Description
Komatsu BZ210-1 Galeo Mobile Soil Recycler Operation and Maintenance Manual (SEAM048202T)
Komatsu BZ210-1 Galeo Mobile Soil Recycler Index:
VENBM60000 PW148-10
FOREWORD
Safety
General
How to read the shop manual
Hoisting instructions
Coating materials
Standard tightening torque
Electric wire code
Conversion tables
Units
GENERAL
Specification dimension drawings
Working ranges
Weight table
Fuel, coolant and lubricants
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
Engine related parts
Power train
Swing machinery & motor
Undercarriage
Transmission
Hydraulic quick coupler
Travel motor
Clutch control circuit
Axle
Suspension lock cylinder
Braking system
Gear pump
Priority valve
Power brake valve
Accumulator for brake valve
Steering system
Steering column
Orbitrol valve
Hydraulic equipment layout drawings
Hydraulic circuit diagram
Hydraulic tank
Hydraulic pump
Pilot pressure control (PPC) system
Control valve
CLSS
Centre swivel joint
Travel PPC pedal
Work equipment – Swing PPC valve
Solenoid valve block with integrated ATT – EPC
Boom safety valve
Hydraulic cylinder
Work equipment
Air conditioner
Electrical wiring diagram
Electrical system
Engine controller
Pump controller
Electrical control system
Machine control system diagram
Machine monitor system
KOMTRAX system
Overload warning device
Sensor
PPC levers
1st attachment circuit hydraulic performance (main valve bypassed)
Travel system
Lubrication diagrams
Standard value table for engine related parts
Standard value table for chassis related parts
PM clinic service
STANDARD VALUE TABLE
TESTING AND ADJUSTING
Measuring engine speed
Measuring intake air pressure (boost pressure)
Checking exhaust gas colour
Measuring and adjusting valve clearance
Testing compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Measuring fuel delivery, return and leakage
Bleeding air from fuel circuit
Checking and adjusting air conditioner compressor belt tension
Replacing the fan belt
Measurement of clearance in swing circle bearing
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel
Inspection and adjustment of control circuit oil pressure
Inspection and adjustment of pump PC (valve inlet) control oil pressure
Inspection and adjustment of pump LS differential pressure
Measurement of solenoid valve output pressure
Adjustment of work equipment and swing PPC valve
Measuring and adjusting quick coupler control valve output pressure
Testing travel motor relief pressure
Testing propshaft speed
Testing transmission clutch control circuit
Inspection of locations of hydraulic drift of work equipment
Release of remaining pressure in hydraulic circuit
Measurement of oil leakage
Air bleeding of various parts
Inspection procedures for diode
Special function of monitor panel
Changing the lubrication interval times
TROUBLESHOOTING
Troubleshooting
General information on troubleshooting
Connector location chart and circuit diagram by system
Connection table for connector pin numbers
Before carrying out troubleshooting when failure code is displayed
Information contained in troubleshooting table
Troubleshooting by failure code (Display of code)
Failure code [879AKA] – A/C inner sensor open circuit
Failure code [879AKB] – A/C inner sensor short circuit
Failure code [879BKA] – A/C outer sensor open circuit
Failure code [879BKB] – A/C outer sensor short circuit
Failure code [879CKA] – Ventilating sensor open circuit
Failure code [879CKB] – Ventilating sensor short circuit
Failure code [879DKZ] – Sunlight sensor open or short circuit
Failure code [879EMC] – Ventilation damper abnormality
Failure code [879FMC] – Air mix damper abnormality
Failure code [879GKX] – Refrigerant abnormality
Failure code [2G00MA] – Brake oil pressure abnormality
Failure code [6B2JMA] – Travel hydraulic abnormality
Failure code [989L00] – Engine controller lock caution 1
Failure code [989M00] – Engine controller lock caution 2
Failure code [989N00] – Engine controller lock caution 3
Failure code [AA10NX] – Air cleaner clogging
Failure code [AB00KE] – Charge voltage low
Failure code [B@BAZG] – Engine oil pressure low
Failure code [B@BAZK] – Engine oil level low
Failure code [B@BCNS] – Engine coolant overheat
Failure code [B@BCZK] – Engine coolant level low
Failure code [B@HANS] – Hydraulic oil overheat
Failure code [CA111] – EMC critical internal failure
Failure code [CA115] – Engine neutral and backup speed sensor error
Failure code [CA122] – Charge air press sensor high error
Failure code [CA123] – Charge air press sensor low error
Failure code [CA131] – Throttle sensor high error
Failure code [CA132] – Throttle sensor low error
Failure code [CA144] – Coolant temperature sensor high error
Failure code [CA145] – Coolant temp sensor low error
Failure code [CA153] – Charge air temperature sensor high error
Failure code [CA154] – Charge air temperature sensor low error
Failure code [CA187] – Sensor supply 2 voltage low error
Failure code [CA221] – Ambient press sensor high error
Failure code [CA222] – Ambient press sensor low error
Failure code [CA227] – Sensor supply 2 volt high error
Failure code [CA234] – Engine overspeed
Failure code [CA238] – NE speed sensor supply voltage error
Failure code [CA239] – Ne speed sens supply volt high error
Failure code [CA271] – IMV/PCV1 short circuit error
Failure code [CA272] – IMV/PCV1 open error
Failure code [CA295] – Ambient press sens in range error
Failure code [CA322] – Injector #1 (L#1) open/short circuit error
Failure code [CA324] – Injector #3 (L#3) open/short circuit Error
Failure code [CA331] – Injector #2 (L#2) open/short circuit error
Failure code [CA332] – Injector #4 (L#4) open/short circuit error
Failure code [CA343] – ECM critical internal failure
Failure code [CA351] – Injectors drive circuit error
Failure code [CA352] – Sensor 1 supply voltage low error
Failure code [CA356] – Mass air flow sensor high error
Failure code [CA357] – Mass air flow sensor low error
Failure code [CA386] – Sensor 1 supply voltage high error
Failure code [CA428] – Water-in-fuel sensor high error
Failure code [CA429] – Water-in-fuel sensor low error
Failure code [CA435] – Engine oil pressure switch error
Failure code [CA441] – Battery voltage low error
Failure code [CA442] – Battery voltage high error
Failure code [CA449] – Common rail pressure very high error
Failure code [CA451] – Rail pressure sensor high error
Failure code [CA452] – Rail pressure sensor low error
Failure code [CA466] – KVGT motor driver position error
Failure code [CA488] – Charge air temperature high torque derate
Failure code [CA515] – Rail press sens sup volt high error
Failure code [CA516] – Rail press sens sup volt low error
Failure code [CA553] – Common rail pressure high error
Failure code [CA555] – Crankcase press high error 1
Failure code [CA556] – Crankcase press high error 2
Failure code [CA559] – Rail pressure low error
Failure code [CA689] – Engine ne speed sensor error
Failure code [CA691] – Intake air temp sens high error
Failure code [CA692] – Intake air temp sens low error
Failure code [CA697] – ECM int temp sensor high error
Failure code [CA698] – ECM int temp sensor low error
Failure code [CA731] – Engine Bkup speed sensor phase error
Failure code [CA778] – Engine Bkup speed sensor error
Failure code [CA1117] – Persistent data lost error
Failure code [CA1695] – Sensor 5 supply volt high error
Failure code [CA1696] – Sensor 5 supply volt low error
Failure code [CA1843] – Crankcase press sens high error
Failure code [CA1844] – Crankcase press sens low error
Failure code [CA1896] – EGR valve stuck error
Failure code [CA1942] – Crankcase press sens in range error
Failure code [CA1961] – EGR motor driver IC over temp error
Failure code [CA2185] – Throt sensor sup volt high error
Failure code [CA2186] – Throt sensor sup volt low error
Failure code [CA2249] – Rail pressure very low error
Failure code [CA2272] – EGR valve pos sens low error
Failure code [CA2311] – IMV solenoid error
Failure code [CA2349] – EGR valve solenoid open error
Failure code [CA2353] – EGR valve solenoid short error
Failure code [CA2357] – EGR valve servo error
Failure code [CA2373] – Exhaust manifold press sens high error
Failure code [CA2374] – Exhaust manifold press sens low error
Failure code [CA2375] – EGR orifice temp sens high error
Failure code [CA2376] – EGR orifice temp sens low error
Failure code [CA2554] – Exh manifold press sens in range error
Failure code [CA2555] – Grid heater relay volt low error
Failure code [CA2556] – Grid heater relay volt high error
Failure code [CA2961] – EGR orifice temperature high error 1
Failure code [CA2973] – Chg air press sensor in range error
Failure code [CA3419] – Mass air flow sensor sup volt high error
Failure code [CA3421] – Mass air flow sensor sup volt low error
Failure code [CA3724] – EGR/KVGT motor driver power low error
Failure code [CA3741] – Rail press valve trip error
Failure code [CA3918] – KVGT stuck error
Failure code [CA3919] – KVGT motor driver IC over temp error
Failure code [CA3921] – KVGT servo error 2
Failure code [CA3922] – KVGT motor driver open error
Failure code [CA3923] – KVGT motor driver short error
Failure code [D110KB] – Battery relay output voltage
Failure code [D161KA] – Backup alarm relay open circuit
Failure code [D161KB] – Backup alarm relay short circuit
Failure code [D19JKZ] – Personal code relay abnormality
Failure code [D19QKB] – Refuel pump relay short circuit
Failure code [D1EMKA] – Parking brake relay open circuit
Failure code [D1EMKB] – Parking brake relay short circuit
Failure code [D811MC] – KOMTRAX error
Failure code [D862KA] – GPS antenna open circuit
Failure code [D8ALKA] – System operating lamp disconnection (KOMTRAX)
Failure code [D8ALKB] – System operating lamp short circuit (KOMTRAX)
Failure code [D8AQKR] – CAN2 discon (KOMTRAX)
Failure code [DA20MC] – Pump controller
Failure code [DA22KK] – Pump solenoid power low error
Failure code [DA25KP] – 5V sensor 1 power abnormality
Failure code [DA26KP] – 5V sensor 2 power abnormality
Failure code [DA29KQ] – Model selection abnormality
Failure code [DA2LKA] – System operating lamp disconnection (pump con)
Failure code [DA2LKB] – System operating lamp short circuit (pump con)
Failure code [DA2QKR] – CAN2 discon (pump con)
Failure code [DA2RKR] – CAN1 discon (pump con)
Failure code [DAB0KT] – Internal flash memory error
Failure code [DAC3KB] – Cruise control system power supply short circuit
Failure code [DAF0MB] – Monitor ROM abnormality
Failure code [DAF0MC] – Monitor error
Failure code [DAF8KB] – Camera power supply short circuit
Failure code [DAF9KQ] – Model selection abnormality
Failure code [DAFGMC] – GPS module operation error
Failure code [DAFLKA] – Operating lamp open circuit (monitor)
Failure code [DAFLKB] – System operating lamp short circuit (monitor)
Failure code [DAFQKR] – CAN2 discon (monitor)
Failure code [DAZ9KQ] – A/C model selection abnormality
Failure code [DAZQKR] – CAN2 discon (AC)
Failure code [DB2QKR] – CAN2 discon (engine con)
Failure code [DB2RKR] – CAN1 discon (engine con)
Failure code [DDK8KA] – SUSLock forced sw open circuit
Failure code [DDK8KB] – SUSLock forced sw short circuit
Failure code [DDP4KX] – Disconnection in travel PPC pressure switch
Failure code [DDP6L5] – Service brake press sw abnormality
Failure code [DDQ1KA] – SUSLock mode selection sw open circuit
Failure code [DDQ1KB] – SUSLock mode selection sw short circuit
Failure code [DDWCKZ] – Direction switch abnormality
Failure code [DFB1KZ] – Service lever potentio 1 abnormality
Failure code [DFB2KZ] – Service lever potentio 2 abnormality
Failure code [DFB3L8] – Service lever 1 potentio error
Failure code [DFB4L8] – Service lever 2 potentio error
Failure code [DFB5KZ] – Service lever sub potentio 1 abnormality
Failure code [DFB6KZ] – Service lever sub potentio 2 abnormality
Failure code [DGH2KB] – Hydraulic oil temperature sensor short circuit
Failure code [DH10KP] – 24V sensor power abnormality
Failure code [DHA4KA] – Air cleaner clog sensor open circuit
Failure code [DHH2MA] – Return line filter press sensor abnormally
Failure code [DHPAMA] – F pump press sensor abnormality
Failure code [DHS5KX] – Abnormality in travel PPC sensor
Failure code [DHU1KA] – Brake accumulator press sensor open circuit
Failure code [DHU1KY] – Brake accumulator press sensor short circuit
Failure code [DHUCKA] – Parking brake press sensor open circuit
Failure code [DHUCKY] – Parking brake press sensor short circuit
Failure code [DHUGKA] – Service brake press sensor open circuit
Failure code [DHUGKY] – Service brake press sensor short circuit
Failure code [DHX1MA] – Overload sensor abnormality (analog)
Failure code [DLT4KA] – Disconnection in transmission speed sensor
Failure code [DR21KX] – Camera 2 picture rev. drive abnormality
Failure code [DR31KX] – Camera 3 picture rev. drive abnormality
Failure code [DW27KA] – Disconnection in transmission clutch solenoid
Failure code [DW27KB] – Short circuit in transmission clutch solenoid
Failure code [DW27KY] – T/M clutch sol hot short circuit
Failure code [DW4AKA] – Disconnection in suspension lock solenoid
Failure code [DW4AKB] – Short circuit in suspension lock solenoid
Failure code [DW4AKY] – SUSLock sol hot short circuit
Failure code [DW4CKA] – Disconnection in PPC lock solenoid
Failure code [DW4CKB] – PPC lock sol. short circuit
Failure code [DW4MKA] – Disconnection in creep solenoid
Failure code [DW4MKB] – Short circuit in creep solenoid
Failure code [DW44KA] – Disconnection in travel F/R solenoid
Failure code [DW44KB] – Short circuit in travel F/R solenoid
Failure code [DW44KY] – Travel F/R sol hot short circuit
Failure code [DW45KA] – Disconnection in swing holding brake solenoid
Failure code [DW45KB] – Swing holding brake solenoid short circuit
Failure code [DW91KA] – Disconnection in travel neutral solenoid
Failure code [DW91KB] – Short circuit in travel neutral solenoid
Failure code [DWB1KA] – Disconnection in outrigger operation solenoid
Failure code [DWB1KB] – Short circuit in outrigger operation solenoid
Failure code [DWB2KA] – Disconnection in 1st outrigger solenoid
Failure code [DWB2KB] – Short circuit in 1st outrigger solenoid
Failure code [DWB3KA] – Disconnection in 2nd outrigger solenoid
Failure code [DWB3KB] – Short circuit in 2nd outrigger solenoid
Failure code [DWB4KA] – Disconnection in 3rd outrigger solenoid
Failure code [DWB4KB] – Short circuit in 3rd outrigger solenoid
Failure code [DWB5KA] – Disconnection in 4th outrigger solenoid
Failure code [DWB5KB] – Short circuit in 4th outrigger solenoid
Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid
Failure code [DWK0KB] – Short circuit in 2-stage relief solenoid
Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid
Failure code [DWK2KB] – Short circuit in 2-stage back pressure solenoid
Failure code [DXA8KA] – Disconnection in PC-EPC (F) solenoid system
Failure code [DXA8KB] – Short circuit in PC-EPC (F) solenoid
Failure code [DXE0KA] – Disconnection in LS-EPC solenoid system
Failure code [DXE0KB] – Short circuit in LS-EPC solenoid
Failure code [DXE7KA] – Service current EPC2 solenoid disconnection (right hand)
Failure code [DXE7KB] – Service current EPC solenoid short (right hand)
Failure code [DXE8KA] – Service current EPC solenoid disconnection (left hand)
Failure code [DXE8KB] – Service current EPC3 solenoid short (left hand)
Failure code [DXE9KA] – Service current EPC solenoid disconnection (right hand)
Failure code [DXE9KB] – Service current EPC solenoid short (right hand)
Failure code [DXEAKA] – Service Current EPC1 open circuit (left hand)
Failure code [DXEAKB] – Service current EPC1 solenoid short (left hand)
Failure code [DXK3KA] – Travel pedal throttle EPC solenoid open circuit
Failure code [DXK3KB] – Travel pedal throttle EPC solenoid short circuit
Failure code [DY20KA] – Wiper working abnormality
Failure code [DY20MA] – Wiper parking abnormality
Failure code [DY2CKA] – Window washer drive system disconnection
Failure code [DY2CKB] – Washer drive short circuit
Failure code [DY2DKB] – Wiper drive (fwd) short circuit
Failure code [DY2EKB] – Wiper drive (rev) short circuit
Troubleshooting of central lubrication system (CLS)
TROUBLESHOOTING
Troubleshooting when failure code is indicated
OTHER
Hydraulic circuit diagram (1/3)
Hydraulic circuit diagram (2/3)
Hydraulic circuit diagram (3/3)
Circuit diagram (cabin 1/4)
Circuit diagram (cabin 2/4)
Circuit diagram (cabin 3/4)
Circuit diagram (cabin 4/4)
Circuit diagram (machine 1/4))
Circuit diagram (machine 2/4))
Circuit diagram (machine 3/4))
Circuit diagram (machine 4/4))
Connector diagram 1/8
Connector diagram 2/8
Connector diagram 3/8
Connector diagram (4/8)
Connector diagram (5/8)
Connector diagram (6/8)
Connector diagram (7/8)
Connector diagram (8/8)
