Komatsu HB205-1 HB215LC-1 Hybrid Excavator Workshop Repair Service Manual SEN05393 PDF - MKMTSHB205OPEK.zip
A full-service repair manual featuring electrical wiring diagrams for the Komatsu HB205-1 and HB215LC-1 Hybrid Hydraulic Excavators, packed with the technical data needed to service, troubleshoot, fix, and rebuild the machine the way expert technicians do.
Covered within the Komatsu HB205-1, HB215LC-1 Hybrid workshop service repair manual:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,451 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN05393-04 - Hydraulic Excavator HB205-1, HB215LC-1 Hybrid Shop Manual.pdf
MAIN SECTIONS
COVER...1
00 Index and foreword...11
Table of Contents...12
Table of Contents...12
Foreword and general information...24
Safety notice...24
How to read the shop manual...29
Explanation of terms for maintenance standard...31
Handling of hydraulic components...33
Method of disconnecting and connecting push-pull type coupler...35
Handling of electric equipment...38
How to read electric wire code...48
Precautions when performing work...53
Handling of hybrid devices and high-voltage wirings...56
Standard tightening torque table...62
List of Abbreviation...66
Conversion table...70
01 Specifications...75
Specifications...77
Outline of hybrid system...77
Specification dimension drawing...78
Working range diagram...79
Specifications...80
Weight table...83
Table of fuel, coolant and lubricants...85
10 Structure and function...87
Engine and cooling system...89
Engine related parts...89
Cooling system...90
Hybrid relation...92
Configuration and safety functions of hybrid system...92
Cooling system of hybrid component...96
Motor-generator...98
Swing electric motor...99
Electric control unit...102
High-voltage wiring (power cable)...103
Water pump...104
Power train system...106
Power train...106
Swing circle...107
Swing machinery...108
Swing brake...110
Final drive...112
Undercarriage and frame...114
Track frame and idler cushion...114
Hydraulic system...116
Hydraulic components layout drawing...116
Valve control...118
Hydraulic tank...119
CLSS...120
Main pump...124
Control valve...146
Functions and operation by valve...158
Travel motor...195
PPC valve...205
Solenoid valve...224
Attachment circuit selector valve...226
Return oil filter...228
Center swivel joint...230
Accumulator...231
Electrical system...232
Electrical control system...232
Machine monitor system...262
KOMTRAX system...278
Sensors...280
20 Standard value table...287
Standard value table...289
Standard value table for engine...289
Standard value table for machine...290
30 Testing and adjusting...301
Tools for testing, adjusting and troubleshooting...304
Tools for testing, adjusting and troubleshooting...304
Engine and cooling system...309
Testing engine speed...309
Testing boost pressure...311
Checking exhaust gas color...312
Adjusting valve clearance...313
Testing compression pressure...315
Testing blowby pressure...318
Testing engine oil pressure...319
Handling fuel system parts...320
Releasing remaining pressure from fuel system...320
Testing fuel system pressure...321
Cylinder cut-out test mode operation...323
No injection cranking operation...323
Testing fuel delivery, return rate and leakage...324
Bleeding air from fuel circuit...328
Testing fuel circuit for leakage...329
Handling of controller high-voltage circuit...330
Testing and adjusting air conditioner compressor belt tension...331
Replacement of fan belt...332
Undercarriage and frame...333
Testing swing circle bearing clearance...333
Testing and adjusting track tension...334
Hydraulic system...337
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits...337
Testing source pressure of control circuit...340
Testing and adjusting oil pressure in pump PC control circuit...341
Testing and adjusting oil pressure in pump LS control circuit...344
Testing solenoid valve output pressure...348
Testing PPC valve output pressure...351
Adjusting play of work equipment and swing PPC valves...353
Checking parts which cause hydraulic drift of work equipment...354
Releasing remaining pressure from hydraulic circuit...356
Testing oil leakage...357
Bleeding air from each part...359
Cab and its attachments...361
Checking cab tipping stopper...361
Adjusting mirrors...362
Angle adjustment of rear view camera...365
Hybrid relation...366
Testing swing holding brake...366
Cleaning and replacement of oil filter of swing electric motor...367
Operation check of swing emergency stop switch...368
Electrical system...370
Special functions of machine monitor...370
Handling voltage circuit of engine controller...432
Precautions related to hybrid machines...433
Preparation work for troubleshooting of electrical system...434
Procedure for testing diodes...440
Pm Clinic...441
Pm Clinic service...441
40 Troubleshooting...447
General information on troubleshooting...456
Points to remember when troubleshooting...456
Sequence of events in troubleshooting...457
Checks before troubleshooting...458
Classification and procedures for troubleshooting...487
Failure codes table...490
Symptom and troubleshooting numbers...498
Information in troubleshooting table...501
Troubleshooting method for open circuit in wiring harness of pressure sensor system...503
Connector list and layout...505
Connection table for connector pin numbers...516
T- branch box and T- branch adapter table...552
Fuse location table...555
Troubleshooting by failure code...557
Failure code [989L00] Engine Controller Lock Caution 1...557
Failure code [989M00] Engine Controller Lock Caution 2...557
Failure code [989N00] Engine Controller Lock Caution 3...558
Failure code [AA10NX] Air Cleaner Clogging...559
Failure code [AB00KE] Charge Voltage Low...560
Failure code [B@BAZG] Eng Oil Press Low...562
Failure code [B@BAZK] Eng Oil Level Low...563
Failure code [B@BCNS] Eng Water Overheat...564
Failure code [B@BCZK] Eng Water Level Low...566
Failure code [B@HANS] Hyd Oil Overheat...568
Failure code [CA111] ECM Critical Internal Failure...569
Failure code [CA115] Eng Ne and Bkup Speed Sens Error...569
Failure code [CA122] Chg Air Press Sensor High Error...570
Failure code [CA123] Chg Air Press Sensor Low Error...572
Failure code [CA131] Throttle Sensor High Error...574
Failure code [CA132] Throttle Sensor Low Error...576
Failure code [CA144] Coolant Temp Sens High Error...578
Failure code [CA145] Coolant Temp Sens Low Error...580
Failure code [CA153] Chg Air Temp Sensor High Error...582
Failure code [CA154] Chg Air Temp Sensor Low Error...584
Failure code [CA155] Chg Air Temp High Speed Derate...586
Failure code [CA187] Sens Supply 2 Volt Low Error...588
Failure code [CA221] Ambient Press Sens High Error...590
Failure code [CA222] Ambient Press Sens Low Error...592
Failure code [CA227] Sens Supply 2 Volt High Error...594
Failure code [CA234] Eng Overspeed...594
Failure code [CA238] Ne Speed Sens Supply Volt Error...595
Failure code [CA271] IMV/PCV1 Short Error...596
Failure code [CA272] IMV/PCV1 Open Error...598
Failure code [CA322] Inj #1(L#1) Open/Short Error...600
Failure code [CA324] Inj #3(L#3) Open/Short Error...602
Failure code [CA331] Inj #2(L#2) Open/Short Error...604
Failure code [CA332] Inj #4(L#4) Open/Short Error...606
Failure code [CA342] Calibration Code Incompatibility...608
Failure code [CA351] Injectors Drive Circuit Error...609
Failure code [CA352] Sens Supply 1 Volt Low Error...610
Failure code [CA386] Sens Supply 1 Volt High Error...612
Failure code [CA428] Water in Fuel Sensor High Error...614
Failure code [CA429] Water in Fuel Sensor Low Error...616
Failure code [CA435] Eng Oil Press Sw Error...618
Failure code [CA441] Battery Voltage Low Error...620
Failure code [CA442] Battery Voltage High Error...622
Failure code [CA449] Rail Press Very High Error...623
Failure code [CA451] Rail Press Sensor High Error...624
Failure code [CA452] Rail Press Sensor Low Error...626
Failure code [CA488] Chg Air Temp High Torque Derate...628
Failure code [CA553] Rail Press High Error...629
Failure code [CA559] Supply Pump Press Low Error 1...630
Failure code [CA689] Eng Ne Speed Sensor Error...632
Failure code [CA731] Eng Bkup Speed Sens Phase Error...634
Failure code [CA757] All Continuous Data Lost Error...635
Failure code [CA778] Eng Bkup Speed Sensor Error...636
Failure code [CA1633] KOMNET Datalink Timeout Error...639
Failure code [CA2185] Throt Sens Sup Volt High Error...640
Failure code [CA2186] Throt Sens Sup Volt Low Error...641
Failure code [CA2249] Rail Press Very Low Error...642
Failure code [CA2311] IMV Solenoid Error...643
Failure code [CA2555] Grid Htr Relay Open Circuit Error...644
Failure code [CA2556] Grid Htr Relay Short Circuit Error...646
Failure code [D19JKZ] Personal Code Relay Abnormality...648
Failure code [D862KA] GPS Antenna Open Circuit...651
Failure code [DA22KK] Pump Solenoid Power Low Error...652
Failure code [DA25KP] 5V Sensor1 Power Abnormality...654
Failure code [DA26KP] 5V Sensor2 Power Abnormality...656
Failure code [DA29KQ] Model Selection Abnormality...658
Failure code [DA2RMC] CAN Discon (Pump Con Detected)...660
Failure code [DAF8KB] Camera Power Supply Short Circuit...666
Failure code [DAFGMC] GPS Module Error...668
Failure code [DAFRMC] CAN Discon (Monitor Detected)...669
Failure code [DGH2KB] Hyd Oil Sensor Short...676
Failure code [DHPAMA] Pump Press Sensor Abnormality...678
Failure code [DHPBMA] R Pump Press Sensor Abnormality...680
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality...682
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality...684
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality...686
Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open or short circuit...688
Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open or short circuit...690
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality...692
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality...694
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality...696
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit...698
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir...700
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir...702
Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor signal abnormality...704
Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor malfunction...705
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir...706
Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor signal abnormality...708
Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor malfunction...709
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir...710
Failure code [DW43KA] Travel Speed Sol Open Circuit...712
Failure code [DW43KB] Travel Speed Sol Short Circuit...714
Failure code [DW45KA] Swing holding brake solenoid valve open circuit40...716
Failure code [DW45KB] Swing holding brake solenoid valve short circuit40...719
Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop...722
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir...724
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit...726
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit...728
Failure code [DW91KA] Travel Junction Sol. Disc...730
Failure code [DW91KB] Travel Junction Sol. S/C...732
Failure code [DWA2KA] Attachment Sol Open Circuit...734
Failure code [DWA2KB] Attachment Sol Short Circuit...736
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit...738
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit...740
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit...742
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit...744
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit...746
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit...748
Failure code [DXE0KA] LS-EPC Sol Open Circuit...750
Failure code [DXE0KB] LS-EPC Sol Short Circuit...752
Failure code [DXE4KA] Service Current EPC Disc...754
Failure code [DXE4KB] Service Current EPC S/C...756
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit...758
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit...760
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit...762
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit...764
Failure code [DY20KA] Wiper Working Abnormality...766
Failure code [DY20MA] Wiper Parking Abnormality...768
Failure code [DY2CKA] Washer drive discon...770
Failure code [DY2CKB] Washer drive short...772
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit...774
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...776
Troubleshooting by failure code [GA****] (code display)...778
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices...778
Failure code [GA----] Hybrid devices monitoring items list and check sheet...805
Failure code [GA00NS] HYB devices overheat...809
Failure code [GA01KA] Power Cable Interlock Open Circuit...810
Failure code [GA02KZ] DC Line Open/Short Circuit...812
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster...813
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster...814
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster...815
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster...816
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster...817
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster...818
Failure code [GA09KP] Low DC SW Output Volt. After Booster...819
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster...820
Failure code [GA0BKZ] AC Line Open/Short Circuit...821
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure...822
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON...823
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF...824
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure...826
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure...828
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir...829
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure...829
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit...830
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit...830
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded...831
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure...831