Komatsu HB205 -1 Install guide

HYDRAULIC
EXCAVATOR
SEN05393-06
HB205
-1
HB215LC
-1
SERIAL NUMBERS
HB205- 1001
HB215LC-1001
and up

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Notice of revision
HB205-1, HB215LC-1
1
1
Notice of revision 00-1 HB205-1, HB215LC-1
6th revision
The affected pages are indicated by the use of the
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the
list below.
2017/04
List of revised pages
Mark Indication Action required
QPage to be newly added Add
qPage to be replaced Replace
( ) Page to be deleted Discard
Mark Page Revision
number
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Mark Page Revision
number
(06)
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Notice of revision
2
HB205-1, HB215LC-1
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Mark Page Revision
number
2(06)
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Notice of revision
HB205-1, HB215LC-1
3
30-79 (01)
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Mark Page Revision
number
(06) 3
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Notice of revision
4
HB205-1, HB215LC-14
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Mark Page Revision
number
(05)
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Notice of revision
HB205-1, HB215LC-1
5
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Mark Page Revision
number
(06) 5
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Notice of revision
6
HB205-1, HB215LC-16
40-543 (01)
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HB205-1, HB215LC-1
7
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8
HB205-1, HB215LC-1
80-73 (01)
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HB205-1, HB215LC-1
00-1
HB205-1, HB215LC-1
HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1
Machine model Serial number
HB205-1 1001 and up
HB215LC-1 1001 and up
00 Index and foreword 30-1
00-1

Table of Contents
2
HB205-1, HB215LC-1
Table of Contents 2
00 Index and Foreword
Table of Contents.................................................................................................................... 00- 2
2
Table of Contents................................................................................................................. 00- 2 2
Foreword and general information.......................................................................................... 00- 4 4
Safety notice........................................................................................................................ 00- 4 4
How to read the shop manual.............................................................................................. 00- 9 9
Explanation of terms for maintenance standard .................................................................. 00- 11 11
Handling of hydraulic components....................................................................................... 00- 13 13
Method of disconnecting and connecting push-pull type coupler ........................................ 00- 15 15
Handling of electric equipment............................................................................................. 00- 18 18
How to read electric wire code............................................................................................. 00- 28 28
Precautions when performing work...................................................................................... 00- 33 33
Handling of hybrid devices and high-voltage wirings........................................................... 00- 36 36
Standard tightening torque table.......................................................................................... 00- 42 42
List of Abbreviation .............................................................................................................. 00- 46 46
Conversion table.................................................................................................................. 00- 50 50
01 Specifications
Specifications.......................................................................................................................... 01- 3
3
Outline of hybrid system ...................................................................................................... 01- 3 3
Specification dimension drawing.......................................................................................... 01- 4 4
Working range diagram........................................................................................................ 01-5 5
Specifications....................................................................................................................... 01- 6 6
Weight table......................................................................................................................... 01- 9 9
Table of fuel, coolant and lubricants.................................................................................... 01- 11 11
10 Structure and function
Engine and cooling system..................................................................................................... 10- 3
4
Engine related parts............................................................................................................. 10- 3 4
Cooling system .................................................................................................................... 10- 4 5
Hybrid relation......................................................................................................................... 10- 6 7
Configuration and safety functions of hybrid system ........................................................... 10- 6 7
Cooling system of hybrid component................................................................................... 10- 10 11
Motor-generator................................................................................................................... 10- 12 13
Swing electric motor............................................................................................................. 10- 13 14
Electric control unit............................................................................................................... 10- 14 15
High-voltage wiring (power cable)........................................................................................ 10- 15 16
Water pump ......................................................................................................................... 10- 16 17
Power train system ................................................................................................................. 10- 18 18
Power train........................................................................................................................... 10- 18 18
Swing circle.......................................................................................................................... 10- 19 19
Swing machinery.................................................................................................................. 10- 20 20
Swing brake ......................................................................................................................... 10- 22 22
Final drive ............................................................................................................................ 10- 24 24
Undercarriage and frame........................................................................................................ 10- 26 26
Track frame and idler cushion.............................................................................................. 10- 26 26
Hydraulic system..................................................................................................................... 10- 28 28
Hydraulic components layout drawing................................................................................. 10- 28 28
Valve control........................................................................................................................ 10- 30 30
Hydraulic tank ...................................................................................................................... 10- 31 31
CLSS.................................................................................................................................... 10- 32 32
Main pump ........................................................................................................................... 10- 36 36
00-2 (01)

Table of Contents
HB205-1, HB215LC-1
3
Control valve........................................................................................................................ 10- 58 58
Functions and operation by valve........................................................................................ 10- 70 70
Travel motor......................................................................................................................... 10-107 107
PPC valve............................................................................................................................ 10-117 117
Solenoid valve ..................................................................................................................... 10-136 136
Attachment circuit selector valve ......................................................................................... 10-138 138
Return oil filter...................................................................................................................... 10-140 140
Center swivel joint................................................................................................................ 10-142 142
Accumulator......................................................................................................................... 10-143 143
Electrical system..................................................................................................................... 10-144 144
Electrical control system...................................................................................................... 10-144 144
Machine monitor system...................................................................................................... 10-174 174
KOMTRAX system............................................................................................................... 10-190 190
Sensors................................................................................................................................ 10-192 192
20 Standard value table
Standard value table............................................................................................................... 20- 3
3
Standard value table for engine........................................................................................... 20- 3 3
Standard value table for machine........................................................................................ 20- 4 4
30 Testing and adjusting
Tools for testing, adjusting and troubleshooting ..................................................................... 30- 4
4
Tools for testing, adjusting and troubleshooting .................................................................. 30- 4 4
Engine and cooling system..................................................................................................... 30- 9 9
Testing engine speed .......................................................................................................... 30- 9 9
Testing boost pressure ........................................................................................................ 30- 11 11
Checking exhaust gas color................................................................................................. 30- 12 12
Adjusting valve clearance.................................................................................................... 30-13 13
Testing compression pressure............................................................................................. 30- 15 15
Testing blowby pressure...................................................................................................... 30-18 18
Testing engine oil pressure.................................................................................................. 30-19 19
Handling fuel system parts .................................................................................................. 30- 20 20
Releasing remaining pressure from fuel system.................................................................. 30- 20 20
Testing fuel system pressure............................................................................................... 30- 21 21
Cylinder cut-out test mode operation................................................................................... 30- 23 23
No injection cranking operation ........................................................................................... 30- 23 23
Testing fuel delivery, return rate and leakage...................................................................... 30- 24 24
Bleeding air from fuel circuit ................................................................................................ 30- 28 28
Testing fuel circuit for leakage............................................................................................. 30-29 29
Handling of controller high-voltage circuit............................................................................ 30- 30 30
Testing and adjusting air conditioner compressor belt tension............................................ 30- 31 31
Replacement of fan belt....................................................................................................... 30- 32 32
Undercarriage and frame........................................................................................................ 30- 33 33
Testing swing circle bearing clearance................................................................................ 30- 33 33
Testing and adjusting track tension ..................................................................................... 30- 34 34
Hydraulic system .................................................................................................................... 30- 37 37
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits ............ 30- 37 37
Testing source pressure of control circuit............................................................................ 30- 40 40
Testing and adjusting oil pressure in pump PC control circuit............................................. 30- 41 41
Testing and adjusting oil pressure in pump LS control circuit.............................................. 30- 44 44
Testing solenoid valve output pressure ............................................................................... 30- 48 48
Testing PPC valve output pressure ..................................................................................... 30- 51 51
Adjusting play of work equipment and swing PPC valves................................................... 30- 53 53
Checking parts which cause hydraulic drift of work equipment ........................................... 30- 54 54
(01) 00-3

Table of Contents
4
HB205-1, HB215LC-100-3-1
Releasing remaining pressure from hydraulic circuit........................................................... 30- 56
56
Testing oil leakage............................................................................................................... 30- 57 57
Bleeding air from each part.................................................................................................. 30-59 59
Cab and its attachments ......................................................................................................... 30- 61 61
Checking cab tipping stopper............................................................................................... 30- 61 61
Adjusting mirrors.................................................................................................................. 30- 62 62
Angle adjustment of rear view camera................................................................................. 30- 65 65
Hybrid relation......................................................................................................................... 30- 66 66
Testing swing holding brake ................................................................................................ 30- 66 66
Cleaning and replacement of oil filter of swing electric motor.............................................. 30- 67 67
Operation check of swing emergency stop switch............................................................... 30- 68 68
Electrical system..................................................................................................................... 30- 70 70
Special functions of machine monitor.................................................................................. 30- 70 70
Handling voltage circuit of engine controller........................................................................ 30-132 132
Precautions related to hybrid machines............................................................................... 30-133 133
Preparation work for troubleshooting of electrical system ................................................... 30-134 134
Procedure for testing diodes................................................................................................ 30-140 140
Pm Clinic................................................................................................................................. 30-141 141
Pm Clinic service ................................................................................................................. 30-141 141
40 Troubleshooting
General information on troubleshooting.................................................................................. 40- 10
10
Points to remember when troubleshooting .......................................................................... 40- 10
Sequence of events in troubleshooting................................................................................ 40- 11
Checks before troubleshooting............................................................................................ 40- 12
Classification and procedures for troubleshooting............................................................... 40- 41
Failure codes table............................................................................................................... 40- 44
Symptom and troubleshooting numbers.............................................................................. 40- 52
Information in troubleshooting table..................................................................................... 40- 55
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 57
Connector list and layout ..................................................................................................... 40- 59
Connection table for connector pin numbers....................................................................... 40- 70
T- branch box and T- branch adapter table ......................................................................... 40-106
Fuse location table............................................................................................................... 40-109
Troubleshooting by failure code.............................................................................................. 40-111
111
Failure code [989L00] Engine Controller Lock Caution 1 .................................................... 40-111
Failure code [989M00] Engine Controller Lock Caution 2 ................................................... 40-111
Failure code [989N00] Engine Controller Lock Caution 3.................................................... 40-111-1
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-111-2
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-112
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40-114
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40-115
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-116
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-118
Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40-120
Failure code [CA111] ECM Critical Internal Failure............................................................. 40-121
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40-121
Failure code [CA122] Chg Air Press Sensor High Error...................................................... 40-122
Failure code [CA123] Chg Air Press Sensor Low Error....................................................... 40-124
Failure code [CA131] Throttle Sensor High Error................................................................ 40-126
Failure code [CA132] Throttle Sensor Low Error................................................................. 40-128
Failure code [CA144] Coolant Temp Sens High Error......................................................... 40-130
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40-132
Failure code [CA153] Chg Air Temp Sensor High Error...................................................... 40-134
(03)

Table of Contents
HB205-1, HB215LC-1
5
Failure code [CA154] Chg Air Temp Sensor Low Error....................................................... 40- 136
Failure code [CA155] Chg Air Temp High Speed Derate .................................................... 40- 138
Failure code [CA187] Sens Supply 2 Volt Low Error........................................................... 40-140
Failure code [CA221] Ambient Press Sens High Error........................................................ 40-142
Failure code [CA222] Ambient Press Sens Low Error......................................................... 40-144
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40-146
Failure code [CA234] Eng Overspeed................................................................................. 40-146
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 147
Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40-148
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-150
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................ 40-152
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................ 40-154
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................ 40-156
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................ 40-158
Failure code [CA342] Calibration Code Incompatibility ....................................................... 40-160
Failure code [CA351] Injectors Drive Circuit Error............................................................... 40-161
Failure code [CA352] Sens Supply 1 Volt Low Error........................................................... 40-162
Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40-164
Failure code [CA428] Water in Fuel Sensor High Error....................................................... 40-166
Failure code [CA429] Water in Fuel Sensor Low Error........................................................ 40-168
Failure code [CA435] Eng Oil Press Sw Error..................................................................... 40-170
Failure code [CA441] Battery Voltage Low Error................................................................. 40-172
Failure code [CA442] Battery Voltage High Error................................................................ 40-174
Failure code [CA449] Rail Press Very High Error................................................................ 40- 175
Failure code [CA451] Rail Press Sensor High Error............................................................ 40- 176
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 178
Failure code [CA488] Chg Air Temp High Torque Derate ................................................... 40-180
Failure code [CA553] Rail Press High Error ........................................................................ 40-181
Failure code [CA559] Supply Pump Press Low Error 1....................................................... 40-182
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40-184
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 186
Failure code [CA757] All Continuous Data Lost Error ......................................................... 40- 187
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 188
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40-191
Failure code [CA2185] Throt Sens Sup Volt High Error ...................................................... 40- 192
Failure code [CA2186] Throt Sens Sup Volt Low Error....................................................... 40- 193
Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 194
Failure code [CA2311] IMV Solenoid Error.......................................................................... 40-195
Failure code [CA2555] Grid Htr Relay Open Circuit Error................................................... 40-196
Failure code [CA2556] Grid Htr Relay Short Circuit Error ................................................... 40-198
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................. 40- 200
Failure code [D862KA] GPS Antenna Open Circuit............................................................. 40-203
Failure code [DA22KK] Pump Solenoid Power Low Error................................................... 40-204
Failure code [DA25KP] 5V Sensor1 Power Abnormality..................................................... 40-206
Failure code [DA26KP] 5V Sensor2 Power Abnormality..................................................... 40-208
Failure code [DA29KQ] Model Selection Abnormality ......................................................... 40-210
Failure code [DA2RMC] CAN Discon (Pump Con Detected) .............................................. 40- 212
Failure code [DAF8KB] Camera Power Supply Short Circuit .............................................. 40-218
Failure code [DAFGMC] GPS Module Error........................................................................ 40-220
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40-221
Failure code [DGH2KB] Hyd Oil Sensor Short .................................................................... 40-228
Failure code [DHPAMA] Pump Press Sensor Abnormality.................................................. 40- 230
Failure code [DHPBMA] R Pump Press Sensor Abnormality.............................................. 40- 232
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality...................................................... 40-234
(03) 00-3-2

Table of Contents
6
HB205-1, HB215LC-100-3-3
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ............................. 40-236
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality.............................. 40-238
Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open or short circuit 40-240
Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open or short circuit... 40-242
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality.................................... 40-244
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality..................................... 40-246
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality............................. 40-248
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit.... 40-250
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir............................. 40-252
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir................................... 40-254
Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor signal
abnormality .......................................................................................................................... 40-256
Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor malfunction..... 40-257
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir .................................... 40-258
Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor signal
abnormality .......................................................................................................................... 40-260
Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor malfunction ....... 40-261
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir................................ 40-262
Failure code [DW43KA] Travel Speed Sol Open Circuit...................................................... 40-264
Failure code [DW43KB] Travel Speed Sol Short Circuit...................................................... 40-266
Failure code [DW45KA] Swing holding brake solenoid valve open circuit........................... 40-268
Failure code [DW45KB] Swing holding brake solenoid valve short circuit........................... 40-271
Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop............... 40-274
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir................................ 40-276
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit.............................................. 40-278
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit .............................................. 40-280
Failure code [DW91KA] Travel Junction Sol. Disc............................................................... 40-282
Failure code [DW91KB] Travel Junction Sol. S/C................................................................ 40-284
Failure code [DWA2KA] Attachment Sol Open Circuit......................................................... 40-286
Failure code [DWA2KB] Attachment Sol Short Circuit......................................................... 40-288
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit..................................................... 40-290
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit..................................................... 40-292
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit......................................................... 40-294
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit......................................................... 40-296
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit........................................................ 40-298
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ........................................................ 40-300
Failure code [DXE0KA] LS-EPC Sol Open Circuit............................................................... 40-302
Failure code [DXE0KB] LS-EPC Sol Short Circuit............................................................... 40-304
Failure code [DXE4KA] Service Current EPC Disc.............................................................. 40-306
Failure code [DXE4KB] Service Current EPC S/C............................................................... 40-308
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit............................................. 40-310
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit............................................. 40-312
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit ................................................ 40-314
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit................................................. 40-316
Failure code [DY20KA] Wiper Working Abnormality............................................................ 40-318
Failure code [DY20MA] Wiper Parking Abnormality ............................................................ 40-320
Failure code [DY2CKA] Washer drive discon ...................................................................... 40-322
Failure code [DY2CKB] Washer drive short......................................................................... 40-324
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit..................................................... 40-326
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...................................................... 40-328
Troubleshooting by failure code [GA****] (code display)......................................................... 40-330
330
Precaution in hybrid device troubleshooting, and common troubleshooting procedures
for high voltage devices....................................................................................................... 40-330
Failure code [GA----] Hybrid devices monitoring items list and check sheet........................ 40-355
(03)

Table of Contents
HB205-1, HB215LC-1
7
Failure code [GA00NS] HYB devices overheat................................................................... 40-359
Failure code [GA01KA] Power Cable Interlock Open Circuit............................................... 40-360
Failure code [GA02KZ] DC Line Open/Short Circuit............................................................ 40-362
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster......................................... 40-363
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster......................................... 40-364
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster........................................... 40- 365
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster....................................... 40-366
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster........................................... 40-367
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster........................................... 40-368
Failure code [GA09KP] Low DC SW Output Volt. After Booster ......................................... 40-369
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster......................................... 40- 370
Failure code [GA0BKZ] AC Line Open/Short Circuit ........................................................... 40-371
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure..................................................... 40-372
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON........................................... 40- 373
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF.......................................... 40-374
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure ......................................... 40-376
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure......................................... 40- 378
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir..................................... 40-379
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure ......................................... 40- 379
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit........................................... 40-380
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit............................................ 40-380
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded ............................................... 40-381
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure ......................................... 40-381
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt ........................................ 40- 382
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure ................................. 40- 382
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. .................................. 40- 383
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction ........................................... 40- 383
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation ................................. 40-384
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled........................................ 40-384
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction ...................................... 40- 385
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure ....................................... 40-385
Failure code [GA1FMA] Abnormal Swing Motor Driver ....................................................... 40- 386
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU .................................. 40-386
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure................................. 40-387
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal................................... 40-387
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction ...................................... 40-388
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded ................................ 40- 388
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op........................................... 40-389
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled..................................... 40-389
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. ................................ 40-390
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. ................................. 40-390
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir................................. 40- 391
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir...................................... 40-391
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir......................................... 40-392
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat .............................................. 40-393
Failure code [GA1SFS] Contactor Locked........................................................................... 40-394
Failure code [GA1SMC] Contactor Failure .......................................................................... 40- 394
Failure code [GA1TKP] Capacitor Low Output Voltage....................................................... 40-395
Failure code [GA1TNS] Capacitor Overheat ....................................................................... 40- 396
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir......................................... 40-398
Failure code [GA1VFS] Capacitor Contactor Locked .......................................................... 40- 400
Failure code [GA1VMC] Capacitor Contactor Failure.......................................................... 40- 402
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. ..................................... 40-403
Failure code [GA1YNS] Booster Inductor Overheat ............................................................ 40-404
(03) 00-3-4

Table of Contents
8
HB205-1, HB215LC-100-3-5
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ.................................... 40-404-1
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat............................................ 40-404-2
Failure code [GA21KB] Booster IGBT Short Circuit............................................................. 40-404-3
Failure code [GA22NS] Booster IGBT Junction Overheat................................................... 40-405
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sens.0 Opn/Short Cir. .................................. 40-406
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir. .................................. 40-406
Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality........................................... 40-407
Failure code [GA25NS] Gen. Motor Driver IGBT0 overheat................................................ 40-407-1
Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality........................................... 40-407-2
Failure code [GA26NS] Gen. Motor Driver IGBT1 overheat................................................ 40-408
Failure code [GA27KZ] DC before boosting sensor open or short circuit............................ 40-409
Failure code [GA28KZ] DC after boosting sensor open or short circuit............................... 40-409
Failure code [GA60MC] Generator Motor Failure................................................................ 40-410
Failure code [GA60MD] Gen. Mot. Defective Movement..................................................... 40-411
Failure code [GA60N1] Generator Motor Overrun............................................................... 40-412
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir....................................... 40-414
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat..................................... 40-416
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir.................................... 40-417
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir ..................................... 40-418
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction..................................... 40-419
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.................................... 40-419
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir ..................................... 40-420
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction..................................... 40-420
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir.................................... 40-421
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir..................................... 40-422
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction..................................... 40-422
Failure code [GA70KB] HYB Swing Motor Short Circuit...................................................... 40-423
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion...................................... 40-423
Failure code [GA70NS] HYB Swing Motor Overheat........................................................... 40-424
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir................................... 40-426
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction........................................ 40-428
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.......................................... 40-430
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ....................................... 40-430
Failure code [GAA100] Swing emergency stop switch operated......................................... 40-431
Failure code [GAA2KB] Swing Brake sol. Supply Line short cir. ......................................... 40-432
Troubleshooting of electrical system (E-mode)....................................................................... 40-434
434
E-1 Engine does not start (Engine does not crank) ............................................................. 40-434
E-2 Preheater does not operate........................................................................................... 40-440
E-3 When starting switch is turned to ON position, machine monitor displays nothing....... 40-445
E-4 When starting switch is turned to ON position (with engine stopped), basic check
monitor lights up................................................................................................................... 40-448
E-5 Precaution monitor lights up while engine is running.................................................... 40-449
E-6 Emergency stop monitor lights up while engine is running ........................................... 40-451
E-7 Fuel level gauge does not indicate properly.................................................................. 40-452
E-8 Engine coolant temperature gauge does not indicate properly..................................... 40-454
E-9 Hydraulic oil temperature gauge does not indicate properly......................................... 40-456
E-10 HYB system temperature gauge does not indicate properly....................................... 40-458
E-11 Displays on machine monitor are different from those for actual machine.................. 40-460
E-12 Machine monitor does not display some items ........................................................... 40-460
E-13 Function switch does not work.................................................................................... 40-460
E-14 Automatic warm-up system does not operate (in cold season)................................... 40-461
E-15 Auto-decelerator does not operate normally............................................................... 40-462
E-16 Working mode does not change.................................................................................. 40-463
E-17 Travel speed does not change.................................................................................... 40-464
(03)

Table of Contents
HB205-1, HB215LC-1
9
E-18 Alarm buzzer does not stop sounding......................................................................... 40-465
E-19 When starting switch is at OFF position, service meter is not displayed .................... 40- 465
E-20 Machine monitor cannot be set in service mode......................................................... 40-465
E-21 All of work equipment, swing, and travel mechanism do not move or are not locked. 40-466
E-22 Swing holding brake does not operate properly.......................................................... 40-469
E-23 One-touch power max. function does not operate ...................................................... 40- 472
E-24 Travel alarm does not sound or does not stop sounding ............................................ 40-476
E-25 Horn does not sound or does not stop sounding ........................................................ 40-478
E-26 Windshield wiper and window washer do not operate ................................................ 40-480
E-27 "BOOM LOWER" indicator is not displayed properly with monitoring function ........... 40-482
E-28 "ARM OUT" indicator is not displayed properly with monitoring function.................... 40- 484
E-29 "ARM IN" indicator is not displayed properly with monitoring function........................ 40- 486
E-30 "BOOM RAISE" indicator is not displayed properly with monitoring function.............. 40-486
E-31 "BUCKET CURL" indicator is not displayed properly with monitoring function........... 40- 486
E-32 "BUCKET DUMP" indicator is not displayed properly with monitoring function .......... 40- 487
E-33 "SWING" indicator is not displayed properly with monitoring function ........................ 40-487
E-34 "TRAVEL" indicator is not displayed properly with monitoring function....................... 40-488
E-35 "TRAVEL STEERING" indicator is not displayed properly with monitoring function... 40- 490
E-36 "SERVICE" indicator is not displayed properly with monitoring function..................... 40- 492
E-37 Attachment hydraulic circuit cannot be changed......................................................... 40-494
E-38 KOMTRAX system does not operate properly............................................................ 40- 495
Troubleshooting of hydraulic and mechanical system (H-mode)............................................ 40-496
496
Information in troubleshooting table (H mode)..................................................................... 40-498
System diagram of hydraulic and mechanical system......................................................... 40- 496
H-1 Speed or power of all work equipment and travel is low............................................... 40-499
H-2 Engine speed lowers significantly or engine stalls........................................................ 40-501
H-3 All work equipment and travel systems do not work..................................................... 40-502
H-4 Unusual noise comes out from around hydraulic pump................................................ 40-502
H-5 Auto-decelerator does not operate ............................................................................... 40-503
H-6 Fine control performance or response is low................................................................ 40-503
H-7 Speed or power of boom is low..................................................................................... 40- 504
H-8 Speed or power of arm is low ....................................................................................... 40-505
H-9 Speed or power of bucket is low................................................................................... 40- 506
H-10 Work equipment does not move in its single operation .............................................. 40-506
H-11 Hydraulic drift of work equipment is large................................................................... 40-507
H-12 Time lag of work equipment is large ........................................................................... 40-509
H-13 When part of work equipment is relieved singly, other parts of work equipment move 40-509
H-14 Power maximizing function does not work.................................................................. 40-510
H-15 In combined operation of work equipment, speed of part loaded more is low............ 40-510
H-16 When machine swings and travels simultaneously, travel speed is low..................... 40-510
H-17 Machine deviates during travel ................................................................................... 40-511
H-18 Travel speed is low ..................................................................................................... 40-512
H-19 Machine is not steered well or sterring power is low................................................... 40-513
H-20 Travel speed does not shift or travel speed is low or high.......................................... 40-514
H-21 Travel system does not work (only one side).............................................................. 40-515
H-22 Upper structure does not swing.................................................................................. 40- 516
H-23 Swing acceleration or swing speed of upper structure is low ..................................... 40-516
H-24 Upper structure overruns remarkably when it stops swinging .................................... 40-516
H-25 Large shock is made when upper structure stops swinging ....................................... 40-517
H-26 Large sound is made when upper structure stops swinging....................................... 40-517
H-27 Upper structure lowers largely by its own weight........................................................ 40-517
Troubleshooting of engine (S-mode) ...................................................................................... 40-518
518
Method of using troubleshooting chart................................................................................. 40-518
S-1 Engine startability is poor.............................................................................................. 40-522
(03) 00-3-6

Table of Contents
10
HB205-1, HB215LC-100-3-7
S-2 Engine does not start .................................................................................................... 40-523
S-3 Engine does not pick up smoothly................................................................................. 40-526
S-4 Engine stops during operations..................................................................................... 40-527
S-5 Engine does not rotate smoothly................................................................................... 40-528
S-6 Engine lacks output (or lacks power) ............................................................................ 40-529
S-7 Exhaust gas is black (incomplete combustion) ............................................................. 40-530
S-8 Oil consumption is excessive (or exhaust gas is blue).................................................. 40-531
S-9 Oil becomes contaminated quickly................................................................................ 40-532
S-10 Fuel consumption is excessive.................................................................................... 40-533
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) .................................. 40-534
S-12 Oil pressure drops....................................................................................................... 40-535
S-13 Oil level rises (coolant or fuel in oil)............................................................................. 40-536
S-14 Coolant temperature rises too high (overheating)....................................................... 40-537
S-15 Unusual noise is made................................................................................................ 40-538
S-16 Vibration is excessive.................................................................................................. 40-539
Troubleshooting hybrid system (Y-mode)............................................................................... 40-540
540
Precautions related to hybrid machine................................................................................. 40-540
Y-1 Hybrid monitor does not go out..................................................................................... 40-542
Y-2 Upper structure does not swing..................................................................................... 40-544
Y-3 Swing acceleration or swing speed is low..................................................................... 40-546
Y-4 Upper structure overruns largely when stop swinging................................................... 40-547
Y-5 Large shock is made when upper structure stops swinging.......................................... 40-548
Y-6 Large unusual noise is made when upper structure stops swinging............................. 40-548
Y-7 Swing drift on a slope is large ....................................................................................... 40-549
Y-8 Electric swing motor temperature increases abnormally............................................... 40-550
Y-9 Motor-generator temperature increases abnormally..................................................... 40-552
Y-10 Inverter overheats ....................................................................................................... 40-553
Y-11 Capacitor overheats.................................................................................................... 40-554
50 Disassembly and assembly
General information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4
Precautions related to hybrid machine................................................................................. 50- 6
Coating materials list............................................................................................................ 50- 7
Special tools list ................................................................................................................... 50- 10
Sketches of special tools ..................................................................................................... 50- 15
Engine and cooling system..................................................................................................... 50- 20
Removal and installation of fuel supply pump assembly ..................................................... 50- 20
Removal and installation of fuel injector assembly .............................................................. 50- 25
Removal and installation of cylinder head assembly........................................................... 50- 32
Removal and installation of radiator assembly .................................................................... 50- 55
Removal and installation of hydraulic oil cooler assembly................................................... 50- 57
Removal and installation of aftercooler assembly................................................................ 50- 59
Removal and installation of engine front seal...................................................................... 50- 62
Removal and installation of engine rear seal....................................................................... 50- 64
Removal and installation of fuel cooler assembly................................................................ 50- 68
Removal (and installation) of engine, motor generator, and main pump assembly............. 50- 70
Removal and installation of fuel tank assembly................................................................... 50- 86
Hybrid...................................................................................................................................... 50- 89
Draining adding coolant and bleeding air for hybrid system................................................ 50- 89
Removal and installation of hybrid radiator assembly.......................................................... 50- 93
Removal and installation of water pump assembly for hybrid system ................................. 50- 96
Removal and installation of inverter assembly..................................................................... 50- 99
Removal and installation of inverter and capacitor assembly.............................................. 50-103
(03)