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KOMATSU BZ210-1 SHOP MANUAL SEBM031101 – PDF DOWNLOAD
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Description
KOMATSU BZ210-1 SHOP MANUAL SEBM031101 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU BZ210-1 SHOP MANUAL SEBM031101 – PDF DOWNLOAD
Language : English
Pages : 670
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU BZ210-1 SHOP MANUAL SEBM031101 – PDF DOWNLOAD
COVER................................................................................................................................................................. 1 CONTENTS.............................................................................................................................................................. 2 01 GENERAL............................................................................................................................................................ 27 SPECIFICATION DRAWINGS............................................................................................................................................ 28 SPECIFICATIONS.................................................................................................................................................... 29 WEIGHT TABLE...................................................................................................................................................... 33 FUEL, COOLANT AND LUBRICANTS...................................................................................................................................... 34 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....................................................................................................................... 35 ENGINE ACCESSORIES................................................................................................................................................ 36 RADIATOR, OIL COOLER, AND AFTERCOOLER............................................................................................................................. 37 POWER TRAIN SYSTEM DIAGRAM........................................................................................................................................ 38 TRACK FRAME AND RECOIL SPRING..................................................................................................................................... 39 IDLER............................................................................................................................................................. 41 CARRIER ROLLER.................................................................................................................................................... 42 TRACK ROLLER...................................................................................................................................................... 43 SPROCKET.......................................................................................................................................................... 44 TRACK SHOE........................................................................................................................................................ 45 ARRANGEMENT OF HYDRAULIC COMPONENT................................................................................................................................ 48 HYDRAULIC TANK.................................................................................................................................................... 50 HYDRAULIC PUMP.................................................................................................................................................... 51 PC-EPC VALVE...................................................................................................................................................... 67 CONTROL VALVE..................................................................................................................................................... 70 CLSS.............................................................................................................................................................. 93 SELF PRESSURE REDUCING VALVE......................................................................................................................................107 TRAVEL MOTOR (FINAL DRIVE)........................................................................................................................................114 TRAVEL JUNCTION VALVE.............................................................................................................................................123 SOIL BELT CONVERTOR MOTOR.........................................................................................................................................127 RAKING ROTOR MOTOR................................................................................................................................................132 SOIL CUTTER MOTOR.................................................................................................................................................134 ROTARY HAMMER MOTOR...............................................................................................................................................135 DISCHARGE BELT CONVEYOR MOTOR.....................................................................................................................................136 SOLIDIFYING MATERIAL FEEDER.......................................................................................................................................137 AFTERCUTTER MOTOR.................................................................................................................................................138 HYDRAULIC CYLINDER................................................................................................................................................139 VALVE CONTROL.....................................................................................................................................................140 TRAVEL PPC VALVE..................................................................................................................................................141 CRUSHER CASE OPEN/CLOSE PPC VALVE.................................................................................................................................145 6-SPOOL SOLENOID VALVE (A)........................................................................................................................................146 6-SPOOL SOLENOID VALVE (B)........................................................................................................................................147 EPC VALVE.........................................................................................................................................................149 WORK EQUIPMENT....................................................................................................................................................152 MIXER (CRUSHER)...................................................................................................................................................155 SOIL BELT CONVEYOR................................................................................................................................................163 MONITOR SYSTEM....................................................................................................................................................185 SENSORS...........................................................................................................................................................219 20 TESTING AND ADJUSTING..............................................................................................................................................224 STANDARD VALUE TABLE..............................................................................................................................................225 STANDARD VALUE TABLE FOR ENGINE...............................................................................................................................225 STANDARD VALUE TABLE FOR CHASSIS..............................................................................................................................226 TESTING AND ADJUSTING.............................................................................................................................................232 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING..............................................................................................................233 TESTING AND ADJUSTING ENGINE SPEED............................................................................................................................235 MEASURING EXHAUST GAS COLOR...................................................................................................................................236 ADJUSTING VALVE CLEARANCE.....................................................................................................................................237 MEASURING COMPRESSION PRESSURE ...............................................................................................................................239 MEASURING BLOW-BY PRESSURE....................................................................................................................................240 TESTING AND ADJUSTING FUEL INJECTION TIMING...................................................................................................................241 MEASURING ENGINE OIL PRESSURE.................................................................................................................................243 ADJUSTING ENGINE SPEED SENSOR.................................................................................................................................243 EMERGENCY ESCAPE METHOD WHEN ENGINE CONTROL SYSTEM HAS TROUBLE................................................................................................244 TESTING AND ADJUSTING TRACK SHOE TENSION......................................................................................................................245 TESTING AND ADJUSTING SOIL BELT CONVEYOR SHOE TENSION.........................................................................................................246 TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT AND TRAVEL CIRCUITS.....................................................................................247 TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE..........................................................................................................251 TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURE....................................................................................................252 TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE....................................................................................................255 MEASURING SOLENOID VALVE OUTPUT PRESSURE......................................................................................................................259 MEASURING PPC VALVE OUTPUT PRESSURE...........................................................................................................................262 RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT..............................................................................................................263 MEASURING OIL LEAKAGE.........................................................................................................................................263 BLEEDING AIR PROM EACH PART...................................................................................................................................264 PROCEDURE FOR TESTING DIODES..................................................................................................................................266 SPECIAL FUNCTION OF MONITOR PANEL.............................................................................................................................267 TROUBLESHOOTING...................................................................................................................................................295 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................................................296 SEQUENCE OF EVENTS IN TROUBLESHOOTING.........................................................................................................................297 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..............................................................................................................298 CHECKS BEFORE TROUBLESHOOTING.................................................................................................................................306 CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING..............................................................................................................307 CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM.....................................................................................311 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................................................349 T-BRANCH BOX AND T-BRANCH TABLE...............................................................................................................................372 TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND ERROR CODE "MECHANICAL SYSTEM" ARE INDICATED..........................................................374 INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................377 ELECTRICAL SYSTEM SERVICE CODE [E201] (DISCONNECTION IN DISCHARGE BELT CONVEYOR FORWARD SOL SYSTEM).......................................................379 ELECTRICAL SYSTEM SERVICE CODE [E202] (SHORT CIRCUIT IN DISCHARGE BELT CONVEYOR FORWARD SOL SYSTEM).......................................................380 ELECTRICAL SYSTEM SERVICE CODE [E203] (DISCONNECTION IN DISCHARGE BELT CONVEYOR FORWARD SOL SYSTEM).......................................................381 ELECTRICAL SYSTEM SERVICE CODE [E204] (SHORT CIRCUIT IN DISCHARGE BELT CONVEYOR FORWARD SOL SYSTEM).......................................................382 ELECTRICAL SYSTEM SERVICE CODE [E205] (DISCONNECTION IN HAMMER 1 FORWARD EPC VALVE SYSTEM)................................................................383 ELECTRICAL SYSTEM SERVICE CODE [E206] (SHORT CIRCUIT IN HAMMER 1 FORWARD EPC VALVE SYSTEM)................................................................384 ELECTRICAL SYSTEM SERVICE CODE [E207] (DISCONNECTION IN HAMMER 2 FORWARD EPC VALVE SYSTEM)................................................................385 ELECTRICAL SYSTEM SERVICE CODE [E208] (SHORT CIRCUIT IN HAMMER 2 FORWARD EPC VALVE SYSTEM)................................................................386 ELECTRICAL SYSTEM SERVICE CODE [E209] (DISCONNECTION IN HAMMER 3 FORWARD EPC VALVE SYSTEM)................................................................387 ELECTRICAL SYSTEM SERVICE CODE [E210] (SHORT CIRCUIT IN HAMMER 3 FORWARD EPC VALVE SYSTEM)................................................................388 ELECTRICAL SYSTEM SERVICE CODE [E211] (DISCONNECTION IN HAMMER REVERSE SOL SYSTEM)........................................................................389 ELECTRICAL SYSTEM SERVICE CODE [E212] (SHORT CIRCUIT IN HAMMER REVERSE SOL SYSTEM)........................................................................390 ELECTRICAL SYSTEM SERVICE CODE [E213] (DISCONNECTION IN SOIL CUTTER FORWARD EPC VALVE SYSTEM).............................................................391 ELECTRICAL SYSTEM SERVICE CODE [E214] (SHORT CIRCUIT IN SOIL CUTTER FORWARD EPC VALVE SYSTEM).............................................................392 ELECTRICAL SYSTEM SERVICE CODE [E215] (DISCONNECTION IN SOIL CUTTER REVERSE SOL SYSTEM)...................................................................393 ELECTRICAL SYSTEM SERVICE CODE [E216] (SHORT CIRCUIT IN SOIL CUTTER REVERSE SOL SYSTEM)...................................................................394 ELECTRICAL SYSTEM SERVICE CODE [E217] (DISCONNECTION IN SOLIDIFYING MATERIAL FEEDER FORWARD EPC VALVE SYSTEM).............................................395 ELECTRICAL SYSTEM SERVICE CODE [E218] (SHORT CIRCUIT IN SOLIDIFYING MATERIAL FEEDER FORWARD EPC VALVE SYSTEM).............................................396 ELECTRICAL SYSTEM SERVICE CODE [E219] (DISCONNECTION IN SOLIDIFYING MATERIAL FEEDER REVERSE SOL SYSTEM)...................................................397 ELECTRICAL SYSTEM SERVICE CODE [E220] (SHORT CIRCUIT IN SOLIDIFYING MATERIAL FEEDER REVERSE SOL SYSTEM)...................................................398 ELECTRICAL SYSTEM SERVICE CODE [E221] (DISCONNECTION IN RAKING ROTOR FORWARD EPC VALVE SYSTEM)............................................................399 ELECTRICAL SYSTEM SERVICE CODE [E222] (SHORT CIRCUIT IN RAKING ROTOR FORWARD EPC VALVE SYSTEM)............................................................400 ELECTRICAL SYSTEM SERVICE CODE [E223] (DISCONNECTION IN RAKING ROTOR REVERSE SOL SYSTEM)..................................................................401 ELECTRICAL SYSTEM SERVICE CODE [E224] (SHORT CIRCUIT IN RAKING ROTOR REVERSE SOL SYSTEM)..................................................................402 ELECTRICAL SYSTEM SERVICE CODE [E225] (DISCONNECTION IN SOIL FEEDER FORWARD EPC VALVE SYSTEM).............................................................403 ELECTRICAL SYSTEM SERVICE CODE [E226] (SHORT CIRCUIT IN SOIL FEEDER FORWARD EPC VALVE SYSTEM).............................................................404 ELECTRICAL SYSTEM SERVICE CODE [E227] (DISCONNECTION IN SOIL FEEDER REVERSE SOL SYSTEM)...................................................................405 ELECTRICAL SYSTEM SERVICE CODE [E228] (SHORT CIRCUIT IN SOIL FEEDER REVERSE SOL SYSTEM)...................................................................406 ELECTRICAL SYSTEM SERVICE CODE [E229] (DISCONNECTION IN ATT1 SOL SYSTEM)..................................................................................407 ELECTRICAL SYSTEM SERVICE CODE [E230] (SHORT CIRCUIT IN ATT1 SOL SYSTEM)..................................................................................408 ELECTRICAL SYSTEM SERVICE CODE [E231] (DISCONNECTION IN ATT2 SOL SYSTEM)..................................................................................409 ELECTRICAL SYSTEM SERVICE CODE [E232] (SHORT CIRCUIT IN ATT2 SOL SYSTEM)..................................................................................410 ELECTRICAL SYSTEM SERVICE CODE [E233] (DISCONNECTION IN ATT3 SOL SYSTEM)..................................................................................411 ELECTRICAL SYSTEM SERVICE CODE [E234] (SHORT CIRCUIT IN ATT3 SOL SYSTEM)..................................................................................412 ELECTRICAL SYSTEM SERVICE CODE [E235] (DISCONNECTION IN COMPERSSOR SOL SYSTEM)............................................................................413 ELECTRICAL SYSTEM SERVICE CODE [E236] (SHORT CIRCUIT IN COMPRESSOR SOL SYSTEM)............................................................................414 ELECTRICAL SYSTEM SERVICE CODE [E237] (DISCONNECTION IN CRANE EPC VALVE SYSTEM)...........................................................................415 ELECTRICAL SYSTEM SERVICE CODE [E238] (SHORT CIRCUIT IN CRANE EPC VALVE SYSTEM)...........................................................................416 ELECTRICAL SYSTEM SERVICE CODE [E239] (DISCONNECTION IN PC-EPC SYSTEM)....................................................................................417 ELECTRICAL SYSTEM SERVICE CODE [E240] (SHORT CIRCUIT IN PC-EPC SYSTEM)....................................................................................418 ELECTRICAL SYSTEM SERVICE CODE [E241] (DISCONNECTION IN GOVERNOR MOTOR DRIVE SYSTEM)......................................................................419 ELECTRICAL SYSTEM SERVICE CODE [E242] (SHORT CIRCUIT IN GOVERNOR MOTOR DRIVE SYSTEM)......................................................................420 ELECTRICAL SYSTEM SERVICE CODE [E243] (STEP-OUT OF GOBERNOR MOTOR)........................................................................................422 ELECTRICAL SYSTEM SERVICE CODE [E244] (SHORT CIRCUIT IN BATTERY RELAY SYSTEM).............................................................................423 ELECTRICAL SYSTEM SERVICE CODE [E245] (SHORT CIRCUIT IN MONITOR LAMP RELAY SYSTEM)........................................................................424 ELECTRICAL SYSTEM SERVICE CODE [E246] (SHORT CIRCUIT IN HORM RELAY SYSTEM)................................................................................425 ELECTRICAL SYSTEM SERVICE CODE [E247] (SHORT CIRCUIT IN BEACON LAMP RELAY SYSTEM).........................................................................426 ELECTRICAL SYSTEM SERVICE CODE [E248] (DISCONNECTION IN ELECTRICAL INTAKE AIR HEATER RELAY SYSTEM)........................................................427 ELECTRICAL SYSTEM SERVICE CODE [E249] (SHORT CIRCUIT IN ELECTRICAL INTAKE AIR HEATER RELAY SYSTEM)........................................................428 ELECTRICAL SYSTEM SERVICE CODE [E250] (DISCONNECTION IN LIQUID ADDITION UNIT DRIVE RELAY SYSTEM)..........................................................429 ELECTRICAL SYSTEM SERVICE CODE [E251] (SHORT CIRCUIT IN LIQUID ADDITION UNIT DRIVE RALAY SYSTEM)..........................................................430 ELECTRICAL SYSTEM SERVICE CODE [E300] (DISCONNECTION IN WMERGENCY STOP SWITCH SYSTEM).....................................................................431 ELECTRICAL SYSTEM SERVICE CODE [E301] (DISCONNECTION IN ENGINE STOP SWITCH SYSTEM)........................................................................433 ELECTRICAL SYSTEM SERVICE CODE [E302] (ABNORMALITY IN FUEL CONTROL DIAL SYSTEM)...........................................................................434 ELECTRICAL SYSTEM SERVICE CODE [E303] (ABNORMALITY IN GOVERNOR FB POTENTIOMETER SYSTEM)...................................................................436 ELECTRICAL SYSTEM SERVICE CODE [E304] (SHORT CIRCUIT IN DISCHAEGE BELT CONVEYOR ON SWITCH SYSTEM).........................................................438 ELECTRICAL SYSTEM SERVICE CODE [E305] (DISCONNECTION IN DISCHANGE BELT CONVEYOR OFF SWITCH SYSTEM)........................................................439 ELECTRICAL SYSTEM SERVICE CODE [E308] (SHORT CIRCUIT IN FEEDER ON SWITCH SYSTEM)..........................................................................440 ELECTRICAL SYSTEM SERVICE CODE [E309] (DISCONNECTION IN FEEDER OFF/REVERSE SWITCH SYSTEM).................................................................441 ELECTRICAL SYSTEM SERVICE CODE [E310] (SHORT CIRCUIT IN ATT1 ON SWITCH SYSTEM)............................................................................442 ELECTRICAL SYSTEM SERVICE CODE [E311] (DISCONNECTION IN ATT1 OFF SWITCH SYSTEM)...........................................................................443 ELECTRICAL SYSTEM SERVICE CODE [E312] (SHORT CIRCUIT IN ATT2 ON SWITCH SYSTEM)............................................................................444 ELECTRICAL SYSTEM SERVICE CODE [E313] (DISCONNECTION IN ATT2 OFF SWITCH SYSTEM)...........................................................................445 ELECTRICAL SYSTEM SERVICE CODE [E314] (SHORT CIRCUIT IN ATT3 ON SWITCH SYSTEM)............................................................................446 ELECTRICAL SYSTEM SERVICE CODE [E315] (DISCONNECTION IN ATT3 OFF SWITCH SYSTEM)...........................................................................447 ELECTRICAL SYSTEM SERVICE CODE [E316] (SHORT CIRCUIT IN AIR COMPRESSOR ON SWITCH SYSTEM)..................................................................448 ELECTRICAL SYSTEM SERVICE CODE [E317] (SHORT CORCUIT IN AIR CPMPERSSOR OFF SWITCH SYSTEM).................................................................449 ELECTRICAL SYSTEM SERVICE CODE [E318] (SHORT CIRCUIT IN DISCHARGE BELT CONVEYOR MANUAL FORWARD SWITCH SYSTEM).............................................450 ELECTRICAL SYSTEM SERVICE CODE [E319] (SHORT CIRCUIT IN DISCHARGE BELT CONVEYOR MANUAL REVERSE SWITCH SYSTEM).............................................451 ELECTRICAL SYSTEM SERVICE CODE [E320] (SHORT CIRCUIT IN HAMMER MANUAL FORWARD SWITCH SYSTEM)..............................................................452 ELECTRICAL SYSTEM SERVICE CODE [E321] (SHORT CIRCUIT IN HAMMER MANUAL REVERSE SWITCH SYSTEM)..............................................................453 ELECTRICAL SYSTEM SERVICE CODE [E322] (SHORT CIRCUIT IN SOIL CUTTER MANUAL FOEWARD SWITCH SYSTEM).........................................................454 ELECTRICAL SYSTEM SERVICE CODE [E323] (SHORT CIRCUIT IN SOIL CUTTER MANUAL REVERSE SWITCH SYSTEM).........................................................455 ELECTRICAL SYSTEM SERVICE CODE [E324] (SHORT CIRCUIT IN SOLIDIFYING MATERIAL FEEDER MANUAL FORWARD SWITCH SYSTEM).........................................456 ELECTRICAL SYSTEM SERVICE CODE [E325] (SHORT CIRCUIT IN SOLIDIFING MATERIAL FEEDER MANUAL REVERSE SWITCH SYSTEM)..........................................457 ELECTRICAL SYSTEM SERVICE CODE [E326] (SHORT CIRCUIT IN RAKING ROTOR MANUAL FORWARD SWITCH SYSTEM)........................................................458 ELECTRICAL SYSTEM SERVICE CODE [E327] (SHORT CIRCUIT IN RAKING ROTOR MANUAL REVERSE SWITCH SYSTEM)........................................................459 ELECTRICAL SYSTEM SERVICE CODE [E328] (SHORT CIRCUIT IN SOIL FEEDER MANUAL FORWARD SWITCH SYSTEM).........................................................460 ELECTRICAL SYSTEM SERVICE CODE [E329] (SHORT CIRCUIT IN SOIL FEEDER MANUAL REVERSE SWITCH SYSTEM).........................................................461 ELECTRICAL SYSTEM SERVICE CODE [E331] (SHORT CIRCUIT IN CALIBRATION SWITCH SYSTEM)........................................................................462 ELECTRICAL SYSTEM SERVICE CODE [E332] (SHORT CIRCUIT IN RADIO CONTROL CH1 SYSTEM).........................................................................463 ELECTRICAL SYSTEM SERVICE CODE [E333] (SHORT CIRCUIT IN RADIO CONTROL CH2 SYSTEM).........................................................................464 ELECTRICAL SYSTEM SERVICE CODE [E334] (SHORT CIRCUIT IN RADIO CONTROL CH3 SYSTEM).........................................................................465 ELECTRICAL SYSTEM SERVICE CODE [E335] (SHORT CIRCUIT IN RADIO CONTROL CH4 SYSTEM).........................................................................466 ELECTRICAL SYSTEM SERVICE CODE [E336] (ABNORMALITY IN SOIL CUTTER PRESSURE SENSOR SYSTEM).................................................................467 ELECTRICAL SYSTEM SERVICE CODE [E337] (ABNORMALITY IN S_NET SIGNAL SYSTEM)................................................................................468 ELECTRICAL SYSTEM SERVICE CODE [E338] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM).........................................................................469 ELECTRICAL SYSTEM SERVICE CODE [E339] (ABNORMALITY IN MODEL SELECTION SIGNAL SYSTEM)......................................................................470 ELECTRICAL SYSTEM SERVICE CODE [E340] (ABNORMALITY IN CRANE ACCELERATION SIGNAL SYSTEM)...................................................................471 ELECTRICAL SYSTEM SERVICE CODE [E341] (ABNORMALITY IN F PUMP PRESSURE SENSOR SYSTEM)......................................................................472 ELECTRICAL SYSTEM SERVICE CODE [E342] (ABNORMALITY IN R PUMP PRESSURE SENSOR SYSTEM)......................................................................474 ELECTRICAL SYSTEM SERVICE CODE [E343] (ABNORMALITY IN CURRENT FLOW METET SIGNAL SYSTEM)...................................................................476 MECHANICAL SYSTEM ERROR CODE [AA10NX] (CLOGGING OF AIR CLEANER)...........................................................................................477 MECHANICAL SYSTEM ERROR CODE [ABOOKE] (ABNORMAL LOWERING OF CHARGE COLTAGE)...............................................................................478 MECHANICAL SYSTEM ERROR CODE [B@BAZG] (ABNORMAL LOWERING OF ENGINE OIL PRESSURE)..........................................................................479 MECHANICAL SYSTEM ERROR CODE [B@BAZK] (ABNORMAL LOWING OF NEGINE OIL LEVEL)...............................................................................480 MECHANICAL SYSTEM ERROR CODE [B@BCNS] (OVERHEATING OF ENGINE COOLANT).....................................................................................481 MECHANICAL SYSTEM ERROR CODE [B@BCZK] (ABNORMAL LOWERING OF RADIATOR COOLANT LEVEL).......................................................................482 MECHANICAL SYSTEM ERROR CODE [B@HANS] (OVERHEATING OF HYDRAULIC OIL)......................................................................................483 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).................................................................................................................484 INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................486 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK).........................................................................................................487 E-2 ENGINE STOPS DURING OPERATION.........................................................................................................................490 E-3 ENGINE RATATION IS UNSTABLE OR ENGINE HUNTS...........................................................................................................491 E-4 ENGINE DOES NOT STOP..................................................................................................................................493 E-5 ENGINE PREHEATER DOES NOT OPERATE.....................................................................................................................495 E-6 TRAVEL SYSTE AND MANUAL OPERATION SYSTEM DO NOT WORK..................................................................................................497 E-7 NO ITEMS ARE DISPLAYED ON MONITOR PANEL...............................................................................................................499 E-8 SOME ITEMS ARE NOT DISPLAYED ON MONITOR PANEL.........................................................................................................500 E-9 FUEL LEVEL MONITOR LIGHT RED WHILE ENGINE IS RUNNING..................................................................................................500 E-10 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY..........................................................................................501 E-11 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY...........................................................................................502 E-12 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY..........................................................................................................503 E-13 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED................................................................................................504 E-14 PRINTER DOES NOT PRINT...............................................................................................................................505 E-15 SOLIDIFYING MATERIAL LEVEL LAMP (LOWER) DOES NOT LIGHT UP............................................................................................508 E-16 SOLIDIFYING MATERIAL LEVEL LAMP (UPPER) DOES NOT LIGHT UP............................................................................................510 E-17 SOIL PRESENCE IS NOT DISPLAYED NORMALLY ON ORDINARY SCREEN...........................................................................................512 E-18 INTEGRATED LIQUID ADDITION VALUE IS NOT DISPLAYED NORMALLY...........................................................................................513 E-19 TRAVEL/WORK/MANUAL MODE DOES NOT CHANGE..............................................................................................................514 E-20 TRAVEL ALARM DOES NOT SOUND..........................................................................................................................516 E-21 WHILE SOIL FEEDER IS NOT LOADED AT ALL, IT SENSES OVERLOAD AND STOPS.................................................................................518 E-22 WHILE SOLIDIFYING MATERIAL FEEDER IS NOT LOADED AT ALL, IT SENSES OVERLOAD AND STOPS.................................................................519 E-23 WHILE HAMMER IS OVERLOADED, SOIL FEEDER DOES NOT STOP................................................................................................520 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.......522 E-25 WHILE ATTACHMENT 2 IS OVERLOADED, ANY WORK EQUIPMENT (OR ONLY FRONT PROCESSOR, WHEN FRONT PROCESSOR IS SELECTED AS ATTACHMENT 2) DOES NOT STOP.......524 E-26 WHILE ATTACHMENT 3 IS OVERLOADED, ANY WORK EQUIPMENT (OR ONLY FRONT PROCESSOR, WHEN FRONT PROCESSOR IS SELECTED AS ATTACHMENT 3) DOES NOT STOP.......526 E-27 WHILE SOIL FEEDER IS OVERLOADED, SOIL FEEDER, SOILDIFYING MATERIAL FEEDER, AND RAKING ROTOR DO NOT STOP..............................................528 E-28 WHILE SOLIDIFYING MATERIAL FEEDER IS OVERLOADED, SOIL FEEDER, SOILDIFYING MATERIAL FEEDER, AND RAKING ROTOR DO NOT STOP..............................529 E-29 WHILE HAMMER ID NOT LOADED AT ALL, SOIL FEEDER, SOLIDIFYING MATERIAL FEEDER, AND RALING ROTOR, HAMMER,AND SOIL CUTTER STOP...........................530 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......532 E-31 WHILE ATTACHMENT 2 IS NOT LOADED AT ALL, WHOLE WORK EQUIPMENT (OR ONLY FRONT PROCESSOR, WHEN FRONT PROCESSOR IS SELECTED AS ATTACHMENT 2) STOPS......534 E-32 WHILE ATTACHMENT 3 IS NOT LOADED AT ALL, WHOLE WORK EQUIPMENT (OR ONLY FRONT PROCESSOR, WHEN FRONT PROCESSOR IS SELECTED AS ATTACHMENT 3) STOPS......536 E-33 WHILE DISCHARGE BELT CONVEYOR IS NOT LOADED AT ALL, WHOLE WORK EQUIPMENT STOPS.......................................................................538 E-34 WHILE DISCHARGE BELT CONVEYOR IS OVERLOADED, ANY WORK EQUIPMENT ODES NOT STOP........................................................................539 E-35 WHILE SOIL CUTTER IS NOT LOADED AT ALL, SOIL FEEDER, SOLIDIFYING MATERIAL FEEDER, RAKING ROTER, HAMMER, AND SOIL CUTTER STOP.........................540 E-36 WHILE SOIL CUTTER IS OVERLOADED, SOIL FEEDER, SOLIDIFYING MATERIAL FEEDER, RAKING ROTER, HAMMER, AND SOIL CUTTER STOP................................542 E-37 WHILE RAKING ROTOR IS NOT LOADED AT ALL, SOIL FEEDER, SOLIDIFYING MATERIAL FEEDER, AND RAKING ROTOR STOP.............................................544 E-38 WHILE RAKING ROTOR IS OVERLOADED,SOIL FEEDER, SOLIDIFYING MATERIAL FEEDER, AND RAKING ROTOR DO NOT STOP..............................................545 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...................................................................................................546 INFORMATION IN TROUBLESHOOTING TABLE......................................................................................................................547 H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT AND TRAVEL IS LOW..............................................................................................548 H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS .......................................................................................................549 H-3 WORK EQUIPMENT AND TRAVEL SYSTEM DO NOT MOVE..........................................................................................................550 H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP...................................................................................................550 H-5 WHILE SOIL BELT CONVEYOR IS NOT LOADED AT ALL, SOIL BELT CONVEYOR, SOLIDIFYING MATERIAL FEEDER, AND RAKING ROTO STOP..................................551 H-6 WHILE SOIL BELT CONVEYOR IS OVERLOADED, SOIL BELT CONVEYED, SOLIDIFYING MATERIAL FEEDER, AND RAKING ROTO DO NOT STOP..................................552 H-7 WHILE SOLIDIFYING MATERIAL FEEDER IS NOT LOADED AT ALL, SOIL BELT CONVEYOR, SOLIDIFYING MATERIAL FEEDER, AND RAKING ROTO STOP.........................553 H-8 WHILE SOLIDIFYING MATERIAL FEEDER IS OVERLOADED, SOIL BELT CONVEYOR, SOLIDIFYING MATERIAL FEEDER, AND RAKING ROTO STOP................................554 H-9 WHILE DISCHARGE BELT CONVEYOR IS NOT LOADED AT ALL, WHOLE WORK EQUIPMENT STOPS........................................................................555 H-10 WHILE DISCHARGE BELT CONVEYOR IS OVERLOADED, ANY WORK EQUIPMENT DOES NOT STOP........................................................................556 H-11 WHILE RATARY HAMMER IS NOT LOADED AT ALL, SOIL BELT CONVEYOR, SOLIDIFYING MATERIAL FEEDER, AND RAKING ROTOR STOP.....................................557 H-12 WHILE RATARY HAMMER IS OVERLOADED, SOIL BELT CONVEYOR, SOLIDIFYING MATERIAL FEEDER, AND RAKING ROTOR DO NOT STOP.....................................558 H-13 WHILE SOIL CUTTER IS NOT LOADED AT ALL, SOIL BELT CONVEYOR, SOLIDIFYING MATERIAL FEEDER, RAKING ROTOR, ROTARY HAMMER, AND SOIL CUTTER STOP...........559 H-14 WHILE SOIL CUTTER IS OVERLOADED, SOIL BELT CONVEYOR, SOLIDIFYING MATERIAL FEEDER, RAKING ROTOR, ROTARY HAMMER, AND SOIL CUTTER DO NOT STOP...........560 H-15 WHILE RAKING ROTO IS NOT LOADED AT ALL, SOIL BELT CONVEYOR, SOLIDIFYING MATERIAL FEEDER, AND RAKING ROTOR STOP.......................................561 H-16 WHILE RAKING ROTO IS VOERLOADED, SOIL BELT CONVEYOR, SOLIDIFYING MATERIAL FEEDER, AND RAKING ROTOR DO NOT STOP.......................................562 H-17 SHILE ATTACHMENT 1 IS NOT LOADED AT ALL, WHOLE WORK EQUIPMENT (OR ONLY FRONT PROCESSOR, WHEN FRONT PROCESSOR IS SELECTED AS ATTACHMENT 1) STOPS......563 H-18 SHILE ATTACHMENT 1 IS OVERLOADED, WHOLE WORK EQUIPMENT (OR ONLY FRONT PROCESSOR, WHEN FRONT PROCESSOR IS SELECTED AS ATTACHMENT 1) DOES NOT STOPS....564 H-19 SHILE ATTACHMENT 2 IS NOT LOADED AT ALL, WHOLE WORK EQUIPMENT (OR ONLY FRONT PROCESSOR, WHEN FRONT PROCESSOR IS SELECTED AS ATTACHMENT 2) STOPS......565 H-20 SHILE ATTACHMENT 2 IS OVERLOADED, WHOLE WORK EQUIPMENT (OR ONLY FRONT PROCESSOR, WHEN FRONT PROCESSOR IS SELECTED AS ATTACHMENT 2) DOES NOT STOPS....566 H-21 SHILE ATTACHMENT 3 IS NOT LOADED AT ALL, WHOLE WORK EQUIPMENT (OR ONLY FRONT PROCESSOR, WHEN FRONT PROCESSOR IS SELECTED AS ATTACHMENT 3) STOPS......567 H-22 SHILE ATTACHMENT 3 IS VOERLOADED, WHOLE WORK EQUIPMENT (OR ONLY FRONT PROCESSOR, WHEN FRONT PROCESSOR IS SELECTED AS ATTACHMENT 3) DOES NOT STOPS....568 H-23 TIME LAG OF WORK EQUIPMENT IS LARGER.................................................................................................................568 H-24 MACHINE DEVIATES DURING TRAVEL.......................................................................................................................569 H-25 TRAVLE SPEED IS LOW..................................................................................................................................570 H-26 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.................................................................................................571 H-27 TRAVEL SPEED DOES NOT VHANGE OR IT IS LOW OR HIGH....................................................................................................572 H-28 TRAVLE MOTOR DOES NOT WORK (ONLY ONE SIDE)...........................................................................................................572 TROUBLESHOOTING OF ENGINE (S-MODE)............................................................................................................................573 METHOD OF USING TROUBLESHOOTING CHATRS....................................................................................................................574 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).............................................................................................578 S-2 ENGINE DOES NOT START.................................................................................................................................580 (1) ENGINE DOES NOT TURN..............................................................................................................................580 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)..........................................................................581 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)........................................................................582 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..................................................................................................583 S-4 ENGINE STOPS DURING OPERATIONS........................................................................................................................584 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).............................................................................................................585 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)..................................................................................................................586 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)........................................................................................................587 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...............................................................................................588 S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................................................589 S-10 FUEL CONSUMPTION IS EXCESSIVE........................................................................................................................590 S-11 OIL IS IN COLLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..............................................................................591 S-12 OIL PRESSURE MONITOR LIGHT UP (DROP IN OIL PRESSURE).................................................................................................592 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL).................................................................................................................593 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....................................................................................................594 S-15 ABNORMAL NOISE IS MADE...............................................................................................................................595 S-16 VIBRATION IS EXCESSIVE...............................................................................................................................596 30 DISASSEMBLY AND ASSEMBLY...........................................................................................................................................597 METHOD OF USING MANUAL............................................................................................................................................598 PRECAUTIONS WHEN CARRYING OUT OPERATION...........................................................................................................................600 SPECIAL TOOL LIST.................................................................................................................................................602 REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY....................................................................................................603 REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY...............................................................................................................608 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY..........................................................................................................609 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL.....................................................................................................................612 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL......................................................................................................................615 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY................................................................................................................617 REMOVAL AND INSTALLATION OF ENGINE AFTERCOLLER....................................................................................................................622 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEBLY..........................................................................................................623 REMOVAL AND INSTALLATION OF REAIATOR ASSEMBLY.....................................................................................................................624 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY....................................................................................................................626 REMOVAL AND INSTALLATION OF HYDRAILIC TANK ASSEMBLY...............................................................................................................627 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY...............................................................................................................629 REMOVAL AND INSTALLATION OF CINTROL VALVE ASSEMBLY................................................................................................................631 DISASSEMBLY OF WORK EQUIPMENT ASSEMBLY............................................................................................................................633 REMOVAL AND INSTALLATION OF SOLIDIFYING MEATERIAL FEEDER CASE ASSEMBLY............................................................................................640 REMOVAL AND INSTALLATION OF RAKING ROTOR..........................................................................................................................642 REMOVAL AND INSTALLATION OF SOIL HOPPER ASSEMBLY..................................................................................................................643 REMOVAL AND INSTALLATION OF SOIL BELT CONVEYOR ASSEMBLY...........................................................................................................644 REMOVAL AND INSTALLATION OF ROTARY HAMMER AND SOIL CUTTER ASSEMBLY................................................................................................645 REMOVAL AND INSTALLATION OF DISCHARGE BELT CONVEYOR ASSEMBLY......................................................................................................646 SPREADING AND INSTALLATION OF TRACK SHOE ASSEMBLY.................................................................................................................647 REMOVAL AND INSTALLATION OF SPROCKET..............................................................................................................................648 REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY.................................................................................................................649 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY.................................................................................................................650 DISASSEMBLY AND ASSEMBLY OF TRACK ROOLER ASSEMBLY.................................................................................................................651 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY...............................................................................................................654 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER........................................................................................................................655 90 OTHERS.............................................................................................................................................................658 SERIAL NO. 1001-1100..............................................................................................................................................659 HYDRAULIC CIRCUIT DIAGRAM (1/2)...............................................................................................................................659 HYDRAULIC CIRCUIT DIAGRAM (2/2)...............................................................................................................................660 SERIAL NO. 1101 AND UP............................................................................................................................................661 HYDRAULIC CIRCUIT DIAGRAM (1/2)...............................................................................................................................661 HYDRAULIC CIRCUIT DIAGRAM (2/2)...............................................................................................................................662 SERIAL NO. 1001-1100..............................................................................................................................................663 ELECTRICAL CIRCUIT DIAGRAM (1/4)..............................................................................................................................663 ELECTRICAL CIRCUIT DIAGRAM (2/4)..............................................................................................................................664 ELECTRICAL CIRCUIT DIAGRAM (3/4)..............................................................................................................................665 ELECTRICAL CIRCUIT DIAGRAM (4/4)..............................................................................................................................666 SERIAL NO. 1101 AND UP............................................................................................................................................667 ELECTRICAL CIRCUIT DIAGRAM (1/4)..............................................................................................................................667 ELECTRICAL CIRCUIT DIAGRAM (2/4)..............................................................................................................................668 ELECTRICAL CIRCUIT DIAGRAM (3/4)..............................................................................................................................669 ELECTRICAL CIRCUIT DIAGRAM (4/4)..............................................................................................................................670
DESCRIPTION:
KOMATSU BZ210-1 SHOP MANUAL SEBM031101 – PDF DOWNLOAD
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 judgements. 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 further 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 understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance 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 component, 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.
S.S 29/12/24
