranks engine slowly
When fuel dial is placed at FULL position, it does not contact stopper
When engine is cranked with starting motor,
Check items
1) Little fuel comes out even when injection pump piping

sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or
does not return
When fuel filter, strainer are inspected directly, they are
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found to

be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
Speed does not change when operation of certain cylinders is stopped
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
Clean
20-710 BZ210-1
(1)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly

(Follow-up is poor)
General causes why engine does not pick up Causes

smoothly

ap
y
seat
spra
• Improper condition of fuel injction
nk c
alve
• Improper fuel used
tive
el ta
nce
nd v
efec
in fu
r
fere
nge
r line
nt
g
iner
ve a
le, d
pipin
leme
inter
p plu
aine
ance
hole
inde
stra
f val
nozz
er e
, str
fuel
ger,
pum
lear
her
, cyl
mp
act o
lean
filter
tion
char
reat
king
lve c
u
ring
n
p
jectio
cont
injec
feed
air c
air b
, lea
urbo
fuel
r va
ton
ed in
ctive
n pis
ged
ged
rope
ged
ged
ged
ed t
ged
Clog
Defe
Clog
Clog
Clog
Clog
Seiz
Seiz
Clog
Wor
Imp
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
When air cleaner element is inspected directly, it is found to

be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Troubleshooting
Speed does not change when operation of certain cylinders

is stopped
When control rack is pushed, it is found to be heavy, or does not return
When valve clearance is checked directly, it is found to be
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
Clean
Clean
Clean
Clean
BZ210-1 20-711
(1)
TROUBLESHOOTING S-4
S-4 Engine stops during operations
General causes why engine stops during operations
• Seized parts inside engine

• Overheating
a If there is overheating and the engine stops,
carry out troubleshooting for overheating.
• Failure in hydraulic pump

a If the engine stops because of a failure in the
hydraulic pump, carry out troubleshooting for
H mode.
20-712 BZ210-1
(1)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engin e does not rotate Causes

smoothly
p
zzle
pum
• Air in fuel system
d no
feed
• Defective governor mechanism
n
mp a
and
• Defective governor motor mechanism
nk
a If hunting stops when governor spring is dis-
tank
d pu
el ta
ck
r
erno
ol ra
connected, carry out troubleshooting for E
rnor
n fee
fuel
in fu
r
v
mode.
r
gove
een
aine
f go
twee
low
t
ner
f con
hole
betw
i
p str
nt o
too
stra
it be
tank
n of
ion o
her
stme
cuit
ed is
pum
circu
ter,
ratio
el in
reat
erat
ir
el fil
c
adju
e
ope
eed
air b
air in
nt fu
air in
g sp
o p
u
f
f
ctive
ctive
ctive
fficie
idlin
ged
ged
ged
ged,
ged,
Clog
Defe
Clog
Clog
Defe
Defe
Clog
Insu
Clog
Low
Occurs at a certain speed range
Questions
Occurs at low idling

Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Replacement of filters has not been carried out according
to Operation Manual
Fuel tank is found to be empty
Rust, water are found when fuel tank is drained
Leakage from fuel piping
When feed pump is operated,
Check items
1) No response, light, return is quick

2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Seal on injection pump has come off
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
Troubleshooting
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Remedy
Clean
Clean
Clean
Add
BZ210-1 20-713
(1)
TROUBLESHOOTING S-6
S-6 Engine lacks output

(or lacks power)
General causes why engine lacks output Causes

nt
tme
pray
eat
ragm
• Improper fuel used
lve s
djus
k
ve s
l tan
iaph
(if non-specified fuel is used, output drops)
ce
ve a
d va
fecti
e
• Lack of output due to overtaking
or d
eren
in fu
er
fecti
e an
, de
ung
nt
a If there is overheating and lack of output, car-
iping
iner
nsat
f
iner
leme
inter
hole
e
r
e
e
inde
valv
l
c
stra
p
ry out troubleshooting for overheating.
g, d
l
uel p
mpe
n
nozz
stra
ump
a
er e
ger,
her
lear
, cyl
prin
ct of
p
st co
pum
ing f
lter,
ion p
tion
reat
lean
char
lve c
ring
or s
onta
i
boo
injec
f
air b
feed
air c
, lea
urbo
fuel
vern
c
r va
ton
c
j e
ctive
ctive
ed in
n pis
ged
ged
ged
ged
rope
ged
ged
ed t
t go
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Seiz
Seiz
Ben
Wor
Imp
Suddenly
Power was lost
Gradually
Questions

Replacement of filters has not been carried out according
to Operation Manual
Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
High idling speed of engine is low
Leakage from fuel piping
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When fuel dial is placed at FULL position, lever does not contact stopper
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Remedy
Clean
Clean
Clean
Clean
20-714 BZ210-1
(1)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black Causes
ifold
man
d)
on)
eize
take
jecti
at
er s
y
nd in
spra
e se
ve in
lung
ger a
valv
timin efective
essi
nce
ck, p
char
and
fere
(exc
nt
p (ra
turbo
le, d
leme
alve
inter
ance
r
r
p
inde
uffle
pum
pum
nozz
een
v
er e
ger,
lear
, cyl
dm
f
act o
tion
tion
betw
ction
lean
tion
char
ve c
gge
ring
injec
injec
cont
injec
of air
air c
r inje
, clo
l
urbo
r va
ton
ctive
ctive
ctive
n pis
hed
ged
rope
ged
rope
age
ed t
Defe
Defe
Defe
Crus
Clog
Leak
Clog
Seiz
Wor
Imp
Imp
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting
is stopped
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Remedy
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
BZ210-1 20-715
(1)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
a Do not run the engine at idling for more than 20 Causes

minutes continuously. (Both low and high idling)
rger
ocha
General causes why oil consumption is excessive
Turb
• Abnormal combustion of oil
seal
ad
ace
• External leakage of oil
r he
stem
hose
oler
ken
f
l sur
• Wear of lubrication system
inde
il co
, bro
e sy
her
, sea
ug
r cyl
or o
reat
r
intak
ide)
in pl
nde
nd
nd
iping
seal
an o
ine e
er e
or b
lter
, gu
, cyli
om
r
oil d
oil p
oil p
oil fi
rear
blow
ring
stem
ther
turb
in fr
oler
ring
from
from
from
rom
n
iston
brea
il co
al at
lve (
al at
ked
roke
ton
en o
n pis
t suc
en p
kage
kage
kage
n se
kage
n va
n se
ged
n, b
Brok
Clog
Brok
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Lea
Lea
Lea
Oil consumption suddenly increased
Questions
Engine oil becomes contaminated quickly

Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in damper chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
clogged with dirty oil
Troubleshooting
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be
dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Remedy
Clean
20-716 BZ210-1
(1)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated

quickly
• Entry of exhaust gas due to internal wear

• Clogging of lubrication passage
• Improper fuel
• Improper oil used
• Operation under excessive load
BZ210-1 20-717
(1)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes
• Leakage of fuel
n)
jectio
n)
er
pisto
el filt
g
sprin
ive in
mp (
g, fu
r
rnor
cess
cove
er
d pu
pipin
lung
y
gove
a
p (ex
timin
head
e
r
p
p
fuel
e
s
f
p
e
nt of
lder
pum
pum
ction
id
side
from
s
o
al in
stme
h
tion
ction
el in
l inje
age
le
oil se
nozz
injec
adju
of fu
je
e
leak
u
in
f
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Leak
Defe
Defe
Defe
Defe
Defe
Defe
Exte
Operated for long period
Questions
Degree of use of machine

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items

Timing lock on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive

Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy, or does not return
Troubleshooting
When check is made using delivery method, injection timing is

found to be incorrect
Remove head cover and inspect directly
Remove feed pump and inspect directly
When engine speed is measured, low idling and high idling speeds
are found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-718 BZ210-1
(1)
S-11 Oil is in cooling water, or water

spurts back, or water level goes
down
General causes why oil is in cooling water Causes
• Internal leakage in lubrication system

• Internal leakage in cooling system
sket
k
d ga
bloc
ring
r
a
oole
, O-
der
, he
g
cylin
pittin
core
oil c
head
ks in
oler
ulic
b y
r
linde
used
a
il co
crac
y d r
y
en o
en h
en c
s ca
rnal
Brok
Brok
Hole
Brok
Inte
Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back

Hydraulic oil is cloudy white
When hydraulic oil is drained, water is found

shooting
Trouble-
Pressure-tightness test of cylinder head shows there is leakage

Remove oil pan and inspect directly
Replace
Replace
Replace
Replace
Replace
Remedy
BZ210-1 20-719
(1)
S-12 Oil pressure monitor lights up

(Drop in oil pressure)
General causes why oil pressure monitor lights up
• Leakage, clogging, wear of lubricating system

• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
a Standards for engine oil selection
20-720 BZ210-1
(1)
S-13 Oil level rises (Water, fuel in oil)
a If there is oil in the cooling water, carry out trou- Causes

bleshooting for "Oil is in cooling water".
General causes why oil level rises
over
ad c
al
• Water in oil (milky white)
nt se
e he
mp
• Fuel in oil (diluted, and smells of diesel fuel)
et
ipme
ace
gask
nsid
n pu
• Entry of oil from other component
eve
surf
ring
equ
i
o
k
ead
g
r sle
bloc
t
pipin
c
, O-
seal
e
ary
d, h
n j
e
der
core
ting
i
hold
l i
om
rear
t
side
i
hea
osta
x
p au
cylin
y pit
el fr
oler
zzle
rt in
ged
erm
der
pum
de b
of fu
side
il co
a
n
ama
h
n
p
l i
t
y
s ma
ctive
ctive
ctive
ks in
ctive
en o
en c
kage
n, d
Defe
Defe
Defe
Hole
Brok
Defe
Crac
Brok
Wor
Lea
Questions

There is oil in radiator cooling water
Fuel must be added more frequently
Exhaust smoke is white
When engine is first started, drops of water come from
muffler
Leave radiator cap open. When engine is run at idling,
an abnormal number of bubbles appear, or water spurts back
Check items
Oil level goes down in damper chamber

Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Water temperature is low

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Inspect rear seal directly

When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
BZ210-1 20-721
(1)
S-14 Water temperature becomes too

high (Overheating)
General causes why water temperature becomes Causes
too high
• Lack of cooling air (deformation, damage of fan)

• Drop in heat dissipation efficiency
• Defective cooling circulation system
re
en)
ratu
• Rise in oil temperature in hydraulic pump system
ge
et
t op
gask
y
mpe
gau
a Carry out troubleshooting for H mode.
pulle
s no
ins
oil te
ture
ead
tor f
fan
ler
doe
e
pera
h
o
valv
radia
ump
worn
o
tat (
,
core
itting
ead
ater
oil c
r tem
p
ure
lic p
pum
mos
shed
er h
w
ing,
by p
ator
ken
ress
oling
wate
drau
ther
ylind
ater
slipp
, bro
radi
, cru
e
p
d
of co
in hy
en w
s ma
ctive
ctive
ctive
en c
ged
ged
ged
belt
Lack
Defe
Brok
Brok
Defe
Clog
Hole
Defe
Clog
Rise
Clog
Fan
Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Radiator water level monitor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
There is play when fan pulley is rotated

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Hydraulic oil temperature enters red range faster than
engine water temperature
Temperature difference between top and bottom radiator tanks

is excessive
Carry out troubleshooting for H mode.
Temperature difference between top and bottom radiator tanks

is slight
When water filler port is inspected, core is found to be clogged
Troubleshooting
When function test is carried out on thermostat, it does not

open even at cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
20-722 BZ210-1
(1)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an exter- Causes

nal noise.
ifold
e)
etc.)
man
engin
d)
General causes why abnormal noise is made
n)
tion)
ver,
eize
ositio
take
less
er le
c
er s
nd in
e
ce
t of p
• Abnormality due to defective parts
j
liner
ve in
k
aran
lung
c
e, ro
• Abnormal combustion
d ou
ger a
e
der (
renc
essi
nce
e cle
ck, p
e
(valv
• Air sucked in from intake system
boar
ozzl
char
cylin
fere
(exc
erfe
sh
valv
p (ra
ystem
ion n
iding
turbo
a
ing,
inter
lt int
ackl
mp
g
t of
pum
ton r
r (div
t
n pu
lve s
een
c
ushi
ain b
n be
ger,
n
e
e
of pis
d inj
tion
betw
uffle
justm
ic va
o
ed b
char
n, fa
ar tr
t i
injec
eize
njec
ide m
wear
ynam
of air
seiz
urbo
d
d fa
r ge
a
s
i
ctive
ctive
ctive
ct ins
,
ssive
rme
rope
ged
en d
ed t
ing,
age
Defe
Defe
Defo
Defe
Leak
Clog
Miss
Defe
Seiz
Exce
Brok
Imp
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
BZ210-1 20-723
(1)
S-16 Vibration is excessive
a If there is abnormal noise together with the vibra- Causes

tion, carry out troubleshooting also for "Abnormal
k)
. stuc
noise is made".
tion)
d
gne
r, etc
on
injec
isali
General causes why vibration is excessive
ushi
r leve
fuel
pm
en c
ocke
sive
pum
• Defective parts (abnormal wear, breakage)
ring
brok
lve, r
xces
• Improper alignment
bea
ulic
m (va
olts,
ash
• Abnormal combustion
ydra
p (e
main
r
mpe
ing b
ackl
syste
pum
h
rod,
e da
ain b
and
t
alve
oun
g
tion
ushin
cting
nsid
mic v
gine
ar tr
em
injec
art i
dyna
f en
ngin
nne
r ge
mb
ctive
en p
ter o
n co
n ca
rope
se e
ctive
Defe
Brok
Wor
Wor
Cen
Defe
Loo
Imp
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
Vibration occurs at mid-range speed
Check items
Vibration follows engine speed

Exhaust smoke is black

Remove side cover and inspect directly
Inspect directly for loose engine mounting bolts, broken cushion
Troubleshooting
Inspect inside damper directly

When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-724 BZ210-1
(1)
30 DISASSEMBLY AND
ASSEMBLY
METHOD OF USING MANUAL ....................................................................................................................30- 2

PRECAUTIONS WHEN CARRYING OUT OPERATION..............................................................................30- 4
SPECIAL TOOL LIST....................................................................................................................................30- 6
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY ...............................30- 7
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY.......................................................30- 12
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY ..............................................30- 13
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL......................................................................30- 16
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL ........................................................................30- 19
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY..........................................................30- 21
REMOVAL AND INSTALLATION OF ENGINE AFTERCOOLER .................................................................30- 26
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY ...........................................30- 27
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY.....................................................................30- 28
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY ...................................................................30- 30
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY........................................................30- 31
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY.......................................................30- 33
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY .........................................................30- 35
DISASSEMBLY OF WORK EQUIPMENT ASSEMBLY ................................................................................30- 37
REMOVAL AND INSTALLATION OF SOLIDIFYING MATERIAL FEEDER CASE ASSEMBLY ...................30- 44
REMOVAL AND INSTALLATION OF RAKING ROTOR ...............................................................................30- 46
REMOVAL AND INSTALLATION OF SOIL HOPPER ASSEMBLY...............................................................30- 47
REMOVAL AND INSTALLATION OF SOIL BELT CONVEYOR ASSEMBLY ...............................................30- 48
REMOVAL AND INSTALLATION OF ROTARY HAMMER AND SOIL CUTTER ASSEMBLY ......................30- 49
REMOVAL AND INSTALLATION OF DISCHARGE BELT CONVEYOR ASSEMBLY ..................................30- 50
SPREADING AND INSTALLATION OF TRACK SHOE ASSEMBLY............................................................30- 51
REMOVAL AND INSTALLATION OF SPROCKET .......................................................................................30- 52
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY ...........................................................30- 53
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY ...........................................................30- 54
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY..........................................................30- 55
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY .......................................................30- 58
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER..........................................................................30- 59
BZ210-1 30-1
(1)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

REMOVAL AND INSTALLATION OF ASSEMBLIES
SPECIAL TOOLS a This mark gives guidance or precautions

• Special tools that are deemed necessary for when doing the procedure.
removal or installation of parts are listed.
[*1] This mark shows that there are instruc-
• List of the special tools contains the following
tions or precautions for installing parts.
kind of information.
1) Necessity 6 This mark shows oil or water to be
t: Special tools which cannot be substi-
4 This mark shows the weight of a part or a
drained.
tuted, should always be used.
q: Special tools which are very useful if device.
available, can be substituted with com-
mercially available tools.
2) Distinction of new and existing special tools
N: Tools with new part numbers, newly
developed for this model. INSTALLATION OF PARTS
R: Tools with upgraded part numbers, • Except where otherwise instructed, install parts
remodeled from already available tools is the reverse order of removal.
for other models. • Instructions and precautions for installing parts
Blank: Tools already available for other mod- are shown with [*1] mark in the INSTALLATION
els, used without any modification. Section, identifying which step the instructions
are intended for.
3) Circle mark (Q) in sketch column:
• Marks shown in the INSTALLATION Section
A circle mark means that a sketch of the
stand for the following.
special tool is presented in the section of
k
Sketches for Special Tools.
This mark indicates safety-related pre-
a Part No. of special tools starting with 79*T means
cautions which must be followed when
that they are locally made parts and as such not
doing the work.
interchangeable with those made by Komatsu in
a This mark gives guidance or precau-
Japan e.g. 79*T--- xxx --- xxxx.
2 This mark stands for a specific coating
tions when doing the procedure.
REMOVAL OF PARTS
3 This mark indicates the specified
agent to be used.
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
5
torque.
drained.
This mark indicates an amount of oil or
• Various symbols used in the REMOVAL Section
water to be added.
are explained and listed below.
k This mark indicates safety-related pre-

SKETCHES OF SPECIAL TOOLS
• Various special tools are illustrated for the con-
doing the work.
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS q: Special tools which are very useful if

• Special tools which are deemed necessary for available, can be substituted with com-
disassembly and assembly are listed in this sec- mercially available tools.
tion. 2) Distinction of new and existing special tools
• List of the special tools contains the following N: Tools with new part numbers, newly
kind of information. developed for this model.
1) Necessity R: Tools with upgraded part numbers,
t: Special tools which cannot be substi- remodeled from already available tools
tuted, should always be used. for other models.
Blank: Tools already available for other mod-
els, used without any modification.
30-2 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
3) Circle mark (Q) in sketch column: ASSEMBLY

A circle mark means that a sketch of the • Section titled ASSEMBLY contain procedures,
special tool is presented in the section of precautions and the know-how for the work, as
Sketches for Special Tools. well as the amount of oil or water to be added.
4) Part No. of special tools starting with 79*T • Various symbols used in the ASSEMBLY Sec-
means that they are locally made parts and tion are explained and listed below.
k
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T--- xxx This mark indicates safety-related pre-
--- xxxx. cautions which must be followed when
doing the work.
DISASSEMBLY a This mark gives guidance or precau-
2 This mark stands for a specific coating

• The DISASSEMBLY Section contains proce- tions when doing the procedure.
dures, precautions and the amount of oil or
3 This mark indicates the specified

water to be drained. agent to be used.
• Various symbols used in the DISASSEMBLY
5
Section are explained and listed below. torque.
This mark indicates an amount of oil or
k This mark indicates safety-related pre- water to be added.
doing the work.
SKETCHES OF SPECIAL TOOLS
a This mark gives guidance or precautions 1) Various special tools are illustrated for the
when doing the procedure. convenience of local manufacture.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be

drained.
BZ210-1 30-3
(1)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal number Plug (nut end) Nut (elbow end)

02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
BZ210-1 30-5
(1)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity: t..........Cannot be substituted, must always be installed (used)

q..........Extremely useful if available or can be substituted with commercially available part
a New/Remodel: N: .........Tools with new part numbers, newly developed for this model
R: .........Tools with upgraded part numbers, remodeled from items already available for other
models
Blank:...Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).
New/remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
Removal and installation

Stopping oil in hydraulic
of engine and hydraulic D 796-460-1210 Oil stopper t 1
tank
pump assembly
Removal and installation
of fuel injection pump A 795-799-1390 Puller t 1 Removal of drive gear
assembly
Removal and installation 1 795-799-2610 Installer t 1 Press fitting of oil seal
B
of engine front seal 2 795-799-2620 Installer t 1 Press fitting of dust seal
Removal and installation 1 795-799-1170 Installer t 1 Removal of injector
C
of cylinder head assembly 2 790-331-1110 Wrench t Tightening of head bolt
791-616-1040 Remover and installer t 1
Spreading and installa-
Cylinder Removal and installation of
tion of track shoe assem- E 790-105-1100 t 1
(294 kN {30 ton}) master pin
bly
790-101-1102 Hydraulic pump t 1
Disassembly and assem- 1 791-675-1510 Installer t 1 Installation of floating seals
F
bly of track roller 2 791-601-1000 Oil pump q 1 Supply of oil
Removal and installation of
1 797-101-1121 Wrench t 1
nut
Disassembly and assem- Press fitting of bearing

2 796-460-1110 Push tool t 1
bly of carrier roller assem- L inner race
bly 3 796-430-1110 Push tool t 1 Press fitting of collar
4 790-434-1650 Installer t 1 Installation of floating seals
5 791-601-1000 Oil pump q 1 Supply of oil
30-6 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC

PUMP ASSEMBLY
SPECIAL TOOL 2. Drain the coolant.
New/remodel
Coolant: Approx. 22.8 l
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
3. Sling engine hood (1) temporarily.
D 796-460-1210 Oil stopper t 1
REMOVAL
k Disconnect the cable from the negative (–) ter-
k Lower the work equipment to the ground safely

minal of the battery.
and stop the engine. Then, loosen the hydraulic

oil filler cap slowly to release the internal pres-
sure of the hydraulic tank.
a Put tags to the disconnected pipes to prevent a
mistake in re-connecting them.
4. Remove pin (2) and mounting bolt (3), lift off the
1. Remove the hydraulic tank strainer and stop the engine hood.
oil with tool D.
a When not using tool D, remove the drain plug
and drain the oil from the hydraulic tank and
piping.
6 Hydraulic tank: Approx. 147 l
5. Lift off step (4) and rear cover (5).
4 Rear cover: 126 kg
BZ210-1 30-7
(1)
6. Remove fan guards (6) and (7). 10. Disconnect fuel return hose (16).
7. Disconnect air intake hose (13). [*1]
11. Disconnect the following 5 engine wiring con-

nectors.
8. Loosen the 4 bolts of suction tube (9) of hydrau- • (17): E02 (Engine oil temperature switch)
lic pump (8) and remove the tube. • (18): E05 (Engine coolant temperature
sensor)
• (19): E04 (Engine speed sensor)
• (20): E10 (Governor potentiometer)
E11 (Governor motor)
9. Disconnect fuel inlet hose (14) and outlet hose

(15). [*2]
12. Remove bell mouth shroud (21).
13. Disconnect 2 radiator hoses (22) at upper and

lower parts. [*3]
30-8 BZ210-1
(1)
14. Disconnect starting motor wire (23) and connec- 17. Remove covers (30) and (31).
tors (24), (25), and (26).
• (23): Starting motor B terminal (Red) 18. Disconnect the following 8 hoses. [*4]
• (24): E08 (Intermediate connector) • (32): Front pump discharge port hose
• (25): T13 (Starting motor C terminal) • (33): Rear pump discharge port hose
• (26): E03 (Engine oil level sensor) • (34): Pump pressure inlet port hose
• (35): Drain port hose
• (36): EPC basic pressure port hose
(Color band: Yellow)
• (37): Load pressure inlet port hose
(Color band: Red)
• (38): Load pressure inlet port hose
• (39): Suction port hose
15. Disconnect engine chassis ground (27).
19. Disconnect clamp (40).
16. Disconnect cover (28) plate (29).
20. Disconnect the following 3 pump wire connec-

tors.
• (41): A61 (Hydraulic oil temperature sensor)
Color band: White
• (42): V21 (PC-EPC solenoid valve)
Color band: White
• (43): V22 (LS-EPC solenoid valve)
Color band: Red
BZ210-1 30-9
(1)
21. Remove muffler drain tube (44). INSTALLATION

• Install in reverse order of removal.
3 Air intake hose clamp screw:

[*1]
5.4 – 6.4 Nm {0.55 – 0.65 kgm}
3 Fuel inlet hose clamp screw:

[*2]
29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}
3 Radiator hose clamp screw:

[*3]
8.3 – 9.3 Nm {0.85 – 0.95 kgm}

22. Disconnect engine oil filter outlet hose (45) and
engine oil filter inlet hose (46). [*4]
a After tightening the suction hose clamp
23. Remove cover (47). screw, check that the screw is in the position
3 Suction hose clamp screw:

as illustrated below.
8.8 ± 0.5 Nm {90 ± 5 kgm}
24. Disconnect water separator wire clamp (48).
25. Remove the 4 engine mounting bolts (49) at

front and rear parts. [*5] a Install the hose clamp and tighten the clamp
screw as shown in the diagram below.
26. Lift off the engine and hydraulic pump assembly.

a Before lifting off the assembly, check that all
the wires and pipes are disconnected.
4 Engine and hydraulic pump assembly:

770 kg
30-10 BZ210-1
(1)
[*5]
a The engine mounting rubber pads differ in
shape at the front and rear. Place them as il-
lustrated below, and install the engine and
3 Engine mounting bolt:

hydraulic pump assembly.
245 – 308.7 Nm {25 – 31.5 kgm}
• Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant: Approx. 22.8 l
• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic tank: Approx. 147 l

a Tighten the drain plug securely to the speci-
fied torque.
• Bleeding air
See TESTING AND ADJUSTING, Bleeding air
from each part.
BZ210-1 30-11
(1)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY
REMOVAL INSTALLATION

• Carry out installation in the reverse order to re-
moval.
3 Starting motor B terminal mounting nut:

[*1]
1. Open the engine hood.
17.7 – 24.5 Nm {1.8 – 2.5 kgm}
2. Disconnect the 2 starting motor wires. [*1]
• (1), (2): B terminal
2 Both sides of starting motor gasket:
[*2]
• (3): Disconnect from C terminal T13
3 Starting motor mounting bolt:

Gasket sealant (LG-1)
3. Remove 2 mounting bolts (4) and starting motor
assembly (5). [*2] 43 ± 6 Nm {4.38 ± 0.61 kgm}
30-12 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP

ASSEMBLY
SPECIAL TOOL 5. Disconnect fuel inlet hose (5) and fuel outlet
hose (6). [*2]
New/remodel
a Put a wooden plug, etc. in the hose to pre-
Necessity
Symbol
Sketch
vent the fuel from flowing out.
Q'ty
Part No. Part Name
A 795-799-1390 Puller t 1
REMOVAL

2. Lift off rear cover (1).
4 Rear cover: 126 kg 6. Remove tubes (7) and (8) between the fuel filter
and fuel injection pump, and then remove fuel
filter bracket (9). [*3]
3. Remove fan guard (3).
4. Disconnect air intake hose (4). [*1] 7. Remove lubrication tube (10).
8. Remove 6 delivery tubes (11). [*4]
9. Disconnect governor motor connector E11, and

then disconnect governor spring (12) from the
pump. [*5]
BZ210-1 30-13
(1)
10. Using timing pin (13) on the timing gear side, 13. Using tool A, disconnect the shaft and drive
match the timing gear to the injection timing. gear of the fuel injection pump.
a See TESTING AND ADJUSTING, Testing
and adjusting fuel injection timing.
14. Remove 2 fuel injection pump lower bracket

mounting bolts (17).
11. Turn and remove cap (14).
a Use a filter wrench, etc. to remove the cap.
15. Remove sound absorbing material (18).
12. Remove nut (15) and washer (16) of the fuel 16. Remove 4 nuts (19) and fuel injection pump
injection pump. [*6] assembly (20). [*7]
a Take care not to drop the nut and washer
into the case.
30-14 BZ210-1
(1)
INSTALLATION 3) Install fuel injection pump assembly (20)
3 Fuel injection pump mounting

• Carry out installation in the reverse order to re- and tighten 4 nuts (19).
moval.
nut:
3 Air intake hose clamp:

[*1] 9.8 ± 2 Nm {1.0 ± 0.2 kgm}
5.4 – 6.4 Nm {0.55 – 0.65 kgm}
3 Hose clamp:
[*2]
2.84 – 3.82 Nm {0.29 – 0.39 kgm}
3 Joint bolt:
[*3]
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Sleeve nut:
[*4]
24 ± 4 Nm {2.45 ± 0.41 kgm} 4) Install washer (16) and tighten nut (15)
temporarily.
[*5] a Take care not to drop the nut and
a Adjust the governor lever stroke. For details,
k Tighten the nut to the following
washer into the case.
see TESTING AND ADJUSTING, Special
function of monitor panel. torque temporarily so that it will not
3 Temporary tightening torque of

damage the timing pin.
3 Nut: 95 ± 10 Nm {9.7 ± 1.0 kgm}

[*6]
nut:
12.5 ± 2.5 Nm {1.27 ± 0.25 kgm}
[*7]
• Install the fuel injection pump assembly ac-
cording to the following procedure.
1) Check that the timing pin is matched to
the injection timing.
a See step 10 of the removal proce-
dure.
2) Remove plug (21) and turn over timing
pin (22) of the fuel injection pump, and
then install them to the fuel injection
pump again.
a Check that the cut of the pin is
meshed with projection "a" in the
pump.
5) Remove the timing pin on the timing
a See TESTING AND ADJUSTING,
gear side from meshing point "a" and
Testing and adjusting fuel injection
return it to the original position.
timing.
6) Tighten fuel injection pump nut (15) per-
3 Nut:
manently.
95 ± 10 Nm {9.7 ± 1.01 kgm}
• Bleeding air
Bleed air from the fuel system.
BZ210-1 30-15
(1)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

SPECIAL TOOL 6. Remove front oil seal (7) from front cover (6).
[*3]
New/remodel
a If the dust seal is installed, remove it, too.
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 795-799-2610 Installer t 1
B
2 795-799-2620 Installer t 1
REMOVAL
1. Remove the radiator assembly. For details, see
REMOVAL AND INSTALLATION OF RADIA-
TOR ASSEMBLY.
2. Using lever [1], remove fan belt (1).
k Take care not to catch your fingers between

the tensioner and fan pulley.
3. Remove fan pulley (2).
4. Remove 4 mounting bolts (3) and crank pulley

(4). [*1]
a Match the stamp line of 1.6TOP of the crank
pulley to the pointer or make match marks on
the crank pulley and front cover so that you
can install the crank pulley to the correct po-
sition.
5. Remove 20 mounting bolts (5) and front cover

(6). [*2]
30-16 BZ210-1
(1)
INSTALLATION 2. Front cover

• Carry out installation in the reverse order to re- 1) Apply ThreeBond 1207D or equivalent in the
moval. (Excluding the dust seal) form of a string 1 – 2 mm thick to the gasket
fitting face of the front cover.
[*1] 2) Install the gasket to the front cover, and then
a When installing the crank pulley, check the index install them to the engine.
lines A of damper hub B and inertia part C. If 3) Tighten the 20 mounting bolts in the follow-
3 Front cover mounting bolt:

the index lines are shifted from each other more ing order.
than 1.6 mm, replace the crank pulley. If any
piece is chipped from rubber part D, replace the 24 ± 4 Nm {2.45 ± 0.4 kgm}
crank pulley. 4) Remove plastic part [2] (front oil seal guide)
on the inside of the front cover.
a When installing the crank pulley, match the

stamp line matched or the match marks made 3. Dust seal
3 Crank pulley mounting bolt:

when the crank pulley was removed. a Even if a dust seal has not been installed, in-
stall the dust seal contained in the front seal
125 ± 5 Nm {12.75 ± 0.51 kgm} kit.
1) Using tool B2, press fit dust seal (8) to
[*2] [*3] the end of the crankshaft.
1. Front oil seal a Press fit the dust seal until the inside
1) Set front oil seal (7) to tool B1. end of tool B2 touches the end of the
a Since plastic part [2] on the inside of the crankshaft.
front oil seal is used to guide the front
cover to the crankshaft, do not remove it
from the front oil seal.
2) Press fit front oil seal (7) to front cover (6).
a Press fit the front oil seal until the shoul-
der of tool B1 touches the inside end of
the front cover.
BZ210-1 30-17
(1)
30-18 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL

REMOVAL a Drill a hole of approx. 3 mm in diameter on
1. Remove the hydraulic pump assembly, refer to the seal carrier with a drilling machine.
the Hydraulic Pump Assembly Removal section
in this manual.
2. Remove damper assembly (1).
3. Remove the mounting bolts from flywheel

assembly (2) and set guide bolts [1]. Then lift it
off to remove it. [*1]
a Attach a dent puller to a slide hammer and

insert the hammer into the drilled hole. Then
pull out seal (3) by sliding the hammer.
4. Remove seal (3). [*2]

a A suggested method for removing the seal is
to drill a hole approx. 3 mm in diameter on
the seal carrier, then insert a slide hammer
with a dent puller attached into the hole and
pull the seal out.
a The seal may be removed by destroying the
seal carrier with a hammer. When using this
method, take care so the flywheel seal and
crankshaft wear ring are not damaged.
BZ210-1 30-19
(1)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
INSTALLATION 2) Push the oil seal into the flywheel by insert-

• Install in reverse order of removal. ing pilot (2) with oil seal (4) into the crank-
shaft.
3 Flywheel mounting bolt:

[*1] 3) Pull out pilot [2]. Push the oil seal into the
front cover from the inside to the outside.
137 ± 7 Nm {13.97 ± 0.71 kgm} 4) Install the oil seal on the flywheel housing to
a Tighten the mounting bolts in the sequence the proper depth. Use an alignment tool.
illustrated below. a Tap the head, bottom, right and left sides
of the alignment tool to make sure that
the seal carrier is not twisted, when it is
being pushed in.
[*2]
a Install the oil seal in the following manner.
1) Attach pilot [2] to new oil seal (4).
a Before installing the oil seal, clean the
crankshaft sealing face and the seal lip
face. Remove all oil and dry thoroughly
to prevent oil leakage.
30-20 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

SPECIAL TOOLS 10. Remove heat cover (8) from the turbocharger
assembly.
New/remodel
Necessity
Symbol
Sketch
11. Remove exhaust muffler connector cover (9).
Q'ty
Part No. Part Name
1 795-799-1170 Installer t 1
C
2 790-331-1110 Wrench t 1
REMOVAL
k Disconnect the cable from the negative terminal

(–) of battery.
1. Drain engine coolant.
6 Coolant: 22.8 l
12. Disconnect air cleaner suction hose (10). [*6]
2. Close the fuel stop valve.
13. Disconnect air intake hose (11) between the tur-
3. Open up the engine hood. bocharger and the after-cooler. [*7]
4. Remove clamp (1) from the engine oil level 14. Remove V clamp (12) from the exhaust muffler.
gauge guide. [*1]
a Put the clamp aside near the counterweight 15. Disconnect lubricant inlet tube (13) and lubricant
after removing it. outlet tube (14).
5. Disconnect air intake hose (2). [*2] 16. Remove turbocharger assembly (15).
6. Disconnect tubes (3) and (4) between the fuel 17. Detach exhaust manifold (16). [*8]
filter and the fuel injection pump. [*3]
7. Remove bracket (5) in one piece with the fuel fil-

ter assembly. [*4]
8. Remove electrical intake air heater harness CN-

E01 (6).
9. Disconnect six delivery tubes (7). [*5]
18. Detach radiator fan guards (21) and (22).
BZ210-1 30-21
(1)
19. Loosen air compressor belt (23), using wrench 25. Disconnect connector E05 (32) from the engine
[1] and remove it. cooling water temperature sensor, and remove
k Be careful not to get a finger caught in the

the wiring clamp.
belt, when removing it.
20. Remove tension pulley (24).
21. Remove the 4 mounting bolts to detach the fan

and fan pulley (25). [*9]
a Put the fan pulley aside near the radiator.
22. Disconnect radiator inlet hose (26) and heater

hose (27). [*10]
26. Remove the clamps (2 places) and disconnect

the spill tube (33). [*11]
27. Remove 6 nozzle holders (34). [*12]

a If it is difficult to remove the nozzle holder as-
semblies, use tool C1.
a Be careful not to allow dust or foreign matter
to stick where the nozzle holder assembly is
installed.
23. Disconnect connector E12 (29) at terminal B

(28) from the alternator.
24. Remove 3 alternator bracket mounting bolts (30)

and the 2 alternator plate mounting bolts, and
remove alternator assembly (31) in one piece
with the bracket.
28. Disconnect electrical intake air heater wiring

(35) and remove air intake connector (36).
30-22 BZ210-1
(1)
29. Remove head cover (37). [*13] 33. Remove cylinder head gasket (41). [*17]
30. Detach rocker arm assembly (38). [*14]

a Loosen the lock nut, and unscrew the adjust-
ing screw 2 to 3 turns. INSTALLATION
• Install in reverse order of removal.
[*1]
a Coat the threads of the clamp bolt (used for
securing the engine oil level gauge guide)
with gasket sealant.
3 Air intake hose clamp bolt:

[*2]
5.4 – 6.4 Nm {0.55 – 0.65 kgm}
3 Joint bolt:
[*3]
19.6 – 29.4 Nm {2.0 – 3.0 kgm}

31. Remove push rod (39). [*15]
[*4]
a Coat the threads of only one bolt on the head
cover side of the fuel filter bracket with gas-
ket sealant.
3 Sleeve nut:
[*5]
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Air cleaner suction hose clamp bolt:

[*6]
5.4 – 6.4 Nm {0.55 – 0.65 kgm}
3 Intake air hose clamp bolt:

[*7]
32. Remove 26 mounting bolts from cylinder head
5.4 – 6.4 Nm {0.55 – 0.65 kgm}
assembly (40) and lift it off for disassembly. [*16]
4 Cylinder head assembly: 52 kg
BZ210-1 30-23
(1)
[*8] [*14] [*15] [*16] [*17]

a Tighten the exhaust manifold mounting bolts • Mount the rocker arm assembly and the cylinder
3 Exhaust manifold mounting bolt:

in the sequence illustrated below. head assembly in the following manner.
a Check that there is no dust or foreign matter
1st step: Tighten to 24 ± 4 Nm {2.45 ± 0.41 kgm} in stuck to the cylinder head installing face or
the sequence of (1) through (12). inside the cylinders.
2nd step: Tighten to 43 ± 6 Nm {4.38 ± 0.61 kgm} in 1) Place cylinder head gasket (41) on the cylin-
the sequence of (1) through (12). der block.
3rd step: Tighten to 43 ± 6 Nm {4.38 ± 0.61 kgm} in a Check that the gasket is properly
the sequence of (1) through (4). matched with the cylinder block holes.
2) Lift cylinder head assembly (40) and place it
on the cylinder block.
3 Radiator fan and fan pulley

[*9]
mounting bolt: 3) Assemble push rod (39).

33 ± 5 Nm {3.37 ± 0.51 kg} a Coat the push rod surface with engine oil
(SAE 15W-40).
3 Radiator inlet hose clamp bolt:

[*10]
3 Heater hose clamp bolt:

8.3 – 9.3 Nm {0.85 – 0.95 kgm}
8.83 – 14.7 Nm {0.9 – 1.5 kgm}
3 Spill tube bolt:

[*11]
30 ± 5 Nm {3.06 ± 0.51 kgm}
3 Nozzle holder assembly:

[*12]
60 ± 9 Nm {6.12 ± 0.92 kgm}
3 Head cover mounting bolt:

[*13]
24 ± 4 Nm {2.45 ± 0.41 kgm}
30-24 BZ210-1
(1)
4) Install rocker arm assembly (38) and tighten 3rd step:

the bolts by hand. i) If Tool C2 is used:
a Check that the adjusting screw ball is Using an angle tightening wrench (Tool
well seated in the push rod socket. C2), tighten the bolts by turning them
a Coat the threads and seat surface of 90° ± 5° in the sequence of (1) through
mounting bolts (8 mm and 12 mm) with (26).
engine oil (SAE 15W-40).
ii) If Tool C2 is not used:

5) Tighten the cylinder head mounting bolts in Put counter mark on the bolts and cylin-
the sequence as illustrated below. der head with a felt-tip pen, and then
a Coat the threads and seat surface of the tighten the bolts by turning them to 90° ±
3 Cylinder head mounting bolt:

mounting bolts with engine oil (15W-40). 5°.
1st step: Tighten to 90 ± 5 Nm

{9.18 ± 0.51 kgm} in the sequence
of (1) through (26).
2nd step: Tighten to 120 ± 5 Nm
{12.24 ± 0.51 kgm} in the sequence
of (3), (6), (11), (14), (19) and (22).
6) Tighten the rocker arm assembly mounting
3 Rocker arm assembly mounting

bolts (8 mm).
bolt: 24 ± 3 Nm {2.45 ± 0.31 kgm}
BZ210-1 30-25
(1)
DISASSEMBLY AND ASSEMBLY ENGINE AFTERCOOLER
7) Adjust the valve clearance. REMOVAL AND

a Refer to the Adjusting of Valve Clear-
ance section in the TESTING AND AD- INSTALLATION OF ENGINE
JUSTING chapter of this manual. AFTERCOOLER
• Refilling coolant REMOVAL
Refill engine coolant up to the specified level. 1. Open engine hood (1) and cooler front cover (2).
Let the coolant circulate to release any air pock- Remove cover (3).
ets by starting the engine. Check the coolant
level again.
2. Loosen the clamps of right and left hoses (5)

and (6) of aftercooler (4) and disconnect those
hoses.
3. Remove the 4 cooler mounting bolts and after-

cooler assembly.
INSTALLATION
moval.
30-26 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER

ASSEMBLY
REMOVAL 5. Disconnect control valve drain hose (4) and tank
1. Open the engine hood. return hose (5).
a Put an oil stopper to each disconnected port.
2. Remove cover (1).
3. Remove plug (2) of the hydraulic oil cooler drain

hose to drain the hydraulic oil.
a Open the hydraulic tank cap to release the
internal pressure of the tank, and then drain
the oil through the cooler hose.
a If you have loosened the plug at the top of
the hydraulic oil cooler, you can drain the oil
from the piping easily.
6 Hydraulic oil cooler: Approx. 5.0 l
6. Remove the mounting clamp and move reser-

voir tank hose (6) to a proper side.
a Move the hose so that it will not interfere with
the hydraulic oil cooler assembly when the
later is slung.
7. Disconnect hydraulic oil cooler drain hose (8).
8. Remove the 4 mounting bolts and lift off hydrau-

lic oil cooler assembly (9).
a If you have removed the aftercooler mount-
ing bracket bolt, you can remove the hydrau-
lic oil cooler assembly easily.
BZ210-1 30-27
(1)
DISASSEMBLY AND ASSEMBLY RADIATOR
INSTALLATION REMOVAL AND

moval. INSTALLATION OF RADIA-
TOR ASSEMBLY
• Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified level. REMOVAL
Run the engine to circulate the oil through the 1. Drain the coolant.
6
Coolant: Approx. 22.8 l
4. Disconnect reservoir tank hose (4).

a Disconnect the hose from the radiator.
5. Disconnect 2 radiator hoses (5) at the top and

bottom. [*1]
6. Remove fan guards (6) and (7).
7. Remove bell mouth shroud (8). [*2]
30-28 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY RADIATOR
8. Using 2 slings [1], sling the radiator assembly INSTALLATION

temporarily. • Install in reverse order of removal.
3 Radiator hose clamp bolt:

[*1]
8.3 – 9.3 Nm {0.85 – 0.95 kgm}
[*2]
a To maintain the heat balance, make sure
that sponge sheets are assembled in the
original position.
a Adjust clearance a between the radiator cir-
cumference and the bell mouth shroud, us-
ing oblong hole b for mounting the bell mouth
shroud, so that the clearance may be even
9. Remove the 4 mounting bolts and lift off radiator all around the circumference.
assembly (10). a Check that clearance a shows the following
value, measured at 4 points on the right, left,
4 Radiator assembly: 45 kg top and bottom sides.
• Standard clearance a (on all the circum-
ference): More than 13 mm
• Fan diameter c: 620 mm
• Shroud inner diameter d: 650 mm
• Refilling engine coolant

Refill engine coolant through the coolant filler
port up to the specified level. Let the coolant cir-
culate to release any air pockets by starting the
engine. Check the coolant level again.
5 Engine coolant: Approx. 22.8 l
BZ210-1 30-29
(1)
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY

REMOVAL 6. Install the sling to hooks (5) at the top of the tank
a Drain the fuel from the tank. and lift off the tank assembly (6).
1. Remove front side (1) of the tank cover and 4 Fuel tank assembly: Approx. 143 kg
right-hand cover (2).
2. Disconnect the wiring harness connector of

working lamp (3).
3. Disconnect the fuel sensor wiring harness con-

nector.
INSTALLATION
moval.
3 Fuel tank mounting bolt:

[*1]
4. Loosen the clamps of fuel hoses (4) under the 245 – 309 Nm {25.0 – 31.5 kgm}
tank and remove the hoses.
• Refilling with fuel (Fuel tank)
Refill the tank with fuel.
5. Remove the 6 tank mounting bolts. [*1]

a Keep the shims for adjusting the level differ-
ence.
30-30 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY

REMOVAL 7. Loosen the 2 clamps of hydraulic pump suction
k Loosen the oil filler cap of the hydraulic tank

hose (4) on the tank side, remove suction tube
(5) from the pump, and pull out the hose from
gradually to release the internal pressure of the the tank. [*2]
tank. a Mask the hose, tube, pump, and tank.
a Open the hydraulic pump inspection cover and
apply the stopper.
1. Remove the mounting bolts of hydraulic tank

right-hand cover (1) from inside.
2. Remove the hydraulic tank front cover, fuel tank

mounting bolts, and cover (1).
8. Remove the 6 mounting bolts on the underside

of the hydraulic tank. [*3]
9. Install the sling to hooks (6) at the top of the tank

and lift off the hydraulic tank assembly (7).
4 Hydraulic tank assembly: 123 kg
3. Drain the oil through the drain plug on the

underside of the hydraulic tank. [*1]
4. Remove the return hose from the oil cooler.
5. Remove hose clamp (2).
6. Remove 5 hoses (3) for draining the belt con-

veyor, pump, etc.
a Put male or female plugs to the removed
hoses and nipples.
a Take a record of the positions of the discon-
nected hoses to prevent a mistake in re-con-
necting them.
6 Hydraulic tank: 147 l
BZ210-1 30-31
(1)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION • Refilling with oil (Hydraulic tank)

• Carry out installation in the reverse order to re- Add oil through the oil filler to the specified level.
moval. Run the engine to circulate the oil through the
3 Fuel tank drain plug: 5

[*1]
Hydraulic tank: 147 l
58.5 – 78.5 Nm {5.97 – 8.0 kgm}
• Bleeding air
[*2] See TESTING AND ADJUSTING, Bleeding air
a After tightening the suction hose clamp, from each part.
check that the screw is in the range of the fol-
3 Hose clamp:
lowing figure.
8.8 ± 0.5 Nm {90 ± 5 kgm}
a Tighten the hose clamp as shown in the fol-

lowing figure and do not place it on the clamp
corrugations.
3 Hydraulic tank mounting bolt:

[*3]
245.2 – 308.9 Nm {25 – 31.5 kgm}
30-32 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY

REMOVAL 5. Remove partition cover (5) of the engine.

gradually to release the internal pressure of the
tank.
a Drain the oil from the hydraulic tank.
a Disconnect the cable from the negative (–) ter-
1. Open pump right-hand cover (1) and apply the

stopper.
6. Disconnect 3 connectors (6) of the pump sole-

noid and oil temperature sensor.
a Mask the disconnected connectors.
2. Pull out the open stay stopper pin of the inside

hood of engine hood (2).
3. Remove the hood mounting bolts and lift off

hood (2).
7. Remove pump discharge hose (7) and other
4. Remove cover (3) and plate (4). hydraulic hoses.
a Take a record of the positions of the re-
moved hoses to prevent a mistake in rein-
stalling them.
hoses.
BZ210-1 30-33
(1)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
8. Remove the mounting bolt of suction tube (8), INSTALLATION

and then remove the tube. • Carry out installation in the reverse order to re-
moval.
2 Pump shaft spline: Lubricant (LM-G)

[*1]
2 Mating face of pump housing:

[*2]
Gasket sealant (LG-6)
• Refilling with oil
5 Damper case: 0.75 l

9. Install the sling to the eyebolt at the top of the
Add oil through the oil filler to the specified level.
pump and lift up the pump temporarily.
Run the engine to circulate the oil through the
10. Remove the 12 mounting bolts of pump housing
(9) and lift off the pump assembly. [*1] [*2] 5 Hydraulic tank: 147 l
4 Pump assembly: Approx. 170 kg
• Bleeding air
Bleed air from the hydraulic pump system. For
details, see TESTING AND ADJUSTING, Bleed-
ing air from each part.
30-34 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY

REMOVAL a Put caps, plugs, etc. to the removed pres-

sure switches and unions.
gradually to release the internal pressure of the

tank.
a Drain the oil from the hydraulic tank.
a Disconnect the cable from the negative (–) ter-
1. Remove covers (1) and (2) from the top of the

control valve.
2. Disconnect the wiring harness and all connec-

tors of 7-spool valve (3) and 8-spool valve (4)
from the control box.
a Mask the disconnected connectors. 5. Remove all the pilot hoses (9) and (10) of the 7-
spool valve and 8-spool valve.
moved pilot hoses to prevent a mistake in re-
installing them.
hoses and nipples.
6. Remove hydraulic hoses (11), (12), etc. of the

actuator lines of the 7-spool valve and 8-spool
valve in order from the top one.
moved hydraulic hoses to prevent a mistake
in reinstalling them.
3. Remove each pressure switch, 7-spool valve hoses and nipples.
(5), and 8-spool valve (6).
4. Remove brackets (7) and (8).

moved pressure switches to prevent a mis-
take in reinstalling them.
BZ210-1 30-35
(1)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
7. After removing all the wiring harnesses and INSTALLATION

hydraulic hoses, remove bolts (13) and (14) at • Carry out installation in the reverse order to re-
the top of the control valve. Then, install eye- moval.
bolts and sling the control valve temporarily.
8. Remove the mounting bolts of the control valve Add oil through the oil filler to the specified level.
assembly and lift off the control valve assembly. Run the engine to circulate the oil through the
30-36 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
DISASSEMBLY OF WORK EQUIPMENT ASSEMBLY

a Fix work equipment assembly (1) removed from 4. Remove 2 hydraulic hoses (4) of soil cutter
the chassis to a level place. motor (3).
hoses and nipples.
Removal of mixer assembly

1. Install the sling to the hook at the top of the
mixer case and install the chain block to the 5. Remove all the mounting bolts of right and left
front part, and then sling the mixer assembly partition plates (7) of mixer case (5) and hopper
temporarily by the 3 points. frame (6) from only the frame side.
2. Remove the mounting bolts of mounting bracket

(1) on the frame at the front of the mixer case.
3. Remove the mounting bolts of mixer case

mounts (2) and remove t he right and left
mounts.
6. Sling mixer assembly (8) to remove it from the

frame and fix it on a rigid stand.
Installation of mixer assembly

moval.
BZ210-1 30-37
(1)
Disassembly of mixer open/close case 6. Remove 2 soil prevention covers (7) at the right
1. Install the sling to hook (2) of mixer open/close and left parts.
case (1) and lift up the case temporarily.
7. Remove monitor mounting housing (8).
2. Loosen the nuts of right and left fixing bolts (3)
and (4) of the open/close case and open the
case.
3. Remove the lock plates of right and left open/

close case mounting pins (5) and remove the
pins.
8. Remove the mounting bolts of coupling (9), and

then remove the coupling.
9. Remove the bolt of holder (10) and flange (11).

[*1] [*2] [*3]
10. Remove grease supply hose (12).

4. Sling open/close case (1) and fix it to a level
place in a style where you can remove the motor
and rotary hammer easily.
5. Remove the mounting bolts of motor (6), and

then remove the motor. [*3]
11. Using forcing screws, remove case (13).
12. Using forcing screws, remove flange (14).
13. Using the sling, lift up rotary hammer assembly

(15) temporarily.
14. While controlling the crane finely, remove spacer

(16).
30-38 BZ210-1
(1)
21. Sling rotary hammer assembly (15) to remove it

from mixer open/close case (1).
15. Remove right and left soil prevention cover (17).
16. Using forcing screws, remove cover (18). Assembly of mixer open/close case
• Carry out assembly in the reverse order to disas-
17. Remove the mounting bolt of holder (19), and sembly.
then remove the holder. [*4] [*5]
2 Mounting bolt: Adhesive (LT-2A)

[*1]
3 Mounting bolt:
19. While controlling the crane finely, remove spacer [*2]
(21).
98 – 123 Nm {10 – 12.5 kgm}
2 Shaft spline: Lubricant (LM-G)

[*3]

[*4]
3 Mounting bolt:
[*5]
98 – 123 Nm {10 – 12.5 kgm}
20. Using forcing screws, remove right and left

cases (22).
BZ210-1 30-39
(1)
Disassembly of mixer case 3. Install the sling to hook (6) of the soil cutter arm
1. Sling soil cutter (1) with the chain block. While and lift up the soil cutter arm temporarily.
moving the cutter up and down, remove plates
(2) and (3) and right and left covers (4). 4. Remove right and left arm mounting pins (7).
5. Sling soil cutter assembly (1) and remove it from

the mixer case.
2. Remove right and left stoppers (5) of soil cutter

(1).
6. Remove monitor (8) of the rear rotary hammer
and monitor (9) of the front rotary hammer.
30-40 BZ210-1
(1)
7. Remove soil prevention covers (10) from the 13. Using forcing screws, remove case (16).
flanges.
14. Remove left-hand soil prevention covers (17).

8. Remove rear motor mounting flange (11).
15. Using forcing screws, remove cover (18).
9. Remove rear hammer coupling (12). [*1] [*2]

10. Remove grease supply hose (13).
11. Remove the mounting bolt of holder (14), and

12. Remove flange (15). [*5]
BZ210-1 30-41
(1)
17. Lift up rear rotary hammer assembly (20) tempo- 21. Sling rear rotary hammer assembly (20) and
rarily with the sling. remove it from the mixer case.
22. Remove front motor mounting flange (25).
19. While controlling the crane finely, remove right 23. Remove coupling (26). [*1] [*2]
and left spacers (22).
24. Remove the mounting bolt of holder (27), and

20. Using forcing screws, remove right case (23) then remove the holder. [*3] [*4]
and left case (24).
25. Remove flange (28). [*5]
30-42 BZ210-1
(1)
26. Using forcing screws, remove case (29). 30. Remove the mounting bolt of holder (33), and
27. Lift up front rotary hammer assembly (30) tem-

porarily with the sling.
28. Using forcing screws, remove flange (31). 32. While controlling the crane finely, remove right
spacer (35) and left spacer (36).
29. Using forcing screws, remove bearing cover

(32) at the left front. 33. Using forcing screws, remove right case (37)
and left case (38).
BZ210-1 30-43
(1)
DISASSEMBLY AND ASSEMBLY SOLIDIFYING MATERIAL FEEDER CASE
34. Sling front rotary hammer assembly (30) and REMOVAL AND
remove it from the mixer case.
INSTALLATION OF
SOLIDIFYING MATERIAL
FEEDER CASE ASSEMBLY
REMOVAL
1. Remove 5 bolts (3) from feeder case (2) of solid-
ifying material hopper (1).
Assembly of mixer case

• Carry out assembly in the reverse order to disas-
sembly.
2 Coupling mounting bolt: Adhesive (LT-2)

[*1]
Do not stick adhesive to the rubber part 2. Remove coupler (5) of sensor harness (4), and
of the coupling, however. When assem- replace it with coupler (6).
bling, apply grease to the contact sur-
faces of the bolt and aluminum insert.
At this time, do not stick grease to the
threads.
3 Coupling mounting bolt:

[*2]
84 – 93 Nm {8.5 – 9.5 kgm}

[*3]
3 Mounting bolt:
[*4]
98 – 123 Nm {10 – 12.5 kgm} 3. Securely hold the hook of hopper (1) with the lift-
ing tool, and remove hopper (1).
4
2 Shaft spline: Lubricant (LM-G)
[*5]
Hopper: 540 kg
30-44 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY SOLIDIFYING MATERIAL FEEDER CASE
4. Remove clamps (7) of the feeder harness, and 7. Temporarily hoist feeder case assembly (2), and
disconnect connector (8). remove 12 bolts from the hopper frame of 4 legs
a Cover and mask the connector when un- (12).
plugged.
8. Lift and remove feeder case assembly (2).

5. Remove cover (9), open the bottom cover, and a Take care not to forget to remove all harness
remove 3 grease hoses (10) coming from the and hoses.
motor pinion gear, circle, and grease bath.
6. Remove each hoses from 3 hydraulic motors

(11). [*1]
a When removing the hoses and nipples, fill
male or female plugs into them.
a When removing the hoses, write down their
original locations on a paper for reference.
INSTALLATION
• Install all parts and components in the reverse
procedure above.
[*1]
Take extremely care not to twist the hoses when
connecting them.
BZ210-1 30-45
(1)
DISASSEMBLY AND ASSEMBLY RAKING ROTOR
REMOVAL AND INSTALLATION OF RAKING ROTOR

REMOVAL 5. Install the sling to the rotor bracket and lift up the
1. Remove exterior left cover (1) and right cover bracket temporarily.
(2).
6. Remove the 12 mounting bolts of bracket (8) on
the rotor bearing side.
7. Remove the 12 mounting bolts of bracket (9) on

the rotor motor side.
2. Remove grease hose (3) connected to the rotor

shaft bearing.
3. Remove hydraulic hoses (5) of rotor motor (4).

[*1]
a Put male or female plugs to the removed 8. Lift off raking rotor assembly (10).
hoses and nipples.
stalling them.
INSTALLATION
moval.
4. Remove rotor cover (6) and right and left plates
(7). [*1]
Install each hose without twisting it.
30-46 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY SOIL HOPPER
REMOVAL AND INSTALLATION OF SOIL HOPPER ASSEMBLY

REMOVAL 5. Install the sling to the hopper assembly and lift
1. Remove grease hose (1) connected to the rak- up the hopper assembly temporarily.
ing rotor bearing. [*1]
6. Remove the 16 mounting bolts of brackets (9)
2. Remove hydraulic hoses (3) connected to the on hopper frame (8) between the right and left of
raking rotor motor (2). hopper (7).
hoses and nipples.
stalling them.
7. Lift off hopper assembly (10).
4 Hopper assembly: Approx. 1110 kg
3. Remove right mounting bracket (4) and left

mounting bracket (5) of the hopper frame.
INSTALLATION
moval.
4. Remove right and left mounting plates (6) at the
bottom of the hopper. [*1]
BZ210-1 30-47
(1)
DISASSEMBLY AND ASSEMBLY SOIL BELT CONVEYOR
REMOVAL AND INSTALLATION OF SOIL BELT CONVEYOR

ASSEMBLY
REMOVAL 4. Install the slings to the 4 mounts of the belt con-
a Remove the soil hopper assembly. veyor assembly and lift up the belt conveyor
(See Removal of soil hopper assembly.) assembly temporarily.
1. Remove hoses (2) of belt conveyor motor (1) in 5. Remove the 16 mounting bolts of 4 right and left
order. [*1] belt conveyor mounts (5) on the hopper frame.
hoses and nipples.
stalling them.
6. Lift up soil belt conveyor assembly (6). While

changing the slinging point and moving over the
frame, remove soil belt conveyor (6) to the front
of the frame.
2. Remove wiring harness clamp (4), etc. of prox- 4 Belt conveyor assembly:
imity switch (3) at the rear of the frame. Approx. 1360 kg
3. Remove proximity switch case assembly (3) and

keep it so that it will not be an obstacle.
a If this switch is removed, it needs to be ad-
justed. See TESTING AND ADJUSTING for
the adjustment method.
INSTALLATION
moval.
[*1]
30-48 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY ROTARY HAMMER AND SOIL CUTTER
REMOVAL AND INSTALLATION OF ROTARY HAMMER AND SOIL

CUTTER ASSEMBLY
REMOVAL 5. Remove motor cover (8) of soil cutter assembly
1. Remove the right and left fixing bolts (2) of mixer (7), and then remove the hydraulic hoses.
open/close case (1).
6. Remove soil cutter assembly (7). (For the
2. Lift up and fold floor (3). removal procedure, see Disassembly of mixer
case.)
3. Start the engine and operate the control lever of a Put male or female plugs to the removed
the open/close case cylinder by the travel lever hoses and nipples.
to retract cylinder rod (4) and open mixer case
(1).
a Operate the control lever slowly. Never oper-
ate it quickly.
7. Remove motor covers (11) of rotary hammers

(9) and (10), and then remove the hydraulic
hoses.
k After opening mixer case (1), be sure to install 8. Remove rotary hammers (9) and (10). (For the
the case closing prevention safety chain (acces- removal procedure, see Disassembly of mixer
sory) to the hook (5) installed to the lower frame. case.)
4. Remove rotary hammer assembly (6). (For the hoses and nipples.
removal procedure, see Disassembly of mixer
open/close case.)
INSTALLATION
moval.
BZ210-1 30-49
(1)
DISASSEMBLY AND ASSEMBLY DISCHARGE BELT CONVEYOR
REMOVAL AND INSTALLATION OF DISCHARGE BELT CONVEYOR

ASSEMBLY
REMOVAL 6. Remove right and left pins (7) of the mounting
1. Remove right and left wiring harness connectors bracket at the center of the belt conveyor.
(1) of the belt conveyor stop switch.
a Mask the disconnected connectors. 7. Place a rigid and stable stand under the belt
conveyor and lower the belt conveyor assembly.
2. Remove 3 belt conveyor motor hoses (2).

8. While controlling the crane finely, remove right
3. Remove aftercutter hose (3). and left mounting pins (8) of the bracket at the
a Put male or female plugs to the removed end of the belt conveyor.
hoses and nipples.
9. While controlling the crane to move the chassis

4. Install the sling to hook (4) on the side of the belt forward so that the belt conveyor will not inter-
conveyor motor and lift up the belt conveyor fere with the chassis, remove belt conveyor
assembly temporarily. assembly (9).
5. Remove mounting pins (6) of right and left belt

conveyor mounting arms (5).
INSTALLATION
moval.
30-50 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
SPREADING AND INSTALLATION OF TRACK SHOE ASSEMBLY

SPECIAL TOOLS INSTALLATION
New/remodel
[*1]
Necessity
Symbol
Sketch
a Adjust the track shoe tension. For details,
Q'ty
Part No. Part Name
see TESTING AND ADJUSTING, Testing
adjusting track shoe tension.
791-616-1040 Remover and installer t 1
[*2]
Cylinder
E 790-105-1100 t 1 a Using tool E, press fit the master pin so that
(94 kN{30 ton})
the projection of the master pin will be "a".
790-101-1102 Pump t 1
Projection "a" of master pin: 5.5 ± 2 mm
SPREADING
1. Loosen lubricator (1) to slacken the track shoe.
k Since the internal pressure of the adjust-

[*1]
ment cylinder is very high, do not loosen the

lubricator more than 1 turn. If the grease
does not come out sufficiently, move the
machine forward and in reverse.
[*3]
a When installing the dust seal, apply grease
(G2-LI) to the bushing contact surface.
2. Move the machine forward so that the master

pin will be in front of the idler and set block [1].
3. Using tool E, pull out the master pin. [*2]
4. Remove tool E, pull out the temporary pin, and

re mo ve th e dust sea l . W hi l e m ov i ng t he
machine in reverse, spread track shoe (2). [*3]
BZ210-1 30-51
(1)
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL AND INSTALLATION OF SPROCKET

1. Remove the track shoe assembly. For details, • Carry out installation in the reverse order to re-
see Removal of track shoe assembly. moval.
2 Threads of sprocket mounting bolt:

2. Jack up the track frame and set block [1] [*1]
between the track frame and track shoe.
3 Sprocket mounting bolt:

Adhesive (LT-2)
3. Sling sprocket (1) temporarily, remove the
mounting bolts, and lift of sprocket (1). [*1] 343.2 ± 19.6 Nm {35 ± 2 kgm}
4 Sprocket: 40 kg
30-52 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY

1. Remove the sprocket. For details, see Removal • Carry out installation in the reverse order to re-
of sprocket. moval.
k After stopping the engine, loosen the oil fill-

2 Threads of travel motor mounting bolt:
[*1]
er cap of the hydraulic tank to release the in-
ternal pressure of the tank.
3 Travel motor mounting bolt:
Adhesive (LT-2)
2. Remove cover (1). 277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}

a Bleed air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding
air from each part, Bleeding air from travel
motor.

a Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
3. Disconnect 4 travel motor hoses (2) and lift off

travel motor assembly (3). [*1]
a Take care extremely that the nipple seal sur-
face of the hose connecting part will not be
damaged.
4 Travel motor assembly: 140 kg
BZ210-1 30-53
(1)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY

1. Loosen lubricator (1) to slacken the track shoe. • Carry out installation in the reverse order to re-

[*1] moval.
ment cylinder is very high, do not loosen the [*1]

lubricator more than 1 turn. If the grease a Adjust the track shoe tension. For details,
does not come out sufficiently, move the see TESTING AND ADJUSTING, Testing
machine forward and in reverse. adjusting track shoe tension.
2 Threads of track roller assembly

[*2]
mounting bolt: Adhesive (LT-2)

a Set the track roller assembly to the mounting
position with the plug on the outside of the
chassis.
a Operate the jack to lower the chassis gradu-
ally and tighten the mounting bolts temporar-
ily.
a Operate the jack to lower the chassis to the
ground, and then tighten the mounting bolts
permanently.
2. Remove the track roller mounting bolt, jack up
the track frame to raise the chassis, and remove
track roller assembly (2) out of the chassis. [*2]
30-54 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY

SPECIAL TOOLS 3. Pull roller (4) out of shaft (5).
a Since roller is filled with oil of 100 – 115 cc,
New/remodel
drain the oil at this time or spread cloths to
Necessity
Symbol
Sketch
absorb it.
Q'ty
Part No. Part Name
4. Remove floating seals (6) on the opposite side

1 791-675-1510 Installer t 1 from roller (4) and shaft (5).
F
2 791-601-1000 Oil pump q 1
DISASSEMBLY
1. Remove pin (1) and collar (2).
5. Remove collar (8) from shaft (5).
6. Remove bushings (9) and (10) from roller (4).
2. Remove floating seals (3) from collar (2) and

roller (4).
BZ210-1 30-55
(1)
ASSEMBLY 6. Turn over roller (4) and shaft (5).

1. Using push tool [1], press fit bushings (9) and
(10) to roller (4). 7. Using tool F1, install floating seals (3) to collar
(2).
2. Press fit shaft (5) to collar (8). a For the precaution for installing floating seals
(3a) and (3c), see the precaution marked
3. Using tool F1, install floating seals (6) to shaft with a in 3 above.
(5).
a When installing the floating seals, thoroughly
clean, degrease, and dry the contact surfaces of
the O-ring (6c) and floating seal (6a). Take care
that dirt is not sticking to the floating seal contact
surfaces.
8. Install collar (2) to shaft (5), and then install pin

(1).
4. Using tool F1, install floating seals (6) and (3) to

roller (4).
a For the precaution for installing floating seals
(6b), (6d), (3b), and (3d), see the precaution
marked with a in 3 above.
5. Install shaft (5) to roller (4).
9. Using tool F2, apply the standard pressure to

the roller oil filler and check the seal for air leak-
age.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Checking method
After the standard pressure is applied for 10
seconds, the pointer of the gauge must not
lower.
30-56 BZ210-1
(1)
10. Using tool F2, fill the track roller assembly with
oil, and then tighten plug (11).
5 Track roller oil:

100 – 115 cc (EO30-CD)
BZ210-1 30-57
(1)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY

1. Loosen lubricator (1) to slacken the track shoe. • Carry out installation in the reverse order to re-

[*1] moval.
ment cylinder is very high, do not loosen the [*1]

lubricator more than 1 turn. If the grease a Adjust the track shoe tension. For details,
does not come out sufficiently, move the see TESTING AND ADJUSTING, Testing
machine forward and in reverse. adjusting track shoe tension.
2 Threads of carrier roller assembly

[*2]
mounting bolt: Adhesive (LT-2)
2. Using block [1] and hydraulic jack [2], push up

the track shoe to a position where you can pull
out carrier roller assembly (2), and then remove
carrier roller assembly (2). [*2]
30-58 BZ210-1
(1)
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER

SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 797-101-1121 Wrench t 1
2 796-460-1110 Push tool t 1
L 3 796-430-1110 Push tool t 1
4 790-434-1650 Installer t 1
5 791-601-1000 Oil pump q 1
DISASSEMBLY
1. Remove plug (1) and drain the oil. 5. Using tool L1, remove nut (4).
6 Carrier roller assembly: 230 – 250 cc 6. Using push tool [2] and a press, pull shaft
assembly (5) out of roller (6) and remove inner
2. Set the carrier roller assembly on stand [1]. race (7).
4. Remove ring (3).
BZ210-1 30-59
(1)
7. Remove roller (6) from outer races (8) and (9). 2) Using tool L4, install floating seals (11).
a When installing the floating seal, thor-
8. Disassembly of shaft assembly oughly clean, degrease, and dry the con-
1) Using puller [3], remove inner race (10). tact surfaces of the O-ring (11c) and
floating seal (11a). Take care that dirt
will not stick to the floating seal contact
surfaces.
a After installing the floating seals, check
that they are not inclined more than 1
mm.
3) Install floating seals (11), and then press fit
inner race (10) with tool L2.
a For the precaution for installing floating
seals (11b) and (11d), see the precau-
tion marked with a in 2) above.
2) Remove floating seals (11).

3) Using push tool [4], remove collar (12) from
shaft (13).
3. Install roller (6) to shaft assembly (5).
4. Using tool L2, press fit inner race (7).

a While turning the roller, press fit the bearing
until the rotation of the roller becomes a little
heavy.
ASSEMBLY
1. Using push tool [5], press fit outer races (8) and 5. Using tool L1, tighten nut (4) until the hole of the
(9) to roller (6). shaft is matched to the hole of the nut.
2. Assembly of shaft assembly

1) Using tool L3, press fit collar (12) to shaft
(13).
a When press fitting, take care that the col-
2 Fitting of shaft: Engine oil (EO30-CD)

lar will not scuff the shaft.
30-60 BZ210-1
(1)
6. Install ring (3). 9. Using tool L5, apply the standard pressure to
the roller oil filler to check the seal for air leak-
7. Using push-pull scale [8], check that the roller age.
rotates lightly. a Standard pressure: 0.1 MPa {1 kg/cm2}
a Checking method
After the standard pressure is applied for 10
seconds, the pointer of the gauge must not
lower.
8. Fit the O-ring and install cover (2).
10. Using tool L5, fill the carrier roller assembly with
oil, and then tighten plug (1).
5 Carrier roller oil:

230 – 250 cc (EO30-CD)
BZ210-1 30-61
(1)
90 OTHERS
Serial No. 1001 – 1100

HYDRAULIC CIRCUIT DIAGRAM (1/2)........................................................................................................90- 3
Serial No. 1001 – 1100

ELECTRICAL CIRCUIT DIAGRAM (1/4) ......................................................................................................90- 11
BZ210-1 90-1
HYDRAULIC CIRCUIT DIAGRAM (1/2)
Serial No. 1001 – 1100
BZ210-1 90-3
(1)
Serial No. 1001 – 1100
BZ210-1 90-5
(1)
BZ210-1 90-7
(1)
BZ210-1 90-9
(1)
ELECTRICAL CIRCUIT DIAGRAM (1/4)
Serial No. 1001 – 1100
BZ210-1 90-11
(1)
Serial No. 1001 – 1100
BZ210-1 90-13
(1)
Serial No. 1001 – 1100
BZ210-1 90-15
(1)
Serial No. 1001 – 1100
BZ210-1 90-17
(1)
BZ210-1 90-19
(1)
BZ210-1 90-21
(1)
BZ210-1 90-23
(1)
BZ210-1 90-25
(1)

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SEBM031101

MACHINE MODEL SERIAL NUMBER

• BZ210-1 mounts the SAA6D102E-2 engine.

10 STRUCTURE, FUNCTION AND

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

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

90 OTHERS ................................................................................................................................ 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

q 00-1 (1) q 01-1 q 10-20 (1) q 10-48 (1) Q 10-78 (1)

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rub-

Holtz • Used as heat-resisting sealant for re-

• Used as lubricant for sliding portion

SYG2-400CA • Used for normal temperature, light

Molybdenum • Used for heavy load portion

SUNSTAR • Used as primer for cab side

• "S" is used for high-tempera-

SUNSTAR • Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE