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KOMATSU HB205-1 HB215LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05393-10 – PDF DOWNLOAD
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KOMATSU HB205-1 HB215LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05393-10 – PDF DOWNLOAD
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KOMATSU HB205-1 HB215LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05393-10 – PDF DOWNLOAD
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KOMATSU HB205-1 HB215LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05393-10 – PDF DOWNLOAD
Language : English
Pages : 1490
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File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HB205-1 HB215LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05393-10 – PDF DOWNLOAD
Cover.................................................................................................................. 1 Notice of revision..................................................................................................... 3 00 Index and foreword.................................................................................................. 11 Table of Contents.................................................................................................. 12 Table of Contents.............................................................................................. 12 Foreword and general information................................................................................... 24 Safety notice.................................................................................................. 24 How to read the shop manual.................................................................................... 29 Explanation of terms for maintenance standard.................................................................. 31 Handling of hydraulic components............................................................................... 33 Method of disconnecting and connecting push-pull type coupler.................................................. 35 Handling of electric equipment................................................................................. 38 How to read electric wire code................................................................................. 48 Precautions when performing work............................................................................... 53 Handling of hybrid devices and high-voltage wirings............................................................ 56 Standard tightening torque table............................................................................... 62 List of Abbreviation........................................................................................... 66 Conversion table............................................................................................... 70 01 Specifications...................................................................................................... 75 Specifications..................................................................................................... 77 Outline of hybrid system....................................................................................... 77 Specification dimension drawing................................................................................ 78 Working range diagram.......................................................................................... 79 Specifications................................................................................................. 80 Weight table................................................................................................... 83 Table of fuel, coolant and lubricants.......................................................................... 85 10 Structure and function.............................................................................................. 87 Engine and cooling system.......................................................................................... 89 Engine related parts........................................................................................... 89 Cooling system................................................................................................. 90 Hybrid relation.................................................................................................... 92 Configuration and safety functions of hybrid system............................................................ 92 Cooling system of hybrid component............................................................................. 96 Motor-generator................................................................................................ 98 Swing electric motor........................................................................................... 99 Electric control unit.......................................................................................... 102 High-voltage wiring (power cable).............................................................................. 103 Water pump..................................................................................................... 104 Power train system................................................................................................. 106 Power train.................................................................................................... 106 Swing circle................................................................................................... 107 Swing machinery................................................................................................ 108 Swing brake.................................................................................................... 110 Final drive.................................................................................................... 112 Undercarriage and frame............................................................................................ 114 Track frame and idler cushion.................................................................................. 114 Hydraulic system................................................................................................... 116 Hydraulic components layout drawing............................................................................ 116 Valve control.................................................................................................. 118 Hydraulic tank................................................................................................. 119 CLSS........................................................................................................... 120 Main pump...................................................................................................... 124 Control valve.................................................................................................. 146 Functions and operation by valve............................................................................... 158 Travel motor................................................................................................... 195 PPC valve...................................................................................................... 205 Solenoid valve................................................................................................. 224 Attachment circuit selector valve.............................................................................. 226 Return oil filter.............................................................................................. 228 Center swivel joint............................................................................................ 230 Accumulator.................................................................................................... 231 Electrical system.................................................................................................. 232 Electrical control system...................................................................................... 232 Machine monitor system......................................................................................... 262 KOMTRAX system................................................................................................. 278 Sensors........................................................................................................ 280 20 Standard value table................................................................................................ 287 Standard value table............................................................................................... 289 Standard value table for engine................................................................................ 289 Standard value table for machine............................................................................... 290 30 Testing and adjusting............................................................................................... 301 Tools for testing, adjusting and troubleshooting................................................................... 304 Tools for testing, adjusting and troubleshooting............................................................... 304 Engine and cooling system.......................................................................................... 309 Testing engine speed........................................................................................... 309 Testing boost pressure......................................................................................... 311 Checking exhaust gas color..................................................................................... 312 Adjusting valve clearance...................................................................................... 313 Testing compression pressure................................................................................... 315 Testing blowby pressure........................................................................................ 318 Testing engine oil pressure.................................................................................... 319 Handling fuel system parts..................................................................................... 320 Releasing remaining pressure from fuel system.................................................................. 320 Testing fuel system pressure................................................................................... 321 Cylinder cut-out test mode operation........................................................................... 323 No injection cranking operation................................................................................ 323 Testing fuel delivery, return rate and leakage................................................................. 324 Bleeding air from fuel circuit................................................................................. 328 Testing fuel circuit for leakage............................................................................... 329 Handling of controller high-voltage circuit.................................................................... 330 Testing and adjusting air conditioner compressor belt tension.................................................. 331 Replacement of fan belt........................................................................................ 332 Undercarriage and frame............................................................................................ 333 Testing swing circle bearing clearance......................................................................... 333 Testing and adjusting track tension............................................................................ 334 Hydraulic system................................................................................................... 337 Testing and adjusting hydraulic oil pressure in work equipment and travel circuits............................. 337 Testing source pressure of control circuit..................................................................... 340 Testing and adjusting oil pressure in pump PC control circuit.................................................. 341 Testing and adjusting oil pressure in pump LS control circuit.................................................. 344 Testing solenoid valve output pressure......................................................................... 348 Testing PPC valve output pressure.............................................................................. 351 Adjusting play of work equipment and swing PPC valves.......................................................... 353 Checking parts which cause hydraulic drift of work equipment................................................... 354 Releasing remaining pressure from hydraulic circuit............................................................ 356 Testing oil leakage............................................................................................ 357 Bleeding air from each part.................................................................................... 359 Cab and its attachments............................................................................................ 361 Checking cab tipping stopper................................................................................... 361 Adjusting mirrors.............................................................................................. 362 Angle adjustment of rear view camera........................................................................... 365 Hybrid relation.................................................................................................... 366 Testing swing holding brake.................................................................................... 366 Cleaning and replacement of oil filter of swing electric motor................................................. 367 Operation check of swing emergency stop switch................................................................. 368 Electrical system.................................................................................................. 370 Special functions of machine monitor........................................................................... 370 Handling voltage circuit of engine controller.................................................................. 432 Precautions related to hybrid machines......................................................................... 433 Preparation work for troubleshooting of electrical system...................................................... 434 Procedure for testing diodes................................................................................... 440 Pm Clinic.......................................................................................................... 441 Pm Clinic service.............................................................................................. 441 40 Troubleshooting..................................................................................................... 447 General information on troubleshooting............................................................................. 456 Points to remember when troubleshooting........................................................................ 456 Sequence of events in troubleshooting.......................................................................... 457 Checks before troubleshooting.................................................................................. 458 Classification and procedures for troubleshooting.............................................................. 487 Failure codes table............................................................................................ 490 Symptom and troubleshooting numbers............................................................................ 498 Information in troubleshooting table........................................................................... 501 Troubleshooting method for open circuit in wiring harness of pressure sensor system............................ 503 Connector list and layout...................................................................................... 505 Connection table for connector pin numbers..................................................................... 516 T- branch box and T- branch adapter table...................................................................... 552 Fuse location table............................................................................................ 555 Troubleshooting by failure code.................................................................................... 557 Failure code [989L00] Engine Controller Lock Caution 1......................................................... 557 Failure code [989M00] Engine Controller Lock Caution 2......................................................... 557 Failure code [989N00] Engine Controller Lock Caution 3......................................................... 558 Failure code [AA10NX] Air Cleaner Clogging..................................................................... 559 Failure code [AB00KE] Charge Voltage Low....................................................................... 560 Failure code [B@BAZG] Eng Oil Press Low........................................................................ 562 Failure code [B@BAZK] Eng Oil Level Low........................................................................ 563 Failure code [B@BCNS] Eng Water Overheat....................................................................... 564 Failure code [B@BCZK] Eng Water Level Low...................................................................... 566 Failure code [B@HANS] Hyd Oil Overheat......................................................................... 568 Failure code [CA111] ECM Critical Internal Failure............................................................. 569 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.......................................................... 569 Failure code [CA122] Chg Air Press Sensor High Error........................................................... 570 Failure code [CA123] Chg Air Press Sensor Low Error............................................................ 572 Failure code [CA131] Throttle Sensor High Error................................................................ 574 Failure code [CA132] Throttle Sensor Low Error................................................................. 576 Failure code [CA144] Coolant Temp Sens High Error.............................................................. 578 Failure code [CA145] Coolant Temp Sens Low Error............................................................... 580 Failure code [CA153] Chg Air Temp Sensor High Error............................................................ 582 Failure code [CA154] Chg Air Temp Sensor Low Error............................................................. 584 Failure code [CA155] Chg Air Temp High Speed Derate............................................................ 586 Failure code [CA187] Sens Supply 2 Volt Low Error.............................................................. 588 Failure code [CA221] Ambient Press Sens High Error............................................................. 590 Failure code [CA222] Ambient Press Sens Low Error.............................................................. 592 Failure code [CA227] Sens Supply 2 Volt High Error............................................................. 594 Failure code [CA234] Eng Overspeed............................................................................. 594 Failure code [CA238] Ne Speed Sens Supply Volt Error........................................................... 595 Failure code [CA271] IMV/PCV1 Short Error...................................................................... 596 Failure code [CA272] IMV/PCV1 Open Error....................................................................... 598 Failure code [CA322] Inj #1(L#1) Open/Short Error.............................................................. 600 Failure code [CA324] Inj #3(L#3) Open/Short Error.............................................................. 602 Failure code [CA331] Inj #2(L#2) Open/Short Error.............................................................. 604 Failure code [CA332] Inj #4(L#4) Open/Short Error.............................................................. 606 Failure code [CA342] Calibration Code Incompatibility.......................................................... 608 Failure code [CA351] Injectors Drive Circuit Error............................................................. 609 Failure code [CA352] Sens Supply 1 Volt Low Error.............................................................. 610 Failure code [CA386] Sens Supply 1 Volt High Error............................................................. 612 Failure code [CA428] Water in Fuel Sensor High Error........................................................... 614 Failure code [CA429] Water in Fuel Sensor Low Error............................................................ 616 Failure code [CA435] Eng Oil Press Sw Error.................................................................... 618 Failure code [CA441] Battery Voltage Low Error................................................................. 620 Failure code [CA442] Battery Voltage High Error................................................................ 622 Failure code [CA449] Rail Press Very High Error................................................................ 623 Failure code [CA451] Rail Press Sensor High Error.............................................................. 624 Failure code [CA452] Rail Press Sensor Low Error............................................................... 626 Failure code [CA488] Chg Air Temp High Torque Derate........................................................... 628 Failure code [CA553] Rail Press High Error..................................................................... 629 Failure code [CA559] Supply Pump Press Low Error 1............................................................. 630 Failure code [CA689] Eng Ne Speed Sensor Error................................................................. 632 Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................................... 634 Failure code [CA757] All Continuous Data Lost Error............................................................ 635 Failure code [CA778] Eng Bkup Speed Sensor Error............................................................... 636 Failure code [CA1633] KOMNET Datalink Timeout Error............................................................ 639 Failure code [CA2185] Throt Sens Sup Volt High Error........................................................... 640 Failure code [CA2186] Throt Sens Sup Volt Low Error............................................................ 641 Failure code [CA2249] Rail Press Very Low Error................................................................ 642 Failure code [CA2311] IMV Solenoid Error....................................................................... 643 Failure code [CA2555] Grid Htr Relay Open Circuit Error........................................................ 644 Failure code [CA2556] Grid Htr Relay Short Circuit Error....................................................... 646 Failure code [D19JKZ] Personal Code Relay Abnormality.......................................................... 648 Failure code [D862KA] GPS Antenna Open Circuit................................................................. 651 Failure code [DA22KK] Pump Solenoid Power Low Error............................................................ 652 Failure code [DA25KP] 5V Sensor1 Power Abnormality............................................................. 654 Failure code [DA26KP] 5V Sensor2 Power Abnormality............................................................. 656 Failure code [DA29KQ] Model Selection Abnormality.............................................................. 658 Failure code [DA2RMC] CAN Discon (Pump Con Detected)........................................................... 660 Failure code [DAF8KB] Camera Power Supply Short Circuit........................................................ 666 Failure code [DAFGMC] GPS Module Error......................................................................... 668 Failure code [DAFRMC] CAN Discon (Monitor Detected)............................................................ 669 Failure code [DGH2KB] Hyd Oil Sensor Short..................................................................... 676 Failure code [DHPAMA] Pump Press Sensor Abnormality............................................................ 678 Failure code [DHPBMA] R Pump Press Sensor Abnormality.......................................................... 680 Failure code [DHS3MA] Arm IN PPC Sen. Abnormality.............................................................. 682 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality................................................. 684 Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality.................................................. 686 Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open or short circuit............................. 688 Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open or short circuit.............................. 690 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality..................................................... 692 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality..................................................... 694 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality................................................. 696 Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit.............................. 698 Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir................................................ 700 Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir................................................... 702 Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor signal abnormality............................ 704 Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor malfunction................................... 705 Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir................................................... 706 Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor signal abnormality............................. 708 Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor malfunction.................................... 709 Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir.................................................. 710 Failure code [DW43KA] Travel Speed Sol Open Circuit............................................................ 712 Failure code [DW43KB] Travel Speed Sol Short Circuit........................................................... 714 Failure code [DW45KA] Swing holding brake solenoid valve open circuit40........................................ 716 Failure code [DW45KB] Swing holding brake solenoid valve short circuit40....................................... 719 Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop.................................... 722 Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir............................................. 724 Failure code [DW4WKA] Cancel Bucket Dump Open Circuit.......................................................... 726 Failure code [DW4WKB] Cancel Bucket Dump Short Circuit......................................................... 728 Failure code [DW91KA] Travel Junction Sol. Disc................................................................ 730 Failure code [DW91KB] Travel Junction Sol. S/C................................................................. 732 Failure code [DWA2KA] Attachment Sol Open Circuit.............................................................. 734 Failure code [DWA2KB] Attachment Sol Short Circuit............................................................. 736 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit.......................................................... 738 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit......................................................... 740 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.............................................................. 742 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit............................................................. 744 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit.............................................................. 746 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit............................................................. 748 Failure code [DXE0KA] LS-EPC Sol Open Circuit.................................................................. 750 Failure code [DXE0KB] LS-EPC Sol Short Circuit................................................................. 752 Failure code [DXE4KA] Service Current EPC Disc................................................................. 754 Failure code [DXE4KB] Service Current EPC S/C.................................................................. 756 Failure code [DXE5KA] Merge-divider Main Sol Open Circuit...................................................... 758 Failure code [DXE5KB] Merge-divider Main Sol Short Circuit..................................................... 760 Failure code [DXE6KA] Merge-divider LS Sol Open Circuit........................................................ 762 Failure code [DXE6KB] Merge-divider LS Sol Short Circuit....................................................... 764 Failure code [DY20KA] Wiper Working Abnormality................................................................ 766 Failure code [DY20MA] Wiper Parking Abnormality................................................................ 768 Failure code [DY2CKA] Washer drive discon...................................................................... 770 Failure code [DY2CKB] Washer drive short....................................................................... 772 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit.......................................................... 774 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit.......................................................... 776 Troubleshooting by failure code [GA****] (code display)............................................................ 778 Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices.... 778 Failure code [GA----] Hybrid devices monitoring items list and check sheet..................................... 805 Failure code [GA00NS] HYB devices overheat..................................................................... 809 Failure code [GA01KA] Power Cable Interlock Open Circuit....................................................... 810 Failure code [GA02KZ] DC Line Open/Short Circuit............................................................... 812 Failure code [GA04KG] Abnormal DC HW Volt. Before Booster...................................................... 813 Failure code [GA05KG] Abnormal DC SW Volt. Before Booster...................................................... 814 Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster...................................................... 815 Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster................................................ 818 Failure code [GA08KG] Abnormal. DC HW Volt. After Booster...................................................... 819 Failure code [GA09KG] Abnormal. DC SW Volt. After Booster...................................................... 820 Failure code [GA09KP] Low DC SW Output Volt. After Booster..................................................... 821 Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster................................................. 822 Failure code [GA0BKZ] AC Line Open/Short Circuit............................................................... 823 Failure code [GA11KK] HYB cont. low supply voltage............................................................. 824 Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure............................................................ 826 Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON....................................................... 827 Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF...................................................... 828 Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure..................................................... 830 Failure code [GA14KR] HYB Control. KOMNET Comm. Failure........................................................ 832 Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir................................................. 833 Failure code [GA17KR] Gen. Mot. Drv. Communication Failure..................................................... 833 Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit.................................................... 834 Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit..................................................... 834 Failure code [GA17MB] Gen. Mot. Drv. Function Degraded......................................................... 835 Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure.................................................... 835 Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt..................................................... 836 Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure.................................................. 836 Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.................................................. 837 Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction....................................................... 837 Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation................................................. 838 Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled.................................................... 838 Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction.................................................. 839 Failure code [GA1FKR] Swing Mot. Drv. Communication Failure.................................................... 839 Failure code [GA1FMA] Abnormal Swing Motor Driver.............................................................. 840 Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU.................................................. 840 Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure.................................................. 841 Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal................................................... 841 Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction..................................................... 842 Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded.................................................. 842 Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op........................................................ 843 Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled................................................... 843 Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir................................................. 844 Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir................................................. 844 Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir................................................. 845 Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir.................................................. 845 Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir.................................................... 846 Failure code [GA1NNS] Swing Motor Driver IGBT Overheat......................................................... 847 Failure code [GA1SFS] Contactor Locked......................................................................... 850 Failure code [GA1SMC] Contactor Failure........................................................................ 850 Failure code [GA1TKP] Capacitor Low Output Voltage............................................................. 851 Failure code [GA1TNS] Capacitor Overheat....................................................................... 854 Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir..................................................... 856 Failure code [GA1VFS] Capacitor Contactor Locked............................................................... 858 Failure code [GA1VMC] Capacitor Contactor Failure.............................................................. 860 Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ.................................................. 861 Failure code [GA1YNS] Booster Inductor Overheat................................................................ 862 Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ.................................................. 863 Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat........................................................ 864 Failure code [GA21KB] Booster IGBT Short Circuit............................................................... 865 Failure code [GA22NS] Booster IGBT Junction Overheat........................................................... 867 Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sens.0 Opn/Short Cir................................................. 868 Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir................................................. 868 Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality...................................................... 869 Failure code [GA25NS] Gen. Motor Driver IGBT0 overheat......................................................... 870 Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality...................................................... 871 Failure code [GA26NS] Gen. Motor Driver IGBT1 overheat......................................................... 872 Failure code [GA27KZ] DC before boosting sensor open or short circuit40-409.................................... 873 Failure code [GA28KZ] DC after boosting sensor open or short circuit........................................... 873 Failure code [GA60MC] Generator Motor Failure.................................................................. 874 Failure code [GA60MD] Gen. Mot. Defective Movement............................................................. 875 Failure code [GA60N1] Generator Motor Overrun.................................................................. 876 Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir.................................................... 878 Failure code [GA61NS] Generator Motor Temp. Sensor Overheat.................................................... 880 Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir................................................. 881 Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir.................................................. 882 Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction.................................................. 883 Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir................................................. 883 Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir.................................................. 884 Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction.................................................. 884 Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir................................................. 885 Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir.................................................. 886 Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction.................................................. 886 Failure code [GA70KB] HYB Swing Motor Short Circuit............................................................ 887 Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion.................................................. 887 Failure code [GA70NS] HYB Swing Motor Overheat................................................................. 888 Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir.................................................. 890 Failure code [GA72MA] HYB Swing Motor Resolver Malfunction..................................................... 892 Failure code [GA72MC] HYB Swing Motor Resolver Defect Op....................................................... 894 Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ.................................................... 894 Failure code [GAA100] Swing emergency stop switch operated..................................................... 895 Failure code [GAA2KB] Swing Brake sol. Supply Line short cir................................................... 896 Troubleshooting of electrical system (E-mode)...................................................................... 898 E-1 Engine does not start (Engine does not crank).............................................................. 898 E-2 Preheater does not operate................................................................................. 904 E-3 When starting switch is turned to ON position, machine monitor displays nothing............................ 909 E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up......... 912 E-5 Precaution monitor lights up while engine is running....................................................... 913 E-6 Emergency stop monitor lights up while engine is running................................................... 915 E-7 Fuel level gauge does not indicate properly................................................................ 916 E-8 Engine coolant temperature gauge does not indicate properly................................................ 918 E-9 Hydraulic oil temperature gauge does not indicate properly................................................. 920 E-10 HYB system temperature gauge does not indicate properly................................................... 922 E-11 Displays on machine monitor are different from those for actual machine................................... 924 E-12 Machine monitor does not display some items............................................................... 924 E-13 Function switch does not work............................................................................. 924 E-14 Automatic warm-up system does not operate (in cold season)................................................ 925 E-15 Auto-decelerator does not operate normally................................................................ 926 E-16 Working mode does not change.............................................................................. 927 E-17 Travel speed does not change.............................................................................. 928 E-18 Alarm buzzer does not stop sounding....................................................................... 929 E-19 When starting switch is at OFF position, service meter is not displayed................................... 929 E-20 Machine monitor cannot be set in service mode............................................................. 929 E-21 All of work equipment, swing, and travel mechanism do not move or are not locked.......................... 930 E-22 Swing holding brake does not operate properly............................................................. 933 E-23 One-touch power max. function does not operate............................................................ 936 E-24 Travel alarm does not sound or does not stop sounding..................................................... 940 E-25 Horn does not sound or does not stop sounding............................................................. 942 E-26 Windshield wiper and window washer do not operate......................................................... 944 E-27 "BOOM LOWER" indicator is not displayed properly with monitoring function................................. 946 E-28 "ARM OUT" indicator is not displayed properly with monitoring function.................................... 948 E-29 "ARM IN" indicator is not displayed properly with monitoring function..................................... 950 E-30 "BOOM RAISE" indicator is not displayed properly with monitoring function................................. 950 E-31 "BUCKET CURL" indicator is not displayed properly with monitoring function................................ 950 E-32 "BUCKET DUMP" indicator is not displayed properly with monitoring function................................ 951 E-33 "SWING" indicator is not displayed properly with monitoring function...................................... 951 E-34 "TRAVEL" indicator is not displayed properly with monitoring function..................................... 952 E-35 "TRAVEL STEERING" indicator is not displayed properly with monitoring function............................ 954 E-36 "SERVICE" indicator is not displayed properly with monitoring function.................................... 956 E-37 Attachment hydraulic circuit cannot be changed............................................................ 958 E-38 KOMTRAX system does not operate properly.................................................................. 959 Troubleshooting of hydraulic and mechanical system (H-mode)........................................................ 960 System diagram of hydraulic and mechanical system.............................................................. 960 Information in troubleshooting table (H mode).................................................................. 962 H-1 Speed or power of all work equipment and travel is low..................................................... 963 H-2 Engine speed lowers significantly or engine stalls......................................................... 965 H-3 All work equipment and travel systems do not work.......................................................... 966 H-4 Unusual noise comes out from around hydraulic pump......................................................... 966 H-5 Auto-decelerator does not operate.......................................................................... 967 H-6 Fine control performance or response is low................................................................ 967 H-7 Speed or power of boom is low.............................................................................. 968 H-8 Speed or power of arm is low............................................................................... 969 H-9 Speed or power of bucket is low............................................................................ 970 H-10 Work equipment does not move in its single operation...................................................... 970 H-11 Hydraulic drift of work equipment is large................................................................ 971 H-12 Time lag of work equipment is large....................................................................... 973 H-13 When part of work equipment is relieved singly, other parts of work equipment move........................ 973 H-14 Power maximizing function does not work................................................................... 974 H-15 In combined operation of work equipment, speed of part loaded more is low................................. 974 H-16 When machine swings and travels simultaneously, travel speed is low....................................... 974 H-17 Machine deviates during travel............................................................................ 975 H-18 Travel speed is low....................................................................................... 976 H-19 Machine is not steered well or sterring power is low...................................................... 977 H-20 Travel speed does not shift or travel speed is low or high................................................ 978 H-21 Travel system does not work (only one side)............................................................... 979 H-22 Upper structure does not swing............................................................................ 980 H-23 Swing acceleration or swing speed of upper structure is low............................................... 980 H-24 Upper structure overruns remarkably when it stops swinging................................................ 980 H-25 Large shock is made when upper structure stops swinging................................................... 981 H-26 Large sound is made when upper structure stops swinging................................................... 981 H-27 Upper structure lowers largely by its own weight.......................................................... 981 Troubleshooting of engine (S-mode)................................................................................. 982 Method of using troubleshooting chart.......................................................................... 982 S-1 Engine startability is poor................................................................................ 986 S-2 Engine does not start...................................................................................... 987 S-3 Engine does not pick up smoothly........................................................................... 990 S-4 Engine stops during operations............................................................................. 991 S-5 Engine does not rotate smoothly............................................................................ 992 S-6 Engine lacks output (or lacks power)....................................................................... 993 S-7 Exhaust gas is black (incomplete combustion)............................................................... 994 S-8 Oil consumption is excessive (or exhaust gas is blue)...................................................... 995 S-9 Oil becomes contaminated quickly........................................................................... 996 S-10 Fuel consumption is excessive............................................................................. 997 S-11 Oil is in coolant (or coolant spurts or coolant level goes down).......................................... 998 S-12 Oil pressure drops........................................................................................ 999 S-13 Oil level rises (coolant or fuel in oil)..................................................................1000 S-14 Coolant temperature rises too high (overheating)..........................................................1001 S-15 Unusual noise is made.....................................................................................1002 S-16 Vibration is excessive....................................................................................1003 Troubleshooting hybrid system (Y-mode).............................................................................1004 Precautions related to hybrid machine..........................................................................1004 Y-1 Hybrid monitor does not go out.............................................................................1006 Y-2 Upper structure does not swing.............................................................................1008 Y-3 Swing acceleration or swing speed is low...................................................................1010 Y-4 Upper structure overruns largely when stop swinging........................................................1011 Y-5 Large shock is made when upper structure stops swinging....................................................1012 Y-6 Large unusual noise is made when upper structure stops swinging............................................1012 Y-7 Swing drift on a slope is large............................................................................1013 Y-8 Electric swing motor temperature increases abnormally......................................................1014 Y-9 Motor-generator temperature increases abnormally...........................................................1016 Y-10 Inverter overheats........................................................................................1017 Y-11 Capacitor overheats.......................................................................................1018 50 Disassembly and assembly............................................................................................1019 General information on disassembly and assembly....................................................................1022 How to read Disassembly and Assembly...........................................................................1022 Precautions related to hybrid machine..........................................................................1024 Coating materials list.........................................................................................1025 Special tools list.............................................................................................1028 Sketches of special tools......................................................................................1033 Engine and cooling system..........................................................................................1038 Removal and installation of fuel supply pump assembly..........................................................1038 Removal and installation of fuel injector assembly.............................................................1043 Removal and installation of cylinder head assembly.............................................................1050 Removal and installation of radiator assembly..................................................................1073 Removal and installation of hydraulic oil cooler assembly......................................................1075 Removal and installation of aftercooler assembly...............................................................1077 Removal and installation of engine front seal..................................................................1080 Removal and installation of engine rear seal...................................................................1082 Removal and installation of fuel cooler assembly...............................................................1086 Removal (and installation) of engine, motor generator, and main pump assembly..................................1088 Removal and installation of fuel tank assembly.................................................................1104 Hybrid.............................................................................................................1107 Draining adding coolant and bleeding air for hybrid system.....................................................1107 Removal and installation of hybrid radiator assembly...........................................................1111 Removal and installation of water pump assembly for hybrid system..............................................1114 Removal and installation of inverter assembly..................................................................1117 Removal and installation of inverter and capacitor assembly....................................................1121 Draining and adding generator lubricating oil..................................................................1126 Removal and installation of tandem pump assembly...............................................................1128 Removal and installation of motor-generator assembly...........................................................1131 Removal and installation of motor-generator housing assembly...................................................1139 Removal and installation of swing electric motor assembly......................................................1150 Power train........................................................................................................1163 Removal and installation of final drive assembly...............................................................1163 Disassembly and assembly of final drive........................................................................1165 Removal and installation of sprocket...........................................................................1174 Removal and installation of swing motor and swing machinery assembly50.........................................1175 Disassembly and assembly of swing machinery assembly...........................................................1185 Removal and installation of swing circle assembly..............................................................1200 Undercarriage and frame............................................................................................1201 Separation and connection of track shoe assembly...............................................................1201 Disassembly and assembly of idler..............................................................................1204 Disassembly and assembly of idler cushion assembly.............................................................1207 Disassembly and assembly of track roller.......................................................................1209 Disassembly and assembly of carrier roller.....................................................................1211 Removal and installation of revolving frame assembly...........................................................1215 Removal and installation of counterweight assembly.............................................................1217 Hydraulic system...................................................................................................1219 Removal and installation of center swivel joint assembly.......................................................1219 Disassembly and assembly of center swivel joint assembly.......................................................1221 Removal and installation of hydraulic tank assembly............................................................1223 Removal and installation of main pump assembly.................................................................1228 Removal and installation of main pump input shaft oil seal.....................................................1233 Removal and installation of control valve assembly.............................................................1234 Disassembly and assembly of control valve......................................................................1239 Disassembly and assembly of work equipment PPC valve assembly..................................................1243 Disassembly and assembly of travel PPC valve...................................................................1245 Work equipment.....................................................................................................1248 Removal and installation of work equipment assembly............................................................1248 Disassembly and assembly of work equipment cylinder assembly...................................................1251 Cab and its attachments............................................................................................1257 Removal and installation of operator's cab assembly............................................................1257 Removal and installation of operator's cab glass (adhered window glass)........................................1261 Removal and installation of front window assembly..............................................................1271 Removal and installation of floor frame assembly...............................................................1278 Removal and installation of air conditioner unit assembly......................................................1283 Removal and installation of work equipment control lever assembly..............................................1286 Electrical system..................................................................................................1300 Removal and installation of engine controller assembly.........................................................1300 Removal and installation of pump controller assembly...........................................................1302 Removal and installation of machine monitor assembly...........................................................1305 Removal and installation of KOMTRAX terminal assembly..........................................................1307 60 Maintenance standard................................................................................................1309 Engine and cooling system..........................................................................................1312 Engine mount...................................................................................................1312 Cooling system.................................................................................................1313 Power train........................................................................................................1315 Swing circle...................................................................................................1315 Swing machinery................................................................................................1316 Swing brake....................................................................................................1318 Final drive....................................................................................................1320 Sprocket.......................................................................................................1322 Undercarriage and frame............................................................................................1324 Track frame and idler cushion..................................................................................1324 Idler..........................................................................................................1326 Track roller...................................................................................................1328 Carrier roller.................................................................................................1329 Track shoe.....................................................................................................1330 Hydraulic system...................................................................................................1336 Main pump......................................................................................................1336 Control valve..................................................................................................1340 Travel motor...................................................................................................1349 Solenoid valve.................................................................................................1362 Attachment circuit selector valve..............................................................................1363 Center swivel joint............................................................................................1364 Work equipment.....................................................................................................1366 Work equipment.................................................................................................1366 Dimension of work equipment....................................................................................1368 Work equipment cylinder........................................................................................1372 80 Appendix............................................................................................................1375 Air conditioner....................................................................................................1377 Precautions for refrigerant....................................................................................1377 Air conditioner component......................................................................................1378 Configuration and function of refrigeration cycle..............................................................1380 Outline of refrigeration cycle.................................................................................1381 Air conditioner unit...........................................................................................1384 Air conditioner controller.....................................................................................1389 Compressor.....................................................................................................1390 Condenser and Modulator........................................................................................1391 Procedure for testing and troubleshooting......................................................................1392 Circuit diagram and arrangement of connector pins..............................................................1394 System diagram.................................................................................................1396 Detail of air conditioner unit.................................................................................1398 Parts and connectors layout....................................................................................1400 Testing air leakage (duct).....................................................................................1404 Testing with self-diagnosis function...........................................................................1405 Testing temperature control....................................................................................1408 Testing vent (mode) changeover.................................................................................1410 Testing FRESH/RECIRC air changeover............................................................................1413 Testing inner sensor...........................................................................................1415 Testing evaporator temperature sensor..........................................................................1416 Testing sunlight sensor........................................................................................1418 Testing (dual) pressure switch for refrigerant.................................................................1419 Testing relays.................................................................................................1421 Troubleshooting chart 1........................................................................................1422 Troubleshooting chart 2........................................................................................1424 Information in troubleshooting table...........................................................................1426 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)...............1427 Troubleshooting for compressor and refrigerant system (Air is not cooled)......................................1431 Troubleshooting for blower motor system (No air comes out or air flow is abnormal).............................1434 Troubleshooting for temperature control........................................................................1437 Troubleshooting for vent (mode) changeover.....................................................................1440 Troubleshooting for FRESH/RECIRC air changeover................................................................1442 Troubleshooting for temperature sensor system..................................................................1444 Troubleshooting with gauge pressure............................................................................1445 Connection of service tool.....................................................................................1448 Precautions for disconnecting and connecting air conditioner piping............................................1450 Handling of compressor oil.....................................................................................1452 Desiccant replacement procedure................................................................................1454 90 Diagrams and drawings...............................................................................................1457 Hydraulic circuit diagram..........................................................................................1459 Symbols used in hydraulic circuit diagrams.....................................................................1459 Hydraulic circuit diagram......................................................................................1463 Electrical circuit diagram.........................................................................................1467 Symbols used in electric circuit diagrams......................................................................1467 Electrical circuit diagram ....................................................................................1471 Index..................................................................................................................1483
DESCRIPTION:
KOMATSU HB205-1 HB215LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05393-10 – PDF DOWNLOAD
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are explained in “Standard value table”.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
A. Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
B. Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
S.S 30/12/24
