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KOMATSU HYBRID HB205-1M0 HB215LC-1M0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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KOMATSU HYBRID HB205-1M0 HB215LC-1M0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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KOMATSU HYBRID HB205-1M0 HB215LC-1M0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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KOMATSU HYBRID HB205-1M0 HB215LC-1M0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 1492
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HYBRID HB205-1M0 HB215LC-1M0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Cover...................................................................................................................... 1 00 Index and foreword.................................................................................................. 3 Table of Contents.................................................................................................. 4 Foreword and general information................................................................................... 16 Safety notice.................................................................................................. 16 How to read the shop manual.................................................................................... 23 Explanation of terms for maintenance standard.................................................................. 25 Handling equipment of fuel system devices...................................................................... 27 Handling of hydraulic components............................................................................... 28 Method of disconnecting and connecting push-pull type coupler.................................................. 30 Handling of electric equipment................................................................................. 33 How to read electric wire code................................................................................. 43 Precautions when performing work............................................................................... 48 Handling of hybrid devices and high-voltage wirings............................................................ 51 Standard tightening torque table............................................................................... 59 List of Abbreviation........................................................................................... 63 Conversion table............................................................................................... 67 01 Specifications...................................................................................................... 73 Contents........................................................................................................... 74 Specifications..................................................................................................... 75 Outline of hybrid system....................................................................................... 75 Specification dimension drawing................................................................................ 76 Working range diagram.......................................................................................... 77 Specifications................................................................................................. 78 Weight table................................................................................................... 81 Table of fuel, coolant and lubricants.......................................................................... 83 10 Structure and function.............................................................................................. 85 Contents........................................................................................................... 86 Engine and cooling system.......................................................................................... 87 Engine related parts........................................................................................... 87 Cooling system................................................................................................. 88 Hybrid relation.................................................................................................... 90 Configuration and safety functions of hybrid system............................................................ 90 Cooling system of hybrid component............................................................................. 94 Motor-generator................................................................................................ 96 Swing electric motor........................................................................................... 97 Electric control unit.......................................................................................... 98 High-voltage wiring (power cable).............................................................................. 99 Water pump..................................................................................................... 100 Power train system................................................................................................. 102 Power train.................................................................................................... 102 Swing circle................................................................................................... 103 Swing machinery and swing brake................................................................................ 104 Final drive.................................................................................................... 106 Undercarriage and frame............................................................................................ 108 Track frame and idler cushion.................................................................................. 108 Hydraulic system................................................................................................... 110 Hydraulic components layout drawing............................................................................ 110 Valve control.................................................................................................. 112 Hydraulic tank................................................................................................. 113 CLSS........................................................................................................... 114 Main pump...................................................................................................... 118 Control valve.................................................................................................. 140 Functions and operation by valve............................................................................... 152 Travel motor................................................................................................... 191 PPC valve...................................................................................................... 201 Solenoid valve................................................................................................. 220 Attachment circuit selector valve.............................................................................. 222 Center swivel joint............................................................................................ 224 Accumulator.................................................................................................... 225 Work equipment..................................................................................................... 226 Work equipment................................................................................................. 226 Shims for work equipment....................................................................................... 227 Shims to adjust play of bucket................................................................................. 228 Electrical system.................................................................................................. 230 Electrical control system...................................................................................... 230 Machine monitor system......................................................................................... 259 KOMTRAX system................................................................................................. 282 Sensors........................................................................................................ 288 20 Standard value table................................................................................................ 295 Contents........................................................................................................... 296 Standard service value table....................................................................................... 297 Standard value table for engine................................................................................ 297 Standard value table for machine............................................................................... 298 30 Testing and adjusting............................................................................................... 311 Contents........................................................................................................... 312 Tools for testing, adjusting and troubleshooting................................................................... 314 Tools for testing, adjusting, and troubleshooting.............................................................. 314 Sketch of tools for testing and adjusting...................................................................... 317 Engine and cooling system.......................................................................................... 319 Testing and adjusting engine speed............................................................................. 319 Testing boost pressure......................................................................................... 321 Testing exhaust gas color...................................................................................... 322 Adjusting valve clearance...................................................................................... 323 Testing compression pressure................................................................................... 325 Testing blowby pressure........................................................................................ 328 Testing engine oil pressure.................................................................................... 329 Handling equipment of fuel system devices...................................................................... 330 Releasing remaining pressure from fuel system.................................................................. 330 Testing fuel pressure.......................................................................................... 331 Testing fuel discharge, return and leakage..................................................................... 334 Bleeding air from fuel circuit................................................................................. 338 Testing fuel circuit for leakage............................................................................... 339 Handling cylinder cutout mode operation........................................................................ 340 Handling No-injection cranking operation....................................................................... 340 Handling engine controller high voltage circuit................................................................ 341 Testing and adjusting air conditioner compressor belt tension.................................................. 342 Replacing fan belt............................................................................................. 343 Swing circle and undercarriage..................................................................................... 344 Testing swing circle bearing clearance......................................................................... 344 Testing and adjusting track tension............................................................................ 345 Hydraulic system................................................................................................... 347 Testing source pressure of control circuit..................................................................... 347 Testing and adjusting oil pressure in work equipment and travel circuits....................................... 348 Testing and adjusting oil pressure in pump PC control circuit.................................................. 351 Testing and adjusting oil pressure in pump LS control circuit.................................................. 354 Testing output pressure of solenoid valve...................................................................... 359 Testing PPC valve output pressure.............................................................................. 362 Adjusting play of work equipment and swing PPC valves.......................................................... 364 Isolating parts causing hydraulic drift in work equipment...................................................... 365 Releasing remaining pressure from hydraulic system............................................................. 367 Testing oil leakage............................................................................................ 368 Bleeding air from each part.................................................................................... 370 Exterior parts..................................................................................................... 372 Testing cab tipping stopper.................................................................................... 372 Adjusting mirror............................................................................................... 373 Angle adjustment of rear view camera........................................................................... 376 Hybrid............................................................................................................. 377 Testing swing parking brake.................................................................................... 377 Cleaning and replacement of oil filter in electric swing motor................................................. 379 Operation check of swing emergency stop switch................................................................. 380 Testing water pressure of hybrid coolant....................................................................... 383 Precautions related to hybrid devices.......................................................................... 385 Electrical system.................................................................................................. 386 Special functions of machine monitor........................................................................... 386 Handling voltage circuit of engine controller.................................................................. 448 Preparation for troubleshooting of electrical system........................................................... 449 Testing diodes................................................................................................. 454 Pm Clinic.......................................................................................................... 455 Pm Clinic service.............................................................................................. 455 40 Troubleshooting..................................................................................................... 463 Contents........................................................................................................... 464 General information on troubleshooting............................................................................. 471 Points to remember when troubleshooting........................................................................ 471 Sequence of events in troubleshooting.......................................................................... 473 Checks before troubleshooting.................................................................................. 475 Classification and procedures for troubleshooting.............................................................. 504 Failure codes table............................................................................................ 507 Symptom and troubleshooting numbers............................................................................ 517 Information in troubleshooting table........................................................................... 519 Troubleshooting method for open circuit in wiring harness of pressure sensor system............................ 521 Connector list and layout...................................................................................... 523 Connection table for connector pin numbers..................................................................... 534 T- branch box and T- branch adapter table...................................................................... 570 Fuse location table............................................................................................ 573 Troubleshooting by failure code.................................................................................... 575 Failure code [879AKA] A/C Inner Sensor Open Circuit............................................................ 575 Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 575 Failure code [879BKA] A/C Outer Sensor Open Circuit............................................................ 575 Failure code [879BKB] A/C Outer Sensor Short Circuit........................................................... 575 Failure code [879CKA] Ventilating Sensor Open Circuit.......................................................... 575 Failure code [879CKB] Ventilating Sensor Short Circuit......................................................... 576 Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit.................................................... 576 Failure code [879EMC] Ventilation Damper Abnormality........................................................... 576 Failure code [879FMC] Air Mix Damper Abnormality............................................................... 576 Failure code [879GKX] Refrigerant Abnormality.................................................................. 576 Failure code [989L00] Engine Controller Lock Caution 1......................................................... 577 Failure code [989M00] Engine Controller Lock Caution 2......................................................... 578 Failure code [AA10NX] Air Cleaner Clogging..................................................................... 580 Failure code [AB00KE] Charge Voltage Low....................................................................... 582 Failure code [B@BAZG] Eng Oil Press Low........................................................................ 584 Failure code [B@BAZK] Engine Oil Level Low..................................................................... 585 Failure code [B@BCNS] Eng Water Overheat....................................................................... 586 Failure code [B@BCZK] Radiator Coolant Level Low............................................................... 588 Failure code [B@HANS] Hyd Oil Overheat......................................................................... 590 Failure code [CA111] ECM Critical Internal Failure............................................................. 591 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.......................................................... 591 Failure code [CA122] Chg Air Press Sensor High Error........................................................... 592 Failure code [CA123] Chg Air Press Sensor Low Error............................................................ 594 Failure code [CA131] Throttle Sensor High Error................................................................ 596 Failure code [CA132] Throttle Sensor Low Error................................................................. 598 Failure code [CA144] Coolant Temp Sens High Error.............................................................. 600 Failure code [CA145] Coolant Temp Sens Low Error............................................................... 602 Failure code [CA153] Chg Air Temp Sensor High Error............................................................ 604 Failure code [CA154] Chg Air Temp Sensor Low Error............................................................. 606 Failure code [CA155] Chg Air Temp High Speed Derate............................................................ 608 Failure code [CA187] Sensor Supply 2 Volt Low Error............................................................ 610 Failure code [CA221] Ambient Press Sensor High Error........................................................... 612 Failure code [CA222] Ambient Press Sensor Low Error............................................................ 614 Failure code [CA227] Sensor 2 Supply Volt High Error........................................................... 616 Failure code [CA234] Eng Overspeed............................................................................. 616 Failure code [CA238] Ne Speed Sensor Supply Volt Error......................................................... 617 Failure code [CA271] IMV/PCV1 Short Error...................................................................... 618 Failure code [CA272] IMV/PCV1 Open Error....................................................................... 620 Failure code [CA322] Inj #1(L#1) Open/Short Error.............................................................. 622 Failure code [CA324] Inj #3(L#3) Open/Short Error.............................................................. 624 Failure code [CA331] Inj #2(L#2) Open/Short Error.............................................................. 626 Failure code [CA332] Inj #4(L#4) Open/Short Error.............................................................. 628 Failure code [CA342] Calibration Code Incompatibility.......................................................... 630 Failure code [CA351] Injectors Drive Circuit Error............................................................. 631 Failure code [CA352] Sensor 1 Supply Volt Low Error............................................................ 632 Failure code [CA386] Sensor 1 Supply Volt High Error........................................................... 634 Failure code [CA428] Water in Fuel Sensor High Error........................................................... 636 Failure code [CA429] Water in Fuel Sensor Low Error............................................................ 640 Failure code [CA435] Eng Oil Press Sw Error.................................................................... 644 Failure code [CA441] Battery Voltage Low Error................................................................. 646 Failure code [CA442] Battery Voltage High Error................................................................ 648 Failure code [CA449] Rail Press Very High Error................................................................ 649 Failure code [CA451] Rail Press Sensor High Error.............................................................. 650 Failure code [CA452] Rail Press Sensor Low Error............................................................... 652 Failure code [CA488] Chg Air Temp High Torque Derate........................................................... 654 Failure code [CA553] Rail Press High Error..................................................................... 655 Failure code [CA559] Rail Press Low Error...................................................................... 656 Failure code [CA689] Eng Ne Speed Sensor Error................................................................. 658 Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................................... 660 Failure code [CA757] All Continuous Data Lost Error............................................................ 661 Failure code [CA778] Eng Bkup Speed Sensor Error............................................................... 662 Failure code [CA2185] Throt Sensor Sup Volt High Error......................................................... 666 Failure code [CA2186] Throt Sensor Sup Volt Low Error.......................................................... 667 Failure code [CA2249] Rail Press Very Low Error................................................................ 668 Failure code [CA2311] lMV Solenoid Error....................................................................... 669 Failure code [CA2555] Grid Htr Relay Open Circuit Error........................................................ 670 Failure code [CA2556] Grid Htr Relay Short Circuit Error....................................................... 672 Failure code [D110KB] Battery Relay Drive Short Circuit........................................................ 674 Failure code [D19JKZ] Personal Code Relay Abnormality.......................................................... 676 Failure code [D811MC] KOMTRAX Error............................................................................ 678 Failure code [D862KA] GPS Antenna Open Circuit................................................................. 679 Failure code [D8AQKR] CAN2 Discon (KOMTRAX).................................................................... 680 Failure code [DA22KK] Pump Solenoid Power Low Error............................................................ 682 Failure code [DA25KP] 5V Sensor1 Power Abnormality............................................................. 684 Failure code [DA26KP] 5V Sensor 2 Power Abnormality............................................................ 686 Failure code [DA29KQ] Model Selection Abnormality.............................................................. 688 Failure code [DA2QKR] CAN2 Discon (Pump Con)................................................................... 690 Failure code [DAF8KB] Camera Power Supply Short Circuit........................................................ 692 Failure code [DAF9KQ] Model Selection Abnormality.............................................................. 694 Failure code [DAFGMC] GPS Module Error......................................................................... 695 Failure code [DAZ9KQ] A/C Model Selection Abnormality.......................................................... 696 Failure code [DAZQKR] CAN2 Discon (Aircon ECU)................................................................. 697 Failure code [DB2QKR] CAN2 Discon (Engine Con)................................................................. 698 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit............................................................. 702 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit..................................................... 704 Failure code [DHPAMA] F Pump Press Sensor Abnormality.......................................................... 706 Failure code [DHPBMA] R Pump Press Sensor Abnormality.......................................................... 708 Failure code [DHS3MA] Arm IN PPC Sen. Abnormality.............................................................. 710 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality................................................. 712 Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality.................................................. 714 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality.................................................. 716 Failure code [DHSAKZ] Swing RH PPC Press Sensor Abnormality.................................................... 718 Failure code [DHSBKZ] Swing LH PPC Press Sensor Abnormality.................................................... 720 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality.................................................... 722 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality................................................. 724 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality................................................. 726 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality................................................. 728 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality................................................. 730 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality................................................. 732 Failure code [DHV3KZ] HYB Arm IN PPC Pr. Sen. Opn/Short Cir.................................................... 734 Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir................................................... 737 Failure code [DHVAL8] HYB Swing-R PPC Pr. Sen. Signal Mismatch................................................. 740 Failure code [DHVAMA] HYB Swing-R PPC Sensor Malfunction....................................................... 741 Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir................................................... 742 Failure code [DHVBL8] HYB Swing-L PPC Pr. Sen. Signal Mismatch................................................. 744 Failure code [DHVBMA] HYB Swing-L PPC Sensor Malfunction....................................................... 745 Failure code [DHVCKZ] HYB Arm OUT PPC Pr. Sen. Opn/short Cir................................................... 746 Failure code [DHX1MA] Overload Sensor Abnormality.............................................................. 748 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality.................................................. 750 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality.................................................. 752 Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 754 Failure code [DW43KA] Travel Speed Sol Open Circuit............................................................ 756 Failure code [DW43KB] Travel Speed Sol Short Circuit........................................................... 758 Failure code [DW45KA] Swing Brake Sol Open Circuit............................................................. 760 Failure code [DW45KB] Swing Brake Sol Short Circuit............................................................ 763 Failure code [DW45KK] Swing Brake Sol. Valve Low Sup. Voltage.................................................. 766 Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir..................................................... 768 Failure code [DW91KA] Travel Junction Sol. Disc................................................................ 770 Failure code [DW91KB] Travel Junction Sol. S/C................................................................. 772 Failure code [DWA2KA] Attachment Sol Open Circuit.............................................................. 774 Failure code [DWA2KB] Attachment Sol Short Circuit............................................................. 776 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit.......................................................... 778 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit......................................................... 780 Failure code [DWK2KA] Variable Back Press Sol Open Circuit..................................................... 782 Failure code [DWK2KB] Variable Back Press Sol Short Circuit.................................................... 784 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.............................................................. 786 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit............................................................. 788 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit.............................................................. 790 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit............................................................. 792 Failure code [DXE0KA] LS-EPC Sol Open Circuit.................................................................. 794 Failure code [DXE0KB] LS-EPC Sol Short Circuit................................................................. 796 Failure code [DXE4KA] Service Current EPC Disc................................................................. 798 Failure code [DXE4KB] Service Current EPC S/C.................................................................. 800 Failure code [DXE5KA] Merge-divider Main Sol Open Circuit...................................................... 802 Failure code [DXE5KB] Merge-divider Main Sol Short Circuit..................................................... 804 Failure code [DXE6KA] Merge-divider LS Sol Open Circuit........................................................ 806 Failure code [DXE6KB] Merge-divider LS Sol Short Circuit....................................................... 808 Failure code [DY20KA] Wiper Working Abnormality................................................................ 810 Failure code [DY20MA] Wiper Parking Abnormality................................................................ 812 Failure code [DY2CKB] Washer Drive Short Circuit............................................................... 814 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit.......................................................... 816 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit.......................................................... 818 Troubleshooting by failure code [GA****] (code display)............................................................ 820 Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices.... 820 Failure code [GA----] Hybrid devices monitoring items list and check sheet..................................... 847 Failure code [GA00NS] HYB Equipment Overheat................................................................... 851 Failure code [GA01KA] Power Cable Interlock Open Circuit....................................................... 852 Failure code [GA02KZ] DC Line Open & Short Circuit............................................................. 854 Failure code [GA04KG] Abnormal DC HW Volt. Before Booster...................................................... 855 Failure code [GA05KG] Abnormal DC SW Volt. Before Booster...................................................... 856 Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster...................................................... 857 Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster................................................ 860 Failure code [GA08KG] Abnormal. DC HW Volt. After Booster...................................................... 861 Failure code [GA09KG] Abnormal. DC SW Volt. After Booster...................................................... 862 Failure code [GA09KP] Low DC SW Output Volt. After Booster..................................................... 863 Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster................................................. 864 Failure code [GA0BKZ] AC Line Open & Short Circuit............................................................. 865 Failure code [GA11KK] HYB cont. low supply voltage............................................................. 866 Failure code [GA12NK] High-Voltage Line Start-up Failure....................................................... 868 Failure code [GA12NL] High-Voltage Line Discharge Failure...................................................... 869 Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure..................................................... 870 Failure code [GA14KR] HYB Control. KOMNET Comm. Failure........................................................ 872 Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir................................................. 873 Failure code [GA17KR] Gen. Mot. Drv. Communication Failure..................................................... 873 Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit..................................................... 874 Failure code [GA17MB] Gen. Mot. Drv. Function Degraded......................................................... 875 Failure code [GA18MC] Generator Motor Excitation Unit Failure.................................................. 875 Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt..................................................... 876 Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure.................................................. 876 Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.................................................. 877 Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction....................................................... 877 Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation................................................. 878 Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled.................................................... 878 Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction.................................................. 879 Failure code [GA1FKR] Swing Mot. Drv. Communication Failure.................................................... 879 Failure code [GA1FMA] Abnormal Swing Motor Driver.............................................................. 880 Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU.................................................. 880 Failure code [GA1GKR] Swg Mot. Driver Sub-CPU Comm. Faiure..................................................... 881 Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal................................................... 881 Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction..................................................... 882 Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded.................................................. 882 Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op........................................................ 883 Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled................................................... 883 Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir................................................. 884 Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir................................................. 884 Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir................................................. 885 Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir.................................................. 885 Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir.................................................... 886 Failure code [GA1NNS] Swing Motor Driver IGBT Overheat......................................................... 886 Failure code [GA1SFS] Contactor Locked......................................................................... 887 Failure code [GA1SMC] Contactor Failure........................................................................ 888 Failure code [GA1TKP] Capacitor Low Output Voltage............................................................. 889 Failure code [GA1TNS] Capacitor Overheat....................................................................... 892 Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir..................................................... 894 Failure code [GA1VFS] Capacitor Contactor Locked............................................................... 896 Failure code [GA1VMC] Capacitor Contactor Failure.............................................................. 898 Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ.................................................. 899 Failure code [GA1YNS] Booster Inductor Overheat................................................................ 900 Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ.................................................. 901 Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat........................................................ 901 Failure code [GA22NS] Booster IGBT Junction Overheat........................................................... 902 Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sens.0 Opn/Short Cir................................................. 903 Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir................................................. 903 Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality...................................................... 904 Failure code [GA25NS] Gen. Motor Driver IGBT 0 Overheat........................................................ 904 Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality...................................................... 905 Failure code [GA26NS] Gen. Motor Driver IGBT 1 Overheat........................................................ 905 Failure code [GA27KZ] DC Cur. Sens. Bef. Booster Opn/Short Cir................................................. 906 Failure code [GA28KZ] DC Cur. Sens. Aft. Booster Opn/Short Cir................................................. 906 Failure code [GA2QKR] CAN2 Discon (Hyb Con).................................................................... 907 Failure code [GA60MC] Generator Motor Failure.................................................................. 908 Failure code [GA60N1] Generator Motor Overrun.................................................................. 909 Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir.................................................... 910 Failure code [GA61NS] Generator Motor Temp. Sensor Overheat.................................................... 912 Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir................................................. 913 Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir.................................................. 914 Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction.................................................. 915 Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir................................................. 915 Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir.................................................. 916 Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction.................................................. 916 Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir................................................. 917 Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir.................................................. 918 Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction.................................................. 918 Failure code [GA70KB] HYB Swing Motor Short Circuit............................................................ 919 Failure code [GA70MD] Swing Motor Speed Sensing Malfunction.................................................... 919 Failure code [GA70NS] HYB Swing Motor Overheat................................................................. 920 Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir.................................................. 922 Failure code [GA72MA] HYB Swing Motor Resolver Malfunction..................................................... 924 Failure code [GA72MC] HYB Swing Motor Resolver Defect Op....................................................... 926 Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ.................................................... 926 Failure code [GAA100] Swing Emergency Stop Operation........................................................... 927 Failure code [GAA2KB] Swing Brake sol. Supply Line short cir................................................... 928 Troubleshooting of electrical system (E-mode)...................................................................... 930 E-1 Engine does not start (Engine does not crank).............................................................. 930 E-2 Preheater does not operate................................................................................. 936 E-3 When starting switch is turned to ON position, machine monitor displays nothing............................ 941 E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up......... 944 E-5 Precaution monitor lights up while engine is running....................................................... 945 E-6 Emergency stop monitor lights up while engine is running................................................... 947 E-7 Fuel level gauge does not indicate properly................................................................ 948 E-8 Engine coolant temperature gauge does not indicate properly................................................ 950 E-9 Hydraulic oil temperature gauge does not indicate properly................................................. 952 E-10 HYB system temperature gauge does not indicate properly................................................... 954 E-11 Displays on machine monitor are different from those for actual machine................................... 956 E-12 Machine monitor does not display some items............................................................... 957 E-13 Function switch does not work............................................................................. 957 E-14 Automatic warm-up system does not operate (in cold season)................................................ 958 E-15 Auto-decelerator does not operate normally................................................................ 959 E-16 Working mode does not change.............................................................................. 960 E-17 Travel speed does not change.............................................................................. 961 E-18 Alarm buzzer does not stop sounding....................................................................... 962 E-19 When starting switch is at OFF position, service meter is not displayed................................... 962 E-20 Machine monitor cannot be set in service mode............................................................. 962 E-21 All of work equipment, swing, and travel mechanism do not move or are not locked.......................... 964 E-22 Swing holding brake does not operate properly............................................................. 967 E-23 One-touch power max. function does not operate............................................................ 970 E-24 Travel alarm does not sound or does not stop sounding..................................................... 973 E-25 Horn does not sound or does not stop sounding............................................................. 974 E-26 Windshield wiper and window washer do not operate......................................................... 976 E-27 BOOM DOWN indicator is not displayed properly with monitoring function.................................... 978 E-28 ARM DUMP indicator is not displayed properly with monitoring function..................................... 978 E-29 ARM IN indicator is not displayed properly with monitoring function....................................... 978 E-30 BOOM RAISE indicator is not displayed properly with monitoring function................................... 979 E-31 BUCKET CURL indicator is not displayed properly with monitoring function.................................. 979 E-32 BUCKET DUMP indicator is not displayed properly with monitoring function.................................. 979 E-33 SWING indicator is not displayed properly with monitoring function........................................ 980 E-34 TRAVEL indicator is not displayed properly with monitoring function....................................... 980 E-36 "SERVICE" indicator is not displayed properly with monitoring function.................................... 982 E-37 Attachment hydraulic circuit cannot be changed............................................................ 984 E-38 KOMTRAX system does not operate properly.................................................................. 985 Troubleshooting of hydraulic and mechanical system (H-mode)........................................................ 988 System diagram of hydraulic and mechanical system.............................................................. 988 Information in troubleshooting table (H mode).................................................................. 990 H-1 Speed or power of all work equipment and travel is low..................................................... 991 H-2 Engine speed lowers significantly or engine stalls......................................................... 993 H-3 All work equipment and travel systems do not work.......................................................... 994 H-4 Unusual noise comes out from around hydraulic pump......................................................... 994 H-5 Auto-decelerator does not operate.......................................................................... 995 H-6 Fine control performance or response is low................................................................ 995 H-7 Speed or power of boom is low.............................................................................. 996 H-8 Speed or power of arm is low............................................................................... 997 H-9 Speed or power of bucket is low............................................................................ 998 H-10 Work equipment does not move in its single operation...................................................... 998 H-11 Hydraulic drift of work equipment is large................................................................ 999 H-12 Time lag of work equipment is large.......................................................................1001 H-13 When part of work equipment is relieved singly, other parts of work equipment move........................1001 H-14 Power maximizing function does not work...................................................................1002 H-15 In combined operation of work equipment, speed of part loaded more is low.................................1002 H-16 When machine swings and travels simultaneously, travel speed is low.......................................1002 H-17 Machine deviates during travel............................................................................1003 H-18 Travel speed is low.......................................................................................1004 H-19 Machine is not steered well or sterring power is low......................................................1005 H-20 Travel speed does not shift or travel speed is low or high................................................1006 H-21 Travel system does not work (only one side)...............................................................1007 H-22 Upper structure does not swing............................................................................1008 H-23 Swing acceleration or swing speed of upper structure is low...............................................1008 H-24 Upper structure overruns remarkably when it stops swinging................................................1008 H-25 Large shock is made when upper structure stops swinging...................................................1009 H-26 Large sound is made when upper structure stops swinging...................................................1009 H-27 Upper structure lowers largely by its own weight..........................................................1009 Troubleshooting of engine (S-mode).................................................................................1010 Method of using troubleshooting chart..........................................................................1010 S-1 Engine startability is poor................................................................................1014 S-2 Engine does not start......................................................................................1015 S-3 Engine does not pick up smoothly...........................................................................1018 S-4 Engine stops during operations.............................................................................1019 S-5 Engine does not rotate smoothly............................................................................1020 S-6 Engine lacks output (or lacks power).......................................................................1021 S-7 Exhaust gas is black (incomplete combustion)...............................................................1022 S-8 Oil consumption is excessive (or exhaust gas is blue)......................................................1023 S-9 Oil becomes contaminated quickly...........................................................................1024 S-10 Fuel consumption is excessive.............................................................................1025 S-11 Oil is in coolant (or coolant spurts or coolant level goes down)..........................................1026 S-12 Oil pressure drops........................................................................................1027 S-13 Oil level rises (coolant or fuel in oil)..................................................................1028 S-14 Coolant temperature rises too high (overheating)..........................................................1029 S-15 Unusual noise is made.....................................................................................1030 S-16 Vibration is excessive....................................................................................1031 Troubleshooting hybrid system (Y-mode).............................................................................1032 Precautions related to hybrid machine..........................................................................1032 Y-1 Hybrid monitor does not go out.............................................................................1034 Y-2 Upper structure does not swing.............................................................................1036 Y-3 Swing acceleration or swing speed is low...................................................................1038 Y-4 Upper structure overruns largely when stop swinging........................................................1039 Y-5 Large shock is made when upper structure stops swinging....................................................1040 Y-6 Large unusual noise is made when upper structure stops swinging............................................1040 Y-7 Swing drift on a slope is large............................................................................1041 Y-8 Electric swing motor temperature increases abnormally......................................................1042 Y-9 Motor-generator temperature increases abnormally...........................................................1043 Y-10 Inverter overheats........................................................................................1044 Y-11 Capacitor overheats.......................................................................................1045 50 Disassembly and assembly............................................................................................1047 Contents...........................................................................................................1048 Related information on disassembly and assembly....................................................................1050 How to read this manual........................................................................................1050 Precautions related to hybrid equipment........................................................................1052 Coating materials list.........................................................................................1053 Special tools list.............................................................................................1057 Sketches of special tools......................................................................................1064 Engine and cooling system..........................................................................................1069 Removal and installation of supply pump assembly...............................................................1069 Removal and installation of injector assembly..................................................................1074 Removal and installation of cylinder head assembly.............................................................1081 Removal and installation of radiator assembly..................................................................1103 Removal and installation of hydraulic oil cooler assembly......................................................1105 Removal and installation of aftercooler assembly...............................................................1108 Removal and installation of engine front oil seal..............................................................1111 Removal and installation of engine rear oil seal...............................................................1114 Removal and installation of fan belt...........................................................................1118 Removal and installation of engine, motor-generator, and main pump assembly....................................1121 Removal and installation of fuel tank assembly.................................................................1135 Hybrid related.....................................................................................................1138 Procedures for draining coolant, refilling with coolant, and bleeding air for hybrid system....................1138 Removal and installation of hybrid radiator assembly...........................................................1143 Removal and installation of hybrid water pump assembly.........................................................1146 Removal and installation of inverter assembly..................................................................1148 Removal and installation of inverter and capacitor assembly....................................................1152 Procedure for draining and refilling generator lubricating oil.................................................1157 Removal and installation of tandem pump assembly...............................................................1159 Removal and installation of motor-generator and housing assembly...............................................1162 Removal and installation of rotor and flange assembly.......................................................... 0 Removal and installation of electric swing motor assembly......................................................1172 Power train........................................................................................................1178 Removal and installation of final drive assembly...............................................................1178 Disassembly and assembly of final drive........................................................................1180 Removal and installation of sprocket...........................................................................1189 Removal and installation of swing motor and swing machinery assembly...........................................1190 Disassembly and assembly of swing machinery assembly...........................................................1195 Removal and installation of swing circle assembly..............................................................1210 Undercarriage and frame............................................................................................1211 Separation and connection of track assembly....................................................................1211 Removal and installation of idler and idler cushion assembly...................................................1214 Disassembly and assembly of idler assembly.....................................................................1215 Disassembly and assembly of idler cushion......................................................................1218 Disassembly and assembly of track roller assembly..............................................................1220 Disassembly and assembly of carrier roller assembly............................................................1223 Removal and installation of revolving frame assembly...........................................................1226 Removal and installation of counterweight assembly.............................................................1228 Hydraulic system...................................................................................................1230 Removal and installation of center swivel joint assembly.......................................................1230 Disassembly and assembly of center swivel joint assembly.......................................................1232 Removal and installation of hydraulic tank assembly............................................................1234 Removal and installation of main pump assembly.................................................................1239 Removal and installation of main pump input shaft oil seal.....................................................1243 Removal and installation of control valve assembly.............................................................1244 Disassembly and assembly of control valve assembly.............................................................1249 Disassembly and assembly of work equipment PPC valve assembly..................................................1254 Disassembly and assembly of travel PPC valve assembly..........................................................1256 Work equipment.....................................................................................................1258 Removal and installation of work equipment assembly............................................................1258 Disassembly and assembly of work equipment cylinder assembly...................................................1261 Cab and its attachments............................................................................................1268 Removal and installation of operator's cab assembly............................................................1268 Removal and installation of operator's cab glass (adhered window glass)........................................1271 Removal and installation of front window assembly..............................................................1281 Removal and installation of floor frame assembly...............................................................1288 Removal and installation of air conditioner unit assembly......................................................1292 Removal and installation of work equipment control lever assembly..............................................1296 Electrical system..................................................................................................1310 Removal and installation of engine controller assembly.........................................................1310 Removal and installation of pump controller assembly...........................................................1312 Removal and installation of machine monitor assembly...........................................................1315 Removal and installation of KOMTRAX terminal assembly..........................................................1317 60 Maintenance standard................................................................................................1319 Contents...........................................................................................................1320 Engine and cooling system..........................................................................................1321 Engine mount...................................................................................................1321 Cooling system.................................................................................................1322 Power train........................................................................................................1323 Swing circle...................................................................................................1323 Swing machinery and swing brake................................................................................1324 Final drive....................................................................................................1326 Sprocket.......................................................................................................1328 Undercarriage and frame............................................................................................1330 Track frame and idler cushion..................................................................................1330 Idler..........................................................................................................1332 Track roller...................................................................................................1334 Carrier roller.................................................................................................1335 Track shoe.....................................................................................................1336 Hydraulic system...................................................................................................1340 Main pump......................................................................................................1340 Control valve..................................................................................................1343 Travel motor...................................................................................................1352 PPC valve......................................................................................................1355 Solenoid valve.................................................................................................1364 Attachment circuit selector valve..............................................................................1365 Center swivel joint............................................................................................1366 Work equipment.....................................................................................................1368 Work equipment.................................................................................................1368 Dimensions of work equipment...................................................................................1372 Work equipment cylinder........................................................................................1376 80 Appendix............................................................................................................1379 Contents...........................................................................................................1380 Air conditioner....................................................................................................1381 Precautions for refrigerant........................................................................................1381 Air conditioner component..........................................................................................1382 Configuration and function of refrigeration cycle..................................................................1384 Outline of refrigeration cycle.....................................................................................1385 Air conditioner unit...............................................................................................1388 Air conditioner controller.........................................................................................1394 Compressor.........................................................................................................1395 Condenser and Modulator............................................................................................1396 Sensor.............................................................................................................1397 Procedure for testing and troubleshooting..........................................................................1398 Circuit diagram and arrangement of connector pins..................................................................1400 System diagram.....................................................................................................1402 Parts and connectors layout........................................................................................1404 Testing air leakage (duct).........................................................................................1408 Testing with self-diagnosis function...............................................................................1410 Testing vent (mode) changeover.....................................................................................1412 Testing FRESH/RECIRC air changeover................................................................................1413 Testing sunlight sensor............................................................................................1414 Testing (dual) pressure switch for refrigerant.....................................................................1415 Testing relays.....................................................................................................1416 Troubleshooting chart 1............................................................................................1418 Troubleshooting chart 2............................................................................................1420 Information in troubleshooting table...............................................................................1422 Failure code list related to air conditioner.......................................................................1423 Failure code [879AKA] A/C Inner sensor Open Circuit................................................................1424 Failure code [879AKB] A/C Inner sensor Short Circuit...............................................................1425 Failure code [879BKA] A/C Outer sensor Open Circuit................................................................1426 Failure code [879BKB] A/C Outer sensor Short Circuit...............................................................1428 Failure code [879CKA] Ventilating sensor Open Circuit..............................................................1430 Failure code [879CKB] Ventilating sensor Short Circuit.............................................................1431 Failure code [879DKZ] Sunlight sensor Open or Short Circuit........................................................1432 Failure code [879EMC] Ventilating Damper Abnormality...............................................................1434 Failure code [879FMC] Air Mix Damper Abnormality...................................................................1435 Failure code [879GKX] Refrigerant Abnormality......................................................................1436 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)...................1438 Troubleshooting for compressor and refrigerant system (Air is not cooled)..........................................1440 Troubleshooting for blower motor system (No air comes out or air flow is abnormal).................................1443 Troubleshooting for FRESH/RECIRC air changeover....................................................................1445 Troubleshooting with gauge pressure................................................................................1447 Connection of service tool.........................................................................................1449 Precautions for disconnecting and connecting air conditioner piping................................................1451 Handling of compressor oil.........................................................................................1453 Desiccant replacement procedure....................................................................................1455 90 Diagrams and drawings...............................................................................................1457 Contents...........................................................................................................1458 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 HYBRID HB205-1M0 HB215LC-1M0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
General precautions
1) Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Locate a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When performing any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear the safety glasses when hitting parts with a hammer.
B. Always wear the safety glasses when grinding parts with a grinder, etc.
4) When performing any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the operator’s compartment.
5) Only qualified workers must perform the work and operation which require license or qualification.
S.S 27/12/24
