Komatsu HB215LC-2 Install guide
HYDRAULIC
EXCAVATOR
SEN06488-01
HB215LC
-2
SERIAL NUMBERS
50001
and up
00 Index and foreword
Index
Index
(ALL-0310-001-A-00-A)
00 Index and foreword .......................................................................................................................00-1
Index .........................................................................................................................................00-2
Foreword, safety and general information ................................................................................... 00-16
Important safety notice (Hybrid)........................................................................................... 00-16
How to read the shop manual.............................................................................................. 00-23
Explanation of terms for maintenance standard .................................................................... 00-25
Handling equipment of fuel system devices .......................................................................... 00-27
Handling of intake system parts........................................................................................... 00-28
Handling of hydraulic equipment.......................................................................................... 00-29
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-31
Handling of electrical equipment.......................................................................................... 00-34
How to read electric wire code (Hybrid) ................................................................................ 00-42
Precautions when performing operation ............................................................................... 00-47
Practical use of KOMTRAX................................................................................................. 00-52
Handling hybrid components and high voltage wiring harness................................................ 00-53
Standard tightening torque table.......................................................................................... 00-56
List of abbreviation ............................................................................................................. 00-62
Conversion table................................................................................................................ 00-67
01 Specification.................................................................................................................................01-1
Table of contents ........................................................................................................................01-2
Specifications.............................................................................................................................01-3
Specification drawing ...........................................................................................................01-3
Working range drawings .......................................................................................................01-4
Specifications ......................................................................................................................01-5
Weight table ........................................................................................................................01-9
Table of fuel, coolant, and lubricants .................................................................................... 01-11
10 Structure and function ...................................................................................................................10-1
Table of contents ........................................................................................................................10-2
Engine and cooling system..........................................................................................................10-3
Engine related parts .............................................................................................................10-3
VFT ....................................................................................................................................10-5
EGR system piping drawing..................................................................................................10-9
EGR system circuit diagram................................................................................................ 10-11
EGR valve......................................................................................................................... 10-12
EGR cooler........................................................................................................................ 10-14
KCCV layout drawing ......................................................................................................... 10-16
KCCV ventilator ................................................................................................................. 10-18
KDOC muffler .................................................................................................................... 10-20
Cooling system .................................................................................................................. 10-22
Hybrid system .......................................................................................................................... 10-24
Outline of hybrid system ..................................................................................................... 10-24
Configuration of hybrid system ............................................................................................ 10-25
Protective function of hybrid component............................................................................... 10-26
Protection function for workers when disassembling hybrid component................................... 10-28
Cooling system of hybrid component ................................................................................... 10-30
Interlock function................................................................................................................ 10-31
Motor-generator ................................................................................................................. 10-32
Electric swing motor ........................................................................................................... 10-34
Electric control unit............................................................................................................. 10-36
High voltage wiring harness (power cable) ........................................................................... 10-37
Water pump....................................................................................................................... 10-38
Power train............................................................................................................................... 10-39
Power train system............................................................................................................. 10-39
Swing circle ....................................................................................................................... 10-41
Swing machinery with swing brake ...................................................................................... 10-42
Final drive ......................................................................................................................... 10-44
Undercarriage and frame........................................................................................................... 10-46
Track frame and idler cushion ............................................................................................. 10-46
00-2 HB215LC-2
Find manuals at https://best-manuals.com
00 Index and foreword
Index
Hydraulic system ...................................................................................................................... 10-48
Hydraulic component layout................................................................................................ 10-48
Valve control...................................................................................................................... 10-50
Hydraulic tank.................................................................................................................... 10-52
CLSS................................................................................................................................ 10-54
Main pump ........................................................................................................................ 10-59
Control valve ..................................................................................................................... 10-89
Travel motor .................................................................................................................... 10-144
PPC valve ....................................................................................................................... 10-157
Solenoid valve ................................................................................................................. 10-180
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-183
Attachment circuit selector valve (for low pressure circuit).................................................... 10-185
Center swivel joint............................................................................................................ 10-188
Accumulator .................................................................................................................... 10-190
Work equipment ..................................................................................................................... 10-191
Work equipment............................................................................................................... 10-191
Work equipment shim....................................................................................................... 10-192
Bucket play adjustment shim............................................................................................. 10-193
Cab and its attachments.......................................................................................................... 10-194
Cab mount and cab tipping stopper ................................................................................... 10-194
ROPS cab....................................................................................................................... 10-195
Electrical system .................................................................................................................... 10-196
Electrical control system ................................................................................................... 10-196
Machine monitor system................................................................................................... 10-253
KOMTRAX system........................................................................................................... 10-277
Sensor ............................................................................................................................ 10-280
20 Standard value tables....................................................................................................................20-1
Table of contents ........................................................................................................................20-2
Standard service value table........................................................................................................20-3
Standard value table for engine.............................................................................................20-3
Standard value table for machine ..........................................................................................20-5
Standard value table for electrical system............................................................................. 20-20
30 Testing and adjusting ....................................................................................................................30-1
Table of contents ........................................................................................................................30-2
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ...............................................................................................30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
Engine and cooling system..........................................................................................................30-8
Testing engine speed ...........................................................................................................30-8
Testing boost pressure ....................................................................................................... 30-10
Testing exhaust gas color ................................................................................................... 30-13
Testing and adjusting valve clearance.................................................................................. 30-14
Testing compression pressure............................................................................................. 30-17
Testing blowby pressure ..................................................................................................... 30-21
Testing engine oil pressure ................................................................................................. 30-22
Testing fuel pressure .......................................................................................................... 30-23
Testing fuel discharge, return and leakage............................................................................ 30-28
Bleeding air from fuel system .............................................................................................. 30-30
Testing fuel circuit for leakage ............................................................................................. 30-32
Handling cylinder cutout mode operation.............................................................................. 30-33
Handling no-injection cranking operation.............................................................................. 30-34
Testing and adjusting air conditioner compressor belt tension ................................................ 30-35
Replacing fan belt .............................................................................................................. 30-36
Hybrid system .......................................................................................................................... 30-37
Precautions related to hybrid equipment .............................................................................. 30-37
Bleeding air from hybrid cooling system ............................................................................... 30-38
Testing water pressure of hybrid coolant............................................................................... 30-40
Testing swing parking brake................................................................................................ 30-42
Cleaning and replacing oil filter of electric swing motor .......................................................... 30-43
HB215LC-2 00-3
Find manuals at https://best-manuals.com
00 Index and foreword
Index
Power train............................................................................................................................... 30-44
Testing swing circle bearing clearance ................................................................................. 30-44
Undercarriage and frame........................................................................................................... 30-45
Testing and adjusting track tension ...................................................................................... 30-45
Hydraulic system ...................................................................................................................... 30-46
Releasing remaining pressure from hydraulic circuit.............................................................. 30-46
Testing oil pressure of control circuit .................................................................................... 30-50
Testing and adjusting oil pressure in work equipment and travel circuits .................................. 30-51
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-54
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-58
Testing outlet pressure of solenoid valve .............................................................................. 30-66
Testing PPC valve outlet pressure ....................................................................................... 30-70
Adjusting play of work equipment and swing PPC valves....................................................... 30-72
Testing pump swash plate sensor........................................................................................ 30-73
Isolating the parts causing hydraulic drift in work equipment................................................... 30-74
Testing oil leakage ............................................................................................................. 30-76
Bleeding air from hydraulic circuit ........................................................................................ 30-78
Cab and its attachments............................................................................................................ 30-80
Testing cab tipping stopper ................................................................................................. 30-80
Adjusting mirrors................................................................................................................ 30-81
Electrical system ...................................................................................................................... 30-84
Special functions of machine monitor................................................................................... 30-84
KOMTRAX terminal start-up procedure .............................................................................. 30-156
Adjusting rearview camera angle....................................................................................... 30-159
Handling voltage circuit of engine controller........................................................................ 30-161
Handling battery disconnect switch .................................................................................... 30-162
Testing diodes ................................................................................................................. 30-163
Pm clinic ................................................................................................................................ 30-164
Pm Clinic service ............................................................................................................. 30-164
40 Troubleshooting............................................................................................................................40-1
Table of contents ........................................................................................................................40-2
Related information on troubleshooting....................................................................................... 40-10
Troubleshooting points ....................................................................................................... 40-10
Sequence of events in troubleshooting................................................................................. 40-12
Checks before troubleshooting............................................................................................ 40-14
Inspection procedure before troubleshooting ........................................................................ 40-16
Preparation for troubleshooting of electrical system............................................................... 40-37
Classification and procedures for troubleshooting ................................................................. 40-43
Symptom and troubleshooting numbers ............................................................................... 40-46
Information in troubleshooting table ..................................................................................... 40-49
Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................... 40-51
Connector list and layout .................................................................................................... 40-53
Connector contact identification........................................................................................... 40-64
T-branch box and T-branch adapter table ........................................................................... 40-102
Fuse location table........................................................................................................... 40-107
Failure codes table........................................................................................................... 40-109
Troubleshooting by failure code (Display of code) ...................................................................... 40-120
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-120
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-121
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-122
Failure code [879BKB] A/C Outer Sensor Short Circuit........................................................ 40-123
Failure code [879CKA] Ventilating Sensor Open Circuit....................................................... 40-124
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-125
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-126
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-127
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-128
Failure code [879GKX] Refrigerant Abnormality.................................................................. 40-129
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-130
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-131
00-4 HB215LC-2
Find manuals at https://best-manuals.com
00 Index and foreword
Index
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-132
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3............................................ 40-133
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 ............................................ 40-134
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2............................................ 40-135
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-136
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-138
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-140
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-141
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-142
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-143
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-145
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-146
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-147
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-149
Failure code [CA131] Throttle Sensor High Error................................................................. 40-151
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-153
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-155
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-157
Failure code [CA153] Chg Air Temp Sensor High Error........................................................ 40-159
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-161
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-163
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-165
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-167
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-169
Failure code [CA234] Eng Overspeed ................................................................................ 40-170
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-171
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-172
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-173
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-175
Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-177
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-178
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-180
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-182
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-184
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-186
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-187
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-188
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-190
Failure code [CA357] Mass Air Flow Sensor Low Error........................................................ 40-192
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-194
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-195
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-197
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-199
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-200
Failure code [CA442] Battery Voltage High Error................................................................. 40-202
Failure code [CA449] Rail Press Very High Error................................................................. 40-203
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-204
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-206
Failure code [CA466] KVGT Motor Driver Position Error ...................................................... 40-208
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-210
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-211
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-213
Failure code [CA553] Rail Press High Error ........................................................................ 40-215
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-216
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-217
Failure code [CA559] Rail Press Low Error......................................................................... 40-218
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-220
Failure code [CA691] Intake Air Temp Sens High Error........................................................ 40-222
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-224
HB215LC-2 00-5
Find manuals at https://best-manuals.com
00 Index and foreword
Index
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-226
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-227
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-228
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-229
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-232
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-233
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-234
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-235
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-237
Failure code [CA1896] EGR Valve Stuck Error.................................................................... 40-239
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-240
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error............................................. 40-241
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-242
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-244
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-246
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-247
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-249
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-250
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-252
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-254
Failure code [CA2373] Exhaust Manifold Press Sens High Error .......................................... 40-255
Failure code [CA2374] Exhaust Manifold Press Sens Low Error........................................... 40-257
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-259
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-261
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-263
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-264
Failure code [CA2555] Grid Htr Relay Volt Low Error........................................................... 40-265
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-267
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-269
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-270
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-271
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-273
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error........................................ 40-275
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-277
Failure code [CA3918] KVGT Stuck Error........................................................................... 40-278
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ............................................ 40-279
Failure code [CA3921] KVGT Servo Error 2........................................................................ 40-280
Failure code [CA3922] KVGT Motor Driver Open Error ........................................................ 40-281
Failure code [CA3923] KVGT Motor Driver Short Error ........................................................ 40-283
Failure code [D110KB] Battery Relay Drive Short Circuit...................................................... 40-285
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-287
Failure code [D811MC] KOMTRAX Error............................................................................ 40-290
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-291
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-292
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-294
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-295
Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-296
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-297
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...................................................... 40-299
Failure code [DA26KP] 5V Sensor 2 Power Abnormality...................................................... 40-301
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-303
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ....................................... 40-305
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ....................................... 40-307
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-308
Failure code [DA2RKR] CAN1 Discon (Pump Con) ............................................................. 40-311
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-312
Failure code [DAF0MC] Monitor Error ................................................................................ 40-313
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-314
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-316
00-6 HB215LC-2
Find manuals at https://best-manuals.com
00 Index and foreword
Index
Failure code [DAFGMC] GPS Module Error........................................................................ 40-317
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-318
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-320
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-321
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-322
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-323
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-327
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-332
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-338
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-340
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................. 40-341
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-344
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality........................................ 40-347
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ................................... 40-349
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality................................... 40-351
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality .................................. 40-353
Failure code [DHSAKZ] Swing RH PPC Press Sensor Abnormality ...................................... 40-355
Failure code [DHSBKZ] Swing LH PPC Press Sensor Abnormality....................................... 40-357
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .................................... 40-359
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-361
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ............................... 40-363
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .............................. 40-365
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ............................... 40-367
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ............................... 40-369
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt. ..................................... 40-371
Failure code [DHVAL8] HYB Swing-R PPC Pr. Sen. Signal Mismatch................................... 40-374
Failure code [DHVAMA] HYB Swing-R PPC Sensor Malfunction .......................................... 40-375
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen. Opn/Short Cir........................................ 40-377
Failure code [DHVBL8] HYB Swing-L PPC Pr. Sen. Signal Mismatch ................................... 40-379
Failure code [DHVBMA] HYB Swing-L PPC Sensor Malfunction .......................................... 40-380
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality....................................... 40-382
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality ...................................... 40-385
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-388
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ........................................ 40-390
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-392
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-394
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-396
Failure code [DW45KA] Swing Brake Sol Open Circuit ........................................................ 40-398
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-401
Failure code [DW45KK] Swing Brake Sol. Valve Low Sup. Voltage ....................................... 40-404
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. ............................................. 40-406
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-408
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-410
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-412
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-414
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..................................................... 40-416
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit...................................................... 40-418
Failure code [DWK2KA] Variable Back Press Sol Open Circuit............................................. 40-420
Failure code [DWK2KB] Variable Back Press Sol Short Circuit ............................................. 40-422
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-424
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-426
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-428
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-430
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-432
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-434
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................ 40-436
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................. 40-438
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ................................................ 40-440
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ................................................ 40-442
HB215LC-2 00-7
Find manuals at https://best-manuals.com
00 Index and foreword
Index
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ................................................... 40-444
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ................................................... 40-446
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-448
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-450
Failure code [DY2CKB] Washer Drive Short Circuit............................................................. 40-452
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...................................................... 40-454
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ....................................................... 40-456
Failure code [GA****] Precautions related to hybrid components and troubleshooting of high
voltage parts ...................................................................................................... 40-458
Failure code [GA——] Table and check sheet of monitoring items on hybrid
components ....................................................................................................... 40-487
Failure code [GA00NS] HYB Equipment Overheat .............................................................. 40-492
Failure code [GA01KA] Power Cable Interlock Open Circuit................................................. 40-493
Failure code [GA01KB] Power Cable Interlock Short Circuit ................................................. 40-495
Failure code [GA02KZ] DC Line Open & Short Circuit ......................................................... 40-497
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster ........................................... 40-498
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster............................................ 40-499
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster ............................................. 40-500
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster .......................................... 40-501
Failure code [GA08KG] Abnorm. DC HW Volt. After Booster ................................................ 40-502
Failure code [GA09KG] Abnorm. DC SW Volt. After Booster ................................................ 40-503
Failure code [GA09KP] Low DC SW Output Volt. After Booster ............................................ 40-504
Failure code [GA0AKZ] DC Vlt. Sen. Op./Shrt Cir. Aft. Booster ............................................. 40-505
Failure code [GA0BKZ] AC Line Open & Short Circuit ......................................................... 40-506
Failure code [GA10MA] HYB Controller Malfunction............................................................ 40-507
Failure code [GA10MC] HYB Controller Error ..................................................................... 40-508
Failure code [GA12NK] High-Voltage Line Start-up Failure .................................................. 40-509
Failure code [GA13KP] Low HYB Control. Sen. Power Sup. ................................................ 40-510
Failure code [GA13KY] HYB Control. Sen. Power Short Cir ................................................. 40-511
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir........................................ 40-512
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure ............................................ 40-513
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded.................................................. 40-514
Failure code [GA18MC] Gen. Mo.Dr. Excite. Pow. Sup. Failure ............................................ 40-515
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure..................................... 40-516
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con....................................... 40-517
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction ......................................... 40-518
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure .......................................... 40-519
Failure code [GA1FMA] Abnormal Swing Motor Driver ........................................................ 40-520
Failure code [GA1GKR] Swg Mot. Driver Sub-CPU Comm. Failure....................................... 40-521
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal ...................................... 40-522
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded.................................... 40-523
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir ..................................... 40-524
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir ...................................... 40-525
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir..................................... 40-526
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens. Opn/Shrt Cir ........................................ 40-527
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen. Opn/Shrt Cir. .......................................... 40-528
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat ................................................ 40-529
Failure code [GA1SFS] Contactor Locked .......................................................................... 40-530
Failure code [GA1SMC] Contactor Failure.......................................................................... 40-531
Failure code [GA1TKP] Capacitor Low Output Voltage ........................................................ 40-532
Failure code [GA1TNS] Capacitor Overheat ....................................................................... 40-533
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/short Cir. ........................................... 40-535
Failure code [GA1VFS] Capacitor Contactor Locked ........................................................... 40-537
Failure code [GA1VMC] Capacitor Contactor Failure........................................................... 40-539
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ.......................................... 40-540
Failure code [GA1YNS] Booster Inductor Overheat ............................................................. 40-541
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. ...................................... 40-542
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat .............................................. 40-543
Failure code [GA22NS] Booster IGBT Junction Overheat .................................................... 40-544
00-8 HB215LC-2
Find manuals at https://best-manuals.com
00 Index and foreword
Index
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sen.0 Opn/Short Cir......................................... 40-545
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sen.1 Opn/Short Cir......................................... 40-546
Failure code [GA25MA] Gen. Motor Driver IGBT 0 Abnormality ............................................ 40-547
Failure code [GA25NS] Gen. Motor Driver IGBT 0 Overheat ................................................ 40-548
Failure code [GA26MA] Gen. Motor Driver IGBT 1 Abnormality ............................................ 40-549
Failure code [GA26NS] Gen. Motor Driver IGBT 1 Overheat ................................................ 40-550
Failure code [GA27KZ] DC Cur. Sens. Bef. Booster Opn/Short Cir ....................................... 40-551
Failure code [GA2QKR] CAN2 Discon (Hyb Con) ............................................................... 40-552
Failure code [GA2RKR] CAN1 Discon (Hyb Con)................................................................ 40-554
Failure code [GA60KZ] Generator Motor Open/Short Circuit ................................................ 40-555
Failure code [GA60MC] Generator Motor Failure ................................................................ 40-556
Failure code [GA60N1] Generator Motor Overrun ............................................................... 40-558
Failure code [GA61KZ] Gen. Motor Temp. Sens. Opn/Short Cir. ........................................... 40-559
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat ........................................ 40-561
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir ....................................... 40-562
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir ........................................ 40-563
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction........................................ 40-564
Failure code [GA62MC] Gen. Mot. Ph-A Cur. Sen. Defect Op............................................... 40-565
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir ....................................... 40-566
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir ........................................ 40-567
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction........................................ 40-568
Failure code [GA63MC] Gen. Mot. Ph-B Cur. Sen. Defect Op............................................... 40-569
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir....................................... 40-570
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir ........................................ 40-571
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction........................................ 40-572
Failure code [GA64MC] Gen. Mot. Ph-C Cur. Sen. Defect Op. ............................................. 40-573
Failure code [GA70KB] HYB Swing Motor Short Circuit ....................................................... 40-574
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion ........................................ 40-575
Failure code [GA70NS] HYB Swing Motor Overheat ........................................................... 40-576
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. ..................................... 40-577
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction .......................................... 40-579
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op. ........................................... 40-581
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ.......................................... 40-582
Failure code [GAA0KB] HYB Con. Battery Relay Drive Short Cir. ......................................... 40-583
Failure code [GAA2KB] Swing Brake Sol. Supply Line Short Cir. .......................................... 40-585
Failure code [GAA6KP] Low HYB Control. Sen. Power 2 Sup. ............................................. 40-587
Failure code [GAA6KY] HYB Control. Sen. Power 2 Short Cir .............................................. 40-588
Failure code [GACLKA] Operating Lamp Open Circuit (HYB Con) ........................................ 40-589
Failure code [GACLKB] Operating Lamp Short Circuit (HYB Con) ........................................ 40-591
Troubleshooting of electrical system (E-mode) .......................................................................... 40-592
E-1 Engine does not start (Engine does not crank) .............................................................. 40-592
E-2 Manual preheating system does not work..................................................................... 40-598
E-3 Automatic preheating system does not work................................................................. 40-601
E-4 While preheating is working, preheating monitor does not light up .................................. 40-603
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-605
E-6 When starting switch is turned to ON position (before starting engine), engine oil level
monitor lights up in yellow.................................................................................... 40-609
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant
level monitor lights up in yellow ............................................................................ 40-610
E-8 Engine coolant temperature monitor lights up in white while engine is running ................. 40-611
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-612
E-10 Charge level monitor lights up in red while engine is running ........................................ 40-613
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-614
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-615
E-13 Water separator monitor lights up in red while engine is running ................................... 40-616
E-14 Engine coolant temperature monitor lights up in red while engine is running .................. 40-617
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-618
E-16 Hybrid temperature monitor lights up in red while engine is running .............................. 40-619
E-17 Engine oil pressure monitor lights up in red while engine is running .............................. 40-621
HB215LC-2 00-9
00 Index and foreword
Index
E-18 Fuel gauge display does not move from minimum or maximum .................................... 40-622
E-19 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-623
E-20 Engine coolant temperature gauge display does not move from minimum or
maximum........................................................................................................... 40-624
E-21 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full
nor empty).......................................................................................................... 40-625
E-22 Hydraulic oil temperature gauge does not move from minimum or maximum ................. 40-626
E-23 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor
empty) ............................................................................................................... 40-628
E-24 Hybrid temperature gauge does not move from minimum or maximum.......................... 40-629
E-25 Hybrid temperature gauge indicates incorrect temperature (indicates neither full nor
empty) ............................................................................................................... 40-630
E-26 Contents of display on machine monitor is different from actual machine
condition ............................................................................................................ 40-632
E-27 Some areas of machine monitor screen are not displayed............................................ 40-633
E-28 Function switch does not work................................................................................... 40-634
E-29 Automatic warm-up system does not operate (in cold season)...................................... 40-635
E-30 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration
switch is operated............................................................................................... 40-636
E-31 Auto-deceleration function does not operate or is not canceled while lever is
operated ............................................................................................................ 40-637
E-32 Working mode selection screen is not displayed while working mode selector switch is
operated ............................................................................................................ 40-639
E-33 Setting of engine and hydraulic pump is not changed while working mode is
changed............................................................................................................. 40-640
E-34 Travel speed monitor does not change when travel speed switch is operated ................ 40-641
E-35 Travel speed does not change while travel speed selection is changed......................... 40-642
E-36 Alarm buzzer does not stop sounding......................................................................... 40-643
E-37 Service meter is not displayed, while starting switch is in OFF position.......................... 40-644
E-38 Service mode cannot be selected .............................................................................. 40-645
E-39 None of work equipment, swing or travel works........................................................... 40-646
E-40 Any of work equipment, swing and travel cannot be locked .......................................... 40-648
E-41 Upper structure does not swing while swing parking brake cancel switch is set to
CANCEL position................................................................................................ 40-650
E-42 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
position.............................................................................................................. 40-653
E-43 One-touch power maximizing function does not operate, or indicator is not displayed on
monitor .............................................................................................................. 40-655
E-44 One-touch power maximizing function cannot be canceled .......................................... 40-657
E-45 Alarm does not sound during travel............................................................................ 40-658
E-46 Alarm does not stop sounding while machine is stopped.............................................. 40-659
E-47 Horn does not sound ................................................................................................ 40-660
E-48 Horn does not stop sounding..................................................................................... 40-662
E-49 Wiper monitor does not light up, or does not go out, while wiper switch is
operated ............................................................................................................ 40-663
E-50 Wiper does not operate while wiper switch is operated ................................................ 40-664
E-51 Window washer does not operate while window washer switch is operated ................... 40-666
E-52 Boom LOWER is not displayed correctly with monitoring function................................. 40-667
E-53 Arm OUT is not displayed correctly with monitoring function ......................................... 40-668
E-54 Arm IN is not displayed correctly with monitoring function ............................................ 40-669
E-55 Boom RAISE is not displayed correctly with monitoring function ................................... 40-670
E-56 Bucket CURL is not displayed correctly with monitoring function................................... 40-671
E-57 Bucket DUMP is not displayed correctly with monitoring function.................................. 40-672
E-58 Swing is not displayed correctly with monitoring function.............................................. 40-673
E-59 Travel is not displayed correctly with monitoring function ............................................. 40-674
E-60 Service is not displayed correctly with monitoring function ........................................... 40-675
E-61 Attachment hydraulic circuit cannot be changed.......................................................... 40-678
E-62 KOMTRAX system does not operate normally ............................................................ 40-679
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-680
00-10 HB215LC-2
00 Index and foreword
Index
Information described in troubleshooting table (H-mode) ..................................................... 40-680
System chart of hydraulic and mechanical systems............................................................. 40-681
Failure mode and cause table ........................................................................................... 40-683
H-1 All of work equipments and travel operations lack speed or power.................................. 40-689
H-2 Engine speed drops significantly or engine stalls .......................................................... 40-692
H-3 None of work equipment or travel works....................................................................... 40-695
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-696
H-5 Fine control performance or response is poor ............................................................... 40-697
H-6 Boom speed or power is low ....................................................................................... 40-699
H-7 Arm speed or power is low.......................................................................................... 40-703
H-8 Bucket speed or power is low...................................................................................... 40-708
H-9 Work equipment does not move in single operation....................................................... 40-711
H-10 Hydraulic drift of boom is large .................................................................................. 40-712
H-11 Hydraulic drift of arm is large ..................................................................................... 40-713
H-12 Hydraulic drift of bucket is large ................................................................................. 40-714
H-13 Time lag of work equipment is large ........................................................................... 40-715
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-717
H-15 One-touch power maximizing function does not operate .............................................. 40-718
H-16 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-719
H-17 Machine does not travel straight ................................................................................ 40-720
H-18 Travel speed is slow................................................................................................. 40-723
H-19 Machine is hard to steer or travel power is low ............................................................ 40-726
H-20 Travel speed does not change, or travel speed is too slow or fast ................................. 40-730
H-21 One of tracks does not run ........................................................................................ 40-731
H-22 Upper structure does not swing to the right or left ........................................................ 40-733
H-23 Upper structure swings only to the right or left............................................................. 40-734
H-24 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-735
H-25 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-736
H-26 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-737
H-27 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-738
H-28 Shock is large when upper structure stops swinging.................................................... 40-739
H-29 Large unusual noise is heard when upper structure stops swinging .............................. 40-740
H-30 Swing drift on a slope is large while swing parking brake is applied............................... 40-741
H-31 Swing drift on a slope is large while swing parking brake is released............................. 40-742
H-32 Attachment hydraulic circuit cannot be changed while attachment is installed................ 40-743
H-33 Oil flow in attachment circuit cannot be controlled ....................................................... 40-744
Troubleshooting of engine (S-mode)......................................................................................... 40-745
Information mentioned in troubleshooting table (S mode)..................................................... 40-745
S-1 Engine does not crank when starting switch is turned to START position......................... 40-746
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-747
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-748
S-4 Engine startability is poor............................................................................................ 40-749
S-5 Engine does not pick up smoothly ............................................................................... 40-751
S-6 Engine stops during operation ..................................................................................... 40-753
S-7 Engine runs rough or is unstable ................................................................................. 40-755
S-8 Engine lacks power .................................................................................................... 40-756
S-9 Exhaust smoke is black .............................................................................................. 40-758
S-10 Engine oil consumption is excessive .......................................................................... 40-760
S-11 Oil becomes contaminated quickly ............................................................................. 40-761
S-12 Fuel consumption is excessive .................................................................................. 40-762
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-763
S-14 Oil pressure drops.................................................................................................... 40-764
S-15 Fuel mixes into engine oil.......................................................................................... 40-765
S-16 Water mixes into engine oil (milky) ............................................................................. 40-766
HB215LC-2 00-11
00 Index and foreword
Index
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-767
S-18 Unusual noise is heard ............................................................................................. 40-768
S-19 Vibration is excessive ............................................................................................... 40-769
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-770
Troubleshooting for hybrid systems (Y mode)............................................................................ 40-771
Precautions related to hybrid equipment ............................................................................ 40-771
Y-1 Hybrid monitor does not go out .................................................................................... 40-772
Y-2 Machine does not swing.............................................................................................. 40-773
Y-3 Swing acceleration or swing speed is low ..................................................................... 40-776
Y-4 Upper structure overruns excessively when it stops swinging ......................................... 40-777
Y-5 Shock is large when upper structure stops swinging ...................................................... 40-778
Y-6 Large unusual noise is heard when upper structure stops swinging ................................ 40-779
Y-7 Swing drift on a slope is large ...................................................................................... 40-780
Y-8 Electric swing motor temperature increases abnormally................................................. 40-781
Y-9 Motor-generator temperature increases abnormally....................................................... 40-782
Y-10 Inverter temperature increases abnormally ................................................................. 40-783
Y-11 Capacitor temperature increases abnormally .............................................................. 40-784
50 Disassembly and assembly ...........................................................................................................50-1
Table of contents ........................................................................................................................50-2
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual .......................................................................................................50-4
Precautions related to hybrid equipment ................................................................................ 50-6
Coating materials list ............................................................................................................50-7
Special tools list ................................................................................................................. 50-11
Sketches of special tools .................................................................................................... 50-16
Engine and cooling system........................................................................................................ 50-23
Removal and installation of supply pump assembly............................................................... 50-23
Removal and installation of injector assembly....................................................................... 50-27
Removal and installation of cylinder head assembly.............................................................. 50-33
Removal and installation of radiator assembly ...................................................................... 50-51
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-54
Removal and installation of aftercooler assembly .................................................................. 50-57
Removal and installation of engine, motor-generator, and main pump assembly ...................... 50-59
Removal and installation of fan belt...................................................................................... 50-71
Removal and installation of starting motor ............................................................................ 50-74
Removal and installation of engine front oil seal .................................................................... 50-76
Removal and installation of engine rear oil seal..................................................................... 50-79
Removal and installation of fuel cooler assembly .................................................................. 50-82
Removal and installation of fuel tank assembly ..................................................................... 50-84
Removal and installation of engine hood assembly ............................................................... 50-86
Removal and installation of KDOC assembly........................................................................ 50-89
Removal and installation of KCCV assembly ........................................................................ 50-90
Removal and installation of air cleaner assembly .................................................................. 50-96
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly........................ 50-97
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly....................... 50-99
Hybrid system ........................................................................................................................ 50-102
Draining coolant, refilling with coolant, and bleeding air for hybrid system ............................. 50-102
Removal and installation of hybrid radiator assembly .......................................................... 50-106
Removal and installation of hybrid water pump assembly .................................................... 50-109
Removal and installation of inverter assembly .....................................................................50-111
Removal and installation of inverter and capacitor assembly ................................................ 50-114
Procedure for draining and refilling generator lubricating oil ................................................. 50-119
Removal and installation of tandem pump assembly ........................................................... 50-121
Removal and installation of motor-generator and housing assembly ..................................... 50-124
Removal and installation of electric swing motor assembly .................................................. 50-131
Power train system ................................................................................................................. 50-136
Removal and installation of travel motor and final drive assembly......................................... 50-136
Disassembly and assembly of final drive ............................................................................ 50-137
Removal and installation of swing motor and swing machinery assembly.............................. 50-146
00-12 HB215LC-2
00 Index and foreword
Index
Disassembly and assembly of swing machinery assembly................................................... 50-150
Removal and installation of swing circle assembly .............................................................. 50-164
Undercarriage and frame......................................................................................................... 50-165
Separation and connection of track shoe assembly............................................................. 50-165
Removal and installation of sprocket.................................................................................. 50-168
Removal and installation of idler and idler cushion assembly ............................................... 50-169
Disassembly and assembly of idler assembly ..................................................................... 50-170
Disassembly and assembly of idler cushion assembly......................................................... 50-172
Disassembly and assembly of track roller assembly ............................................................ 50-174
Disassembly and assembly of carrier roller assembly.......................................................... 50-176
Removal and installation of revolving frame assembly ......................................................... 50-179
Removal and installation of counterweight assembly ........................................................... 50-181
Hydraulic system .................................................................................................................... 50-184
Removal and installation of center swivel joint assembly ..................................................... 50-184
Disassembly and assembly of center swivel joint assembly ................................................. 50-187
Removal and installation of hydraulic tank assembly ........................................................... 50-189
Removal and installation of main pump assembly ............................................................... 50-192
Removal and installation of control valve assembly ............................................................. 50-196
Disassembly and assembly of control valve assembly......................................................... 50-200
Disassembly and assembly of work equipment PPC valve................................................... 50-206
Disassembly and assembly of travel PPC valve assembly ................................................... 50-208
Work equipment ..................................................................................................................... 50-210
Removal and installation of work equipment assembly ........................................................ 50-210
Disassembly and assembly of work equipment cylinder assembly........................................ 50-213
Cab and its attachments.......................................................................................................... 50-220
Removal and installation of operator's cab assembly........................................................... 50-220
Removal and installation of operator cab glass (adhered glass) ........................................... 50-225
Removal and installation of front window assembly ............................................................. 50-235
Removal and installation of floor frame assembly................................................................ 50-241
Removal and installation of air conditioner unit assembly..................................................... 50-247
Removal and installation of operator's seat......................................................................... 50-251
Removal and installation of seat belt .................................................................................. 50-253
Removal and installation of front wiper assembly ................................................................ 50-255
Electrical system .................................................................................................................... 50-262
Removal and installation of air conditioner compressor assembly......................................... 50-262
Removal and installation of air conditioner condenser assembly .......................................... 50-264
Removal and installation of engine controller assembly ....................................................... 50-266
Removal and installation of pump controller assembly......................................................... 50-268
Removal and installation of machine monitor assembly ....................................................... 50-271
Removal and installation of pump swash plate sensor ......................................................... 50-273
Removal and installation of mass air flow and temperature sensor ....................................... 50-274
Removal and installation of KOMTRAX terminal assembly .................................................. 50-275
60 Maintenance standard...................................................................................................................60-1
Table of contents ........................................................................................................................60-2
Engine and cooling system..........................................................................................................60-3
Engine mount ......................................................................................................................60-3
Cooling system ....................................................................................................................60-4
Power train system .....................................................................................................................60-5
Swing circle ......................................................................................................................... 60-5
Swing machinery with swing brake ........................................................................................60-6
Final drive ...........................................................................................................................60-8
Sprocket............................................................................................................................ 60-10
Undercarriage and frame........................................................................................................... 60-12
Track frame and idler cushion ............................................................................................. 60-12
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-16
Carrier roller ...................................................................................................................... 60-17
Track shoe ........................................................................................................................ 60-18
Hydraulic system ...................................................................................................................... 60-24
HB215LC-2 00-13
00 Index and foreword
Index
Hydraulic tank.................................................................................................................... 60-24
Main pump ........................................................................................................................ 60-25
Control valve ..................................................................................................................... 60-26
Travel motor ...................................................................................................................... 60-36
PPC valve ......................................................................................................................... 60-39
Solenoid valve ................................................................................................................... 60-49
Attachment circuit selector valve (for high-pressure circuit) .................................................... 60-50
Attachment circuit selector valve (for low-pressure circuit) ..................................................... 60-51
Center swivel joint .............................................................................................................. 60-52
Work equipment ....................................................................................................................... 60-53
Work equipment................................................................................................................. 60-53
Work equipment cylinder .................................................................................................... 60-62
80 Appendix......................................................................................................................................80-1
Table of contents ........................................................................................................................80-2
Air conditioner components .........................................................................................................80-3
Precautions for refrigerant.....................................................................................................80-3
Air conditioner component ....................................................................................................80-4
Configuration and function of refrigeration cycle......................................................................80-7
Outline of refrigeration cycle..................................................................................................80-8
Air conditioner unit .............................................................................................................80-10
Dual pressure switch .......................................................................................................... 80-17
Air conditioner controller .....................................................................................................80-18
Compressor....................................................................................................................... 80-19
Air conditioner condenser ................................................................................................... 80-20
Sunlight sensor.................................................................................................................. 80-22
Outer temperature sensor (outside air temperature sensor) ................................................... 80-23
Procedure for testing and troubleshooting ............................................................................ 80-24
Circuit diagram and arrangement of connector pins............................................................... 80-26
System diagram................................................................................................................. 80-28
Parts and connectors layout................................................................................................ 80-31
Testing air leakage (duct).................................................................................................... 80-35
Testing with self-diagnosis function ...................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-41
Testing FRESH/RECIRC air changeover.............................................................................. 80-43
Testing sunlight sensor ....................................................................................................... 80-44
Testing (dual) pressure switch for refrigerant......................................................................... 80-45
Testing relays .................................................................................................................... 80-46
Troubleshooting chart 1 ...................................................................................................... 80-47
Troubleshooting chart 2 ...................................................................................................... 80-48
Information in troubleshooting table ..................................................................................... 80-51
Failure code list related to air conditioner.............................................................................. 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-54
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-55
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-57
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-59
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-60
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-61
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-63
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-64
Failure code [879GKX] Refrigerant Abnormality.................................................................... 80-65
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-66
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-68
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-71
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-73
Troubleshooting with gauge pressure................................................................................... 80-75
Connection of service tool................................................................................................... 80-78
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-80
00-14 HB215LC-2
00 Index and foreword
Index
Handling of compressor oil.................................................................................................. 80-82
Desiccant replacement ....................................................................................................... 80-84
90 Diagrams and drawings.................................................................................................................90-1
Table of contents ........................................................................................................................90-2
Hydraulic circuit diagram .............................................................................................................90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram.......................................................................................................90-7
Electric circuit diagram .............................................................................................................. 90-13
Symbols in electric circuit diagram.......................................................................................90-13
Electrical circuit diagram..................................................................................................... 90-17
Electrical circuit diagram of air conditioner unit...................................................................... 90-47
Index.................................................................................................................................................................... 1
HB215LC-2 00-15
00 Index and foreword
Foreword, safety and general information
Foreword, safety and general information
(ALL-0370-001-A-00-A)
Important safety notice (Hybrid)
(HB380-1120-012-A-00-A)
Important safety precautions
(Rev. 2013/04)
•Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu.
Some of the servicing and repair methods require use of special tools designed by Komatsu for special
purposes.
•The symbol mark kis indicated for such matters that require special precautions. The work indicated
with this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Precautions peculiar to hybrid machine
kk This machine is equipped with the hybrid
system consisting of an electric motor and a
diesel engine. The above Hybrid mark is
attached to each explanation peculiar to the
hybrid system (contents different from those
for the common diesel engine machine). Be
sure to read the Operation and Maintenance
Manual, "Introduction", "Safety", "Handling
hybrid components and high voltage wiring
harness" in this manual, and Structure and
operation, "Hybrid system" (Chapter 10) to
understand the hybrid system.
kk The persons who engage in the installing or
removing work of the hybrid devices (motor-
generator, capacitor, inverter, electric swing
motor) must follow the local Industrial Safety
and Health Law concerning electricity.
kk Never disassemble the hybrid devices for
quality assurance. The hybrid devices and
high-voltage wiring (orange color) must be
replaced in a unit.
kk Before handling a hybrid device, be sure to
discharge the capacitor. For details see
Testing and adjusting, "Capacitor discharge
procedure" (Chapter 30).
kk When handling the hybrid devices or high-
voltage wirings, be sure to follow "Handling
hybrid components and high voltage wiring
harness".
kk When handling the hybrid devices or high-
voltage wirings, you are required to look into
the charge level inspection window on the
contactor box at the top of the capacitor and
check that the LED display indicates that the
capacitor is discharged. Before discharging
the capacitor, check the indicating function
of this LED according to the following
procedure.
1. Both LEDs light up 1 minute after the
engine is started.
2. Only 1 LED lights up after the starting
switch is turned to OFF position. (When
the starting switch is turned to OFF
position, 1 LED goes off.)
If the above cannot be confirmed while no
failure is occurring in the hybrid system, the
LED display function of showing the charge
level of the capacitor may be defective. In
this case, replace the capacitor according to
"Precautions for normal testing and
adjusting".
Safety points
•Good arrangement
•Correct work clothes
•Observance of work standard
•Practice of making and checking signals
•Prohibition of operation and handling by
unlicensed workers
•Safety check before starting work
•Wearing protective goggles (for cleaning or
grinding work)
•Wearing shielding goggles and protectors (for
welding work)
•Good physical condition and preparation
•Precautions against work which you are not
used to or you are used to too much
00-16 HB215LC-2
00 Index and foreword
Foreword, safety and general information
General precautions
kk Inappropriate handling creates an extreme
danger. Read and understand what is
described in the Operation and Maintenance
Manual before operating the machine. In
addition read this manual carefully and
understand its contents before starting work.
•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.
•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.
•When performing any operation, always wear
safety shoes and helmet. Do not wear loose
work clothes, or clothes with buttons missing.
•Always wear the protective eyeglasses when
hitting parts with a hammer.
•Always wear the protective eyeglasses when
grinding parts with a grinder, etc.
•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.
•Only qualified workers must perform the work
and operation which require license or
qualification.
•Keep all tools in good condition, learn the correct
way to use them, and use the proper ones.
Before starting work, thoroughly check the tools,
machine, forklift truck, service car, etc.
•If welding repairs are needed, always have a
trained and experienced welder perform the
work. When performing welding work, always
wear welding gloves, apron, shielding goggles,
cap and other clothes suited for welding work.
•Before starting work, warm up your body
thoroughly to start work under good condition.
•Avoid continuing work for long hours and take
rests at proper intervals to keep your body in
good condition and at the provided place.
Precautions for preparatory work
•Before adding oil or making any repairs, place
the machine on a firm and level ground, and
apply the parking brake and chock the wheels or
tracks to prevent the machine from moving.
•Before starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If this
is not possible, insert the lock pin or use blocks
to prevent the work equipment from falling. In
addition, be sure to lock all the control levers
and hang warning tag on them.
•When performing the disassembling or
assembling work, support the machine securely
with blocks, jacks, or stands before starting the
work.
•Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
Precautions during work
•For the machine equipped with a battery
disconnect switch, before starting the work,
check that the system operating lamp is turned
OFF, and then turn the battery disconnect switch
to the OFF(Q) position and pull the switch key
out. For machines without a battery disconnect
switch, before starting the work, remove the
cables from the battery. Always remove the
cable from the negative (-) terminal first.
•Before disconnecting or removing components
of the oil or fuel or water or air circuits, first
release the remaining pressure completely from
the circuit. When removing the oil filter cap, a
drain plug, or an oil pressure pickup plug, loosen
it slowly to prevent the oil from spurting out.
•When removing or installing the checking plug or
the piping in the fuel circuit, wait 30 seconds or
longer after the engine is shut down and start
the work after the remaining pressure is
released from the fuel circuit.
•The coolant and oil in the circuits are hot when
the engine is shut down, so be careful not to get
scalded. Wait for the oil and coolant to cool
before performing any work on the oil or coolant
circuits.
•Before starting work, shut down the engine.
When working on or around a rotating part, in
particular, shut down the engine. When checking
the machine without shutting down the engine
(measuring oil pressure, revolving speed,
temperature, etc.), take extreme care not to get
caught in rotating parts or moving parts.
•When raising a heavy component (heavier than
25 kg), use a hoist or crane. Before starting work,
check that the slings (wire ropes, chains, and
hooks) are free from damage. Always use slings
which have ample capacity and install them to
proper places. Operate the hoist or crane slowly
to prevent the component from hitting any other
HB215LC-2 00-17
00 Index and foreword
Foreword, safety and general information
part. Do not work with any part still raised by the
hoist or crane.
•When removing a part which is under internal
pressure or under reaction force of a spring,
always leave 2 bolts in diagonal positions.
Loosen those 2 bolts gradually and alternately to
release the pressure, and then remove the part.
•When removing components, be careful not to
break or damage the electrical wiring. Damaged
wiring may cause a fire.
•When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it off immediately. Fuel or oil on the floor
can cause you to slip and can even cause fires.
•As a general rule, do not use gasoline to wash
parts. Do not use it to clean electrical parts, in
particular.
•Be sure to assemble all parts again in their
original places. Replace any damaged parts and
parts which must not be reused with new parts.
When installing hoses and wiring harnesses, be
sure that they will not be damaged by contact
with other parts when the machine is operated.
•When installing high pressure hoses and tubes,
make sure that they are not twisted. Damaged
hoses and tubes are dangerous, so be
extremely careful when installing hoses and
tubes for high pressure circuits. In addition,
check that connections of them are correct.
•When assembling or installing parts, always
tighten them to the specified torques. When
installing protective parts such as guards, or
parts which vibrate violently or rotate at high
speed, be particularly careful to check that they
are installed correctly.
•When aligning 2 holes, never insert your fingers
or hand. Be careful not to get your fingers
caught in a hole.
•When measuring hydraulic pressure, check that
the measuring tools are correctly installed.
•Take care when removing or installing the tracks
of track-type machines. Since the track shoe
may separate suddenly when you remove it,
never let anyone stand at either end of the track
shoe.
•If the engine is operated for a long time in a
closed place which is not ventilated well, you
may suffer from gas poisoning. Accordingly,
open the windows and doors to ventilate the
place well.
Precautions for slinging work and making
signals
•Only one appointed worker must make signals
and co-workers must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at a place where
he is well seen from the operator's seat and
where he can see the working condition easily.
The signaler must always stand in front of the
load and guide the operator safely.
•Never stand under the load.
•Do not move a load over a person.
•Never stand on the load.
•Do not prevent the load from swinging or
falling down by holding it simply with the
hands.
•The sling workers and assistant workers
other than the guide must move to a place
where they are not caught between the load
and materials or equipment on the ground or
hit by the load even if the crane starts
abruptly.
•Check the slings before starting sling work.
•Keep putting on gloves during sling work. (Put
on leather gloves, if available.)
•Measure the weight of the load by the eye and
check its center of gravity.
•Use proper sling corresponding to the weight of
the load and method of slinging. If too thick wire
ropes are used to sling a light load, the load may
slip and fall.
•Do not sling a load with one wire rope alone. If it
is slung so, It may rotate and may slip out of the
rope. Install two or more wire ropes
symmetrically.
kSlinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
•Hanging angle must be 60° or smaller as a rule.
•When hanging a heavy load (25 kg or heavier),
the hanging angle of the rope must be narrower
than that of the hook.
aWhen hoisting a load with 2 or more ropes,
the force subjected to each rope increases
with the hanging angle. The figure below
shows the variation of allowable load in kg
when hoisting is made with 2 ropes, each of
which is allowed to sling up to 9.8 kN {1,000
kg} vertically, at various hanging angles.
When the 2 ropes sling a load vertically, they
can sling up to 2,000 kg of total weight. This
weight is reduced to 1,000 kg when the 2
ropes make a hanging angle of 120°. If the 2
ropes sling a 2,000 kg load at a lifting angle
of 150° each rope is subjected to a force as
large as 39.2kN {4,000 kg}.
00-18 HB215LC-2
This manual suits for next models
1
Other Komatsu Excavator manuals
Komatsu
Komatsu PC130-8 User manual
Komatsu
Komatsu PC2000-8 BACKHOE User manual
Komatsu
Komatsu PC160LC-8 User manual
Komatsu
Komatsu PC210LL-10 Manual
Komatsu
Komatsu PC200LC-8 Install guide
Komatsu
Komatsu PC240LC-11 Install guide
Komatsu
Komatsu PC240LC-11 Manual
Komatsu
Komatsu PVVl70ES-6 Manual
Komatsu
Komatsu PW160-7K Series User manual
Komatsu
Komatsu PC130-7 Install guide
Komatsu
Komatsu 15045 Manual
Komatsu
Komatsu PC490LC-10 Install guide
Komatsu
Komatsu PC210LC-11 Install guide
Komatsu
Komatsu GD705A-4 Install guide
Komatsu
Komatsu Galeo PC1250-7 Backhoe User manual
Komatsu
Komatsu PC20MR-2 Install guide
Komatsu
Komatsu PW400MH-6 Manual
Komatsu
Komatsu PC160LC-8 Manual
Komatsu
Komatsu PC350-7 User manual
Komatsu
Komatsu PC350LC-8 Install guide
