Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU HB215LC-2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06488-11 – PDF DOWNLOAD
$38.95
KOMATSU HB215LC-2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06488-11 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU HB215LC-2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06488-11 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HB215LC-2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06488-11 – PDF DOWNLOAD
Language : English
Pages : 1880
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU HB215LC-2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06488-11 – PDF DOWNLOAD
Cover.......................................................................................................................................... 1 00 Index and foreword ..................................................................................................................... 3 Index ................................................................................................................................. 4 Foreword, safety and general information .............................................................................................. 18 Important safety notice (Hybrid) .................................................................................................. 18 How to read the shop manual ....................................................................................................... 25 Explanation of terms for maintenance standard ..................................................................................... 27 Handling equipment of fuel system devices ......................................................................................... 29 Handling of intake system parts ................................................................................................... 30 Handling of hydraulic equipment ................................................................................................... 31 Method of disconnecting and connecting of push-pull type coupler .................................................................. 33 Handling of electrical equipment .................................................................................................. 36 How to read electric wire code (Hybrid) ........................................................................................... 44 Precautions when performing operation ............................................................................................. 49 Practical use of KOMTRAX .......................................................................................................... 54 Handling hybrid components and high voltage wiring harness ........................................................................ 55 Standard tightening torque table .................................................................................................. 58 List of abbreviation .............................................................................................................. 64 Conversion table .................................................................................................................. 69 01 Specification .......................................................................................................................... 75 Table of contents ..................................................................................................................... 76 Specifications ........................................................................................................................ 77 Specification drawing ............................................................................................................. 77 Working range drawings ............................................................................................................ 78 Specifications .................................................................................................................... 79 Weight table ...................................................................................................................... 83 Table of fuel, coolant, and lubricants ............................................................................................ 85 10 Structure and function ................................................................................................................. 87 Table of contents ..................................................................................................................... 88 Engine and cooling system ............................................................................................................. 89 Engine related parts .............................................................................................................. 89 VFT ............................................................................................................................... 91 EGR system piping drawing ......................................................................................................... 95 EGR system circuit diagram ........................................................................................................ 97 EGR valve ......................................................................................................................... 98 EGR cooler ........................................................................................................................ 100 KCCV layout drawing ............................................................................................................... 102 KCCV ventilator ................................................................................................................... 104 KDOC muffler ...................................................................................................................... 106 Cooling system .................................................................................................................... 108 Hybrid system ......................................................................................................................... 110 Outline of hybrid system .......................................................................................................... 110 Configuration of hybrid system .................................................................................................... 111 Protective function of hybrid component ........................................................................................... 112 Protection function for workers when disassembling hybrid component ............................................................... 114 Cooling system of hybrid component ................................................................................................ 116 Interlock function ................................................................................................................ 117 Motor-generator ................................................................................................................... 118 Electric swing motor .............................................................................................................. 120 Electric control unit ............................................................................................................. 122 High voltage wiring harness (power cable) ......................................................................................... 123 Water pump ........................................................................................................................ 124 Power train ........................................................................................................................... 125 Power train system ................................................................................................................ 125 Swing circle ...................................................................................................................... 127 Swing machinery with swing brake .................................................................................................. 128 Final drive ....................................................................................................................... 130 Undercarriage and frame ............................................................................................................... 132 Track frame and idler cushion ..................................................................................................... 132 Hydraulic system ...................................................................................................................... 134 Hydraulic component layout ........................................................................................................ 134 Valve control ..................................................................................................................... 136 Hydraulic tank .................................................................................................................... 138 CLSS .............................................................................................................................. 140 Main pump ......................................................................................................................... 145 Control valve ..................................................................................................................... 175 Travel motor ...................................................................................................................... 230 PPC valve ......................................................................................................................... 243 Solenoid valve .................................................................................................................... 266 Attachment circuit selector valve (for high pressure circuit) ..................................................................... 269 Attachment circuit selector valve (for low pressure circuit) ...................................................................... 271 Center swivel joint ............................................................................................................... 274 Accumulator ....................................................................................................................... 276 Work equipment ........................................................................................................................ 277 Work equipment .................................................................................................................... 277 Work equipment shim ............................................................................................................... 278 Bucket play adjustment shim ....................................................................................................... 279 Cab and its attachments ............................................................................................................... 280 Cab mount and cab tipping stopper ................................................................................................. 280 ROPS cab .......................................................................................................................... 281 Electrical system ..................................................................................................................... 282 Electrical control system ......................................................................................................... 282 Machine monitor system ............................................................................................................ 339 KOMTRAX system .................................................................................................................... 363 Sensor ............................................................................................................................ 366 20 Standard value tables .................................................................................................................. 385 Table of contents ..................................................................................................................... 386 Standard service value table .......................................................................................................... 387 Standard value table for engine ................................................................................................... 387 Standard value table for machine .................................................................................................. 389 Standard value table for electrical system ........................................................................................ 404 30 Testing and adjusting .................................................................................................................. 413 Table of contents ..................................................................................................................... 414 Related information on testing and adjusting .......................................................................................... 415 Tools for testing and adjusting ................................................................................................... 415 Sketch of tools for testing and adjusting ......................................................................................... 418 Engine and cooling system ............................................................................................................. 420 Testing engine speed .............................................................................................................. 420 Testing boost pressure ............................................................................................................ 422 Testing exhaust gas color ......................................................................................................... 425 Testing and adjusting valve clearance ............................................................................................. 426 Testing compression pressure ...................................................................................................... 429 Testing blowby pressure ........................................................................................................... 433 Testing engine oil pressure ....................................................................................................... 434 Testing fuel pressure ............................................................................................................. 435 Testing fuel discharge, return and leakage ........................................................................................ 440 Bleeding air from fuel system ..................................................................................................... 442 Testing fuel circuit for leakage .................................................................................................. 444 Handling cylinder cutout mode operation ........................................................................................... 445 Handling no-injection cranking operation .......................................................................................... 446 Testing and adjusting air conditioner compressor belt tension ..................................................................... 447 Replacing fan belt ................................................................................................................ 448 Hybrid system ......................................................................................................................... 449 Precautions related to hybrid equipment ........................................................................................... 449 Bleeding air from hybrid cooling system ........................................................................................... 450 Testing water pressure of hybrid coolant .......................................................................................... 452 Testing swing parking brake ....................................................................................................... 454 Cleaning and replacing oil filter of electric swing motor ......................................................................... 455 Power train ........................................................................................................................... 456 Testing swing circle bearing clearance ............................................................................................ 456 Undercarriage and frame ............................................................................................................... 457 Testing and adjusting track tension ............................................................................................... 457 Hydraulic system ...................................................................................................................... 458 Releasing remaining pressure from hydraulic circuit ............................................................................... 458 Testing oil pressure of control circuit ........................................................................................... 462 Testing and adjusting oil pressure in work equipment and travel circuits .......................................................... 463 Testing and adjusting oil pressure in pump PC control circuit ..................................................................... 466 Testing and adjusting oil pressure in pump LS control circuit ..................................................................... 470 Testing outlet pressure of solenoid valve ......................................................................................... 478 Testing PPC valve outlet pressure ................................................................................................. 482 Adjusting play of work equipment and swing PPC valves ............................................................................. 484 Testing pump swash plate sensor ................................................................................................... 485 Isolating the parts causing hydraulic drift in work equipment ..................................................................... 486 Testing oil leakage ............................................................................................................... 488 Bleeding air from hydraulic circuit ............................................................................................... 490 Cab and its attachments ............................................................................................................... 492 Testing cab tipping stopper ....................................................................................................... 492 Adjusting mirrors ................................................................................................................. 493 Electrical system ..................................................................................................................... 496 Special functions of machine monitor .............................................................................................. 496 KOMTRAX terminal start-up procedure ............................................................................................... 570 Adjusting rearview camera angle ................................................................................................... 573 Handling voltage circuit of engine controller ..................................................................................... 575 Handling battery disconnect switch ................................................................................................ 576 Testing diodes .................................................................................................................... 577 Pm clinic ............................................................................................................................. 578 Pm Clinic service ................................................................................................................. 578 40 Troubleshooting ........................................................................................................................ 589 Table of contents ..................................................................................................................... 590 Related information on troubleshooting ................................................................................................ 598 Troubleshooting points ............................................................................................................ 598 Sequence of events in troubleshooting ............................................................................................. 600 Checks before troubleshooting ..................................................................................................... 602 Inspection procedure before troubleshooting ....................................................................................... 604 Preparation for troubleshooting of electrical system .............................................................................. 625 Classification and procedures for troubleshooting ................................................................................. 631 Symptom and troubleshooting numbers ............................................................................................... 634 Information in troubleshooting table .............................................................................................. 637 Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................................................... 639 Connector list and layout ......................................................................................................... 641 Connector contact identification .................................................................................................. 652 T-branch box and T-branch adapter table ........................................................................................... 690 Fuse location table ............................................................................................................... 695 Failure codes table ............................................................................................................... 697 Troubleshooting by failure code (Display of code) ..................................................................................... 708 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................... 708 Failure code [879AKB] A/C Inner Sensor Short Circuit .............................................................................. 709 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................... 710 Failure code [879BKB] A/C Outer Sensor Short Circuit .............................................................................. 711 Failure code [879CKA] Ventilating Sensor Open Circuit ............................................................................. 712 Failure code [879CKB] Ventilating Sensor Short Circuit ............................................................................ 713 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....................................................................... 714 Failure code [879EMC] Ventilation Damper Abnormality .............................................................................. 715 Failure code [879FMC] Air Mix Damper Abnormality .................................................................................. 716 Failure code [879GKX] Refrigerant Abnormality ..................................................................................... 717 Failure code [989L00] Engine Controller Lock Caution1 ............................................................................. 718 Failure code [989M00] Engine Controller Lock Caution2 ............................................................................. 719 Failure code [989N00] Engine Controller Lock Caution3 ............................................................................. 720 Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3 ...................................................................... 721 Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 ...................................................................... 722 Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2 ...................................................................... 723 Failure code [AA10NX] Air Cleaner Clogging ........................................................................................ 724 Failure code [AB00KE] Charge Voltage Low .......................................................................................... 726 Failure code [B@BAZG] Eng Oil Press Low ........................................................................................... 728 Failure code [B@BAZK] Eng Oil Level Low ........................................................................................... 729 Failure code [B@BCNS] Eng Water Overheat .......................................................................................... 730 Failure code [B@BCZK] Eng Water Level Low ......................................................................................... 731 Failure code [B@HANS] Hyd Oil Overheat ............................................................................................ 733 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................................. 734 Failure code [CA122] Chg Air Press Sensor High Error .............................................................................. 735 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................... 737 Failure code [CA131] Throttle Sensor High Error ................................................................................... 739 Failure code [CA132] Throttle Sensor Low Error .................................................................................... 741 Failure code [CA144] Coolant Temp Sens High Error ................................................................................. 743 Failure code [CA145] Coolant Temp Sens Low Error .................................................................................. 745 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................... 747 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 749 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................... 751 Failure code [CA221] Ambient Press Sensor High Error .............................................................................. 753 Failure code [CA222] Ambient Press Sens Low Error ................................................................................. 755 Failure code [CA227] Sensor 2 Supply Volt High Error .............................................................................. 757 Failure code [CA234] Eng Overspeed ................................................................................................ 758 Failure code [CA238] Ne Speed Sensor Supply Volt Error ............................................................................ 759 Failure code [CA239] Ne Speed Sens Supply Volt High Error ......................................................................... 760 Failure code [CA271] IMV/PCV1 Short Error ......................................................................................... 761 Failure code [CA272] IMV/PCV1 Open Error .......................................................................................... 763 Failure code [CA295] Ambient Press Sens In Range Error ............................................................................ 765 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................................. 766 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................................. 768 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................................. 770 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................................. 772 Failure code [CA343] ECM Critical Internal Failure ................................................................................ 774 Failure code [CA351] Injectors Drive Circuit Error ................................................................................ 775 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................... 776 Failure code [CA356] Mass Air Flow Sensor High Error .............................................................................. 778 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................... 780 Failure code [CA386] Sensor 1 Supply Volt High Error .............................................................................. 782 Failure code [CA428] Water in Fuel Sensor High Error .............................................................................. 783 Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................... 785 Failure code [CA435] Eng Oil Press Sw Error ....................................................................................... 787 Failure code [CA441] Battery Voltage Low Error .................................................................................... 788 Failure code [CA442] Battery Voltage High Error ................................................................................... 790 Failure code [CA449] Rail Press Very High Error ................................................................................... 791 Failure code [CA451] Rail Press Sensor High Error ................................................................................. 792 Failure code [CA452] Rail Press Sensor Low Error .................................................................................. 794 Failure code [CA466] KVGT Motor Driver Position Error ............................................................................. 796 Failure code [CA488] Chg Air Temp High Torque Derate .............................................................................. 798 Failure code [CA515] Rail Press Sens Sup Volt High Error .......................................................................... 799 Failure code [CA516] Rail Press Sens Sup Volt Low Error ........................................................................... 801 Failure code [CA553] Rail Press High Error ........................................................................................ 803 Failure code [CA555] Crankcase Press High Error 1 ................................................................................. 804 Failure code [CA556] Crankcase Press High Error 2 ................................................................................. 805 Failure code [CA559] Rail Press Low Error ......................................................................................... 806 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................... 808 Failure code [CA691] Intake Air Temp Sens High Error .............................................................................. 810 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................... 812 Failure code [CA697] ECM Internal Temp Sensor High Error .......................................................................... 814 Failure code [CA698] ECM Int Temp Sensor Low Error ................................................................................ 815 Failure code [CA731] Eng Bkup Speed Sens Phase Error .............................................................................. 816 Failure code [CA778] Eng Bkup Speed Sensor Error .................................................................................. 817 Failure code [CA1117] Persistent Data Lost Error .................................................................................. 820 Failure code [CA1695] Sensor 5 Supply Volt High Error ............................................................................. 821 Failure code [CA1696] Sensor 5 Supply Volt Low Error .............................................................................. 822 Failure code [CA1843] Crankcase Press Sens High Error ............................................................................. 823 Failure code [CA1844] Crankcase Press Sens Low Error .............................................................................. 825 Failure code [CA1896] EGR Valve Stuck Error ....................................................................................... 827 Failure code [CA1942] Crankcase Press Sens In Range Error ......................................................................... 828 Failure code [CA1961] EGR_Motor Driver IC Over Temp Error ......................................................................... 829 Failure code [CA2185] Throt Sensor Sup Volt High Error ............................................................................ 830 Failure code [CA2186] Throt Sensor Sup Volt Low Error ............................................................................. 832 Failure code [CA2249] Rail Press Very Low Error ................................................................................... 834 Failure code [CA2272] EGR Valve Pos Sens Low Error ................................................................................ 835 Failure code [CA2311] IMV Solenoid Error .......................................................................................... 837 Failure code [CA2349] EGR Valve Solenoid Open Error ............................................................................... 838 Failure code [CA2353] EGR Valve Solenoid Short Error .............................................................................. 840 Failure code [CA2357] EGR Valve Servo Error ....................................................................................... 842 Failure code [CA2373] Exhaust Manifold Press Sens High Error ...................................................................... 843 Failure code [CA2374] Exhaust Manifold Press Sens Low Error ....................................................................... 845 Failure code [CA2375] EGR Orifice Temp Sens High Error ............................................................................ 847 Failure code [CA2376] EGR Orifice Temp Sens Low Error ............................................................................. 849 Failure code [CA2387] KVGT Servo Error ............................................................................................ 851 Failure code [CA2554] Exh Manifold Press Sens In Range Error ...................................................................... 852 Failure code [CA2555] Grid Htr Relay Volt Low Error ............................................................................... 853 Failure code [CA2556] Grid Htr Relay Volt High Error .............................................................................. 855 Failure code [CA2961] EGR Orifice Temp High Error 1 ............................................................................... 857 Failure code [CA2973] Chg Air Press Sensor In Range Error ......................................................................... 858 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error .................................................................... 859 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ..................................................................... 861 Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error ....................................................................... 863 Failure code [CA3741] Rail Press Valve Trip Error ................................................................................. 865 Failure code [CA3918] KVGT Stuck Error ............................................................................................ 866 Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ........................................................................ 867 Failure code [CA3921] KVGT Servo Error 2 .......................................................................................... 868 Failure code [CA3922] KVGT Motor Driver Open Error ................................................................................ 869 Failure code [CA3923] KVGT Motor Driver Short Error ............................................................................... 871 Failure code [D110KB] Battery Relay Drive Short Circuit ........................................................................... 873 Failure code [D19JKZ] Personal Code Relay Abnormality ............................................................................. 875 Failure code [D811MC] KOMTRAX Error ............................................................................................... 878 Failure code [D862KA] GPS Antenna Open Circuit .................................................................................... 879 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ....................................................................... 880 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................................................... 882 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ....................................................................................... 883 Failure code [DA20MC] Pump Controller Malfunction ................................................................................. 884 Failure code [DA22KK] Pump Solenoid Power Low Error ............................................................................... 885 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ............................................................................... 887 Failure code [DA26KP] 5V Sensor 2 Power Abnormality ............................................................................... 889 Failure code [DA29KQ] Model Selection Abnormality ................................................................................. 891 Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ...................................................................... 893 Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ..................................................................... 895 Failure code [DA2QKR] CAN2 Discon (Pump Con) ...................................................................................... 896 Failure code [DA2RKR] CAN1 Discon (Pump Con) ...................................................................................... 899 Failure code [DAF0MB] Monitor ROM Abnormality ..................................................................................... 900 Failure code [DAF0MC] Monitor Error ............................................................................................... 901 Failure code [DAF8KB] Camera Power Supply Short Circuit ........................................................................... 902 Failure code [DAF9KQ] Model Selection Abnormality ................................................................................. 904 Failure code [DAFGMC] GPS Module Error ............................................................................................ 905 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ....................................................................... 906 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) ...................................................................... 908 Failure code [DAFQKR] CAN2 Discon (Monitor) ....................................................................................... 909 Failure code [DAZ9KQ] A/C Model Selection Abnormality ............................................................................. 910 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) .................................................................................... 911 Failure code [DB2QKR] CAN2 Discon (Engine Con) .................................................................................... 915 Failure code [DB2RKR] CAN1 Discon (Engine Con) .................................................................................... 920 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ................................................................................ 926 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ........................................................................ 928 Failure code [DHPAMA] F Pump Press Sensor Abnormality ............................................................................. 929 Failure code [DHPBMA] R Pump Press Sensor Abnormality ............................................................................. 932 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ....................................................................... 935 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality .................................................................... 937 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ..................................................................... 939 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality ..................................................................... 941 Failure code [DHSAKZ] Swing RH PPC Press Sensor Abnormality ....................................................................... 943 Failure code [DHSBKZ] Swing LH PPC Press Sensor Abnormality ....................................................................... 945 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ....................................................................... 947 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality .................................................................... 949 Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality .................................................................. 951 Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .................................................................. 953 Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality .................................................................. 955 Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality .................................................................. 957 Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt. ..................................................................... 959 Failure code [DHVAL8] HYB Swing-R PPC Pr. Sen. Signal Mismatch .................................................................... 962 Failure code [DHVAMA] HYB Swing-R PPC Sensor Malfunction .......................................................................... 963 Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen. Opn/Short Cir. ...................................................................... 965 Failure code [DHVBL8] HYB Swing-L PPC Pr. Sen. Signal Mismatch .................................................................... 967 Failure code [DHVBMA] HYB Swing-L PPC Sensor Malfunction .......................................................................... 968 Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality ....................................................................... 970 Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality ....................................................................... 973 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ..................................................................... 976 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ..................................................................... 978 Failure code [DV20KB] Travel Alarm Short Circuit .................................................................................. 980 Failure code [DW43KA] Travel Speed Sol Open Circuit ............................................................................... 982 Failure code [DW43KB] Travel Speed Sol Short Circuit .............................................................................. 984 Failure code [DW45KA] Swing Brake Sol Open Circuit ................................................................................ 986 Failure code [DW45KB] Swing Brake Sol Short Circuit ............................................................................... 989 Failure code [DW45KK] Swing Brake Sol. Valve Low Sup. Voltage ..................................................................... 992 Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. ....................................................................... 994 Failure code [DW91KA] Travel Junction Sol Open Circuit ............................................................................ 996 Failure code [DW91KB] Travel Junction Sol Short Circuit ........................................................................... 998 Failure code [DWA2KA] Attachment Sol Open Circuit .................................................................................1000 Failure code [DWA2KB] Attachment Sol Short Circuit ................................................................................1002 Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit .............................................................................1004 Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit ............................................................................1006 Failure code [DWK2KA] Variable Back Press Sol Open Circuit ........................................................................1008 Failure code [DWK2KB] Variable Back Press Sol Short Circuit .......................................................................1010 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit .................................................................................1012 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ................................................................................1014 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit .................................................................................1016 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ................................................................................1018 Failure code [DXE0KA] LS-EPC Sol Open Circuit .....................................................................................1020 Failure code [DXE0KB] LS-EPC Sol Short Circuit ....................................................................................1022 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ............................................................................1024 Failure code [DXE4KB] Attachment Flow EPC Short Circuit ...........................................................................1026 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ..........................................................................1028 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .........................................................................1030 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ............................................................................1032 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ...........................................................................1034 Failure code [DY20KA] Wiper Working Abnormality ...................................................................................1036 Failure code [DY20MA] Wiper Parking Abnormality ...................................................................................1038 Failure code [DY2CKB] Washer Drive Short Circuit ..................................................................................1040 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .............................................................................1042 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .............................................................................1044 Failure code [GA****] Precautions related to hybrid components and troubleshooting of high voltage parts ..........................1046 Failure code [GA——] Table and check sheet of monitoring items on hybrid components ................................................1075 Failure code [GA00NS] HYB Equipment Overheat ......................................................................................1080 Failure code [GA01KA] Power Cable Interlock Open Circuit ..........................................................................1081 Failure code [GA01KB] Power Cable Interlock Short Circuit .........................................................................1083 Failure code [GA02KZ] DC Line Open & Short Circuit ................................................................................1085 Failure code [GA04KG] Abnormal DC HW Volt. Before Booster .........................................................................1086 Failure code [GA05KG] Abnormal DC SW Volt. Before Booster .........................................................................1087 Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster .........................................................................1088 Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster ....................................................................1091 Failure code [GA08KG] Abnorm. DC HW Volt. After Booster ...........................................................................1092 Failure code [GA09KG] Abnorm. DC SW Volt. After Booster ...........................................................................1093 Failure code [GA09KP] Low DC SW Output Volt. After Booster ........................................................................1094 Failure code [GA0AKZ] DC Vlt. Sen. Op./Shrt Cir. Aft. Booster .....................................................................1095 Failure code [GA0BKZ] AC Line Open & Short Circuit ................................................................................1096 Failure code [GA10MA] HYB Controller Malfunction ..................................................................................1097 Failure code [GA10MC] HYB Controller Error ........................................................................................1098 Failure code [GA12NK] High-Voltage Line Start-up Failure ..........................................................................1099 Failure code [GA13KP] Low HYB Control. Sen. Power Sup. ............................................................................1100 Failure code [GA13KY] HYB Control. Sen. Power Short Cir ...........................................................................1101 Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir ....................................................................1102 Failure code [GA17KR] Gen. Mot. Drv. Communication Failure ........................................................................1103 Failure code [GA17MB] Gen. Mot. Drv. Function Degraded ............................................................................1104 Failure code [GA18MC] Gen. Mo.Dr. Excite. Pow. Sup. Failure .......................................................................1105 Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure .....................................................................1106 Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. ....................................................................1107 Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction .....................................................................1108 Failure code [GA1FKR] Swing Mot. Drv. Communication Failure .......................................................................1109 Failure code [GA1FMA] Abnormal Swing Motor Driver .................................................................................1110 Failure code [GA1GKR] Swg Mot. Driver Sub-CPU Comm. Failure .......................................................................1111 Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal ......................................................................1112 Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded .....................................................................1113 Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir ....................................................................1114 Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir ....................................................................1115 Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir ....................................................................1116 Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens. Opn/Shrt Cir ....................................................................1117 Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen. Opn/Shrt Cir. .....................................................................1118 Failure code [GA1NNS] Swing Motor Driver IGBT Overheat ............................................................................1119 Failure code [GA1SFS] Contactor Locked ............................................................................................1120 Failure code [GA1SMC] Contactor Failure ...........................................................................................1121 Failure code [GA1TKP] Capacitor Low Output Voltage ................................................................................1122 Failure code [GA1TNS] Capacitor Overheat ..........................................................................................1125 Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/short Cir. .......................................................................1127 Failure code [GA1VFS] Capacitor Contactor Locked ..................................................................................1129 Failure code [GA1VMC] Capacitor Contactor Failure .................................................................................1131 Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. ....................................................................1132 Failure code [GA1YNS] Booster Inductor Overheat ...................................................................................1133 Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. ....................................................................1134 Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat ...........................................................................1135 Failure code [GA22NS] Booster IGBT Junction Overheat ..............................................................................1136 Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sen.0 Opn/Short Cir. ....................................................................1137 Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sen.1 Opn/Short Cir. ....................................................................1138 Failure code [GA25MA] Gen. Motor Driver IGBT 0 Abnormality ........................................................................1139 Failure code [GA25NS] Gen. Motor Driver IGBT 0 Overheat ...........................................................................1140 Failure code [GA26MA] Gen. Motor Driver IGBT 1 Abnormality ........................................................................1141 Failure code [GA26NS] Gen. Motor Driver IGBT 1 Overheat ...........................................................................1142 Failure code [GA27KZ] DC Cur. Sens. Bef. Booster Opn/Short Cir ....................................................................1143 Failure code [GA2QKR] CAN2 Discon (Hyb Con) .......................................................................................1144 Failure code [GA2RKR] CAN1 Discon (Hyb Con) .......................................................................................1146 Failure code [GA60KZ] Generator Motor Open/Short Circuit ..........................................................................1147 Failure code [GA60MC] Generator Motor Failure .....................................................................................1148 Failure code [GA60N1] Generator Motor Overrun .....................................................................................1150 Failure code [GA61KZ] Gen. Motor Temp. Sens. Opn/Short Cir. .......................................................................1151 Failure code [GA61NS] Generator Motor Temp. Sensor Overheat .......................................................................1153 Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir ....................................................................1154 Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir .....................................................................1155 Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction .....................................................................1156 Failure code [GA62MC] Gen. Mot. Ph-A Cur. Sen. Defect Op. .........................................................................1157 Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir ....................................................................1158 Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir .....................................................................1159 Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction .....................................................................1160 Failure code [GA63MC] Gen. Mot. Ph-B Cur. Sen. Defect Op. .........................................................................1161 Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir ....................................................................1162 Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir .....................................................................1163 Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction .....................................................................1164 Failure code [GA64MC] Gen. Mot. Ph-C Cur. Sen. Defect Op. .........................................................................1165 Failure code [GA70KB] HYB Swing Motor Short Circuit ...............................................................................1166 Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion .....................................................................1167 Failure code [GA70NS] HYB Swing Motor Overheat ....................................................................................1168 Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. ....................................................................1169 Failure code [GA72MA] HYB Swing Motor Resolver Malfunction ........................................................................1171 Failure code [GA72MC] HYB Swing Motor Resolver Defect Op. .........................................................................1173 Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. ......................................................................1174 Failure code [GAA0KB] HYB Con. Battery Relay Drive Short Cir. .....................................................................1175 Failure code [GAA2KB] Swing Brake Sol. Supply Line Short Cir. .....................................................................1177 Failure code [GAA6KP] Low HYB Control. Sen. Power 2 Sup. ..........................................................................1179 Failure code [GAA6KY] HYB Control. Sen. Power 2 Short Cir .........................................................................1182 Failure code [GACLKA] Operating Lamp Open Circuit (HYB Con) .......................................................................1183 Failure code [GACLKB] Operating Lamp Short Circuit (HYB Con) ......................................................................1185 Troubleshooting of electrical system (E-mode) .........................................................................................1186 E-1 Engine does not start (Engine does not crank) .................................................................................1186 E-2 Manual preheating system does not work ........................................................................................1192 E-3 Automatic preheating system does not work .....................................................................................1195 E-4 While preheating is working, preheating monitor does not light up .............................................................1197 E-5 When starting switch is turned to ON position, machine monitor displays nothing ...............................................1199 E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow ..........1203 E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow ....1204 E-8 Engine coolant temperature monitor lights up in white while engine is running .................................................1205 E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................................................1206 E-10 Charge level monitor lights up in red while engine is running ................................................................1207 E-11 Fuel level monitor lights up in red while engine is running ..................................................................1208 E-12 Air cleaner clogging monitor lights up in yellow while engine is running .....................................................1209 E-13 Water separator monitor lights up in red while engine is running .............................................................1210 E-14 Engine coolant temperature monitor lights up in red while engine is running ..................................................1211 E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................................................1212 E-16 Hybrid temperature monitor lights up in red while engine is running ..........................................................1213 E-17 Engine oil pressure monitor lights up in red while engine is running .........................................................1215 E-18 Fuel gauge display does not move from minimum or maximum .....................................................................1216 E-19 Fuel gauge indicates incorrect amount (indicates neither full nor empty) .....................................................1217 E-20 Engine coolant temperature gauge display does not move from minimum or maximum ...............................................1218 E-21 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty) ..........................1219 E-22 Hydraulic oil temperature gauge does not move from minimum or maximum ........................................................1220 E-23 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty) ...........................1222 E-24 Hybrid temperature gauge does not move from minimum or maximum ...............................................................1223 E-25 Hybrid temperature gauge indicates incorrect temperature (indicates neither full nor empty) ..................................1224 E-26 Contents of display on machine monitor is different from actual machine condition ............................................1226 E-27 Some areas of machine monitor screen are not displayed .......................................................................1227 E-28 Function switch does not work ................................................................................................1228 E-29 Automatic warm-up system does not operate (in cold season) ...................................................................1229 E-30 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated ..................1230 E-31 Auto-deceleration function does not operate or is not canceled while lever is operated .......................................1231 E-32 Working mode selection screen is not displayed while working mode selector switch is operated ................................1233 E-33 Setting of engine and hydraulic pump is not changed while working mode is changed ............................................1234 E-34 Travel speed monitor does not change when travel speed switch is operated ....................................................1235 E-35 Travel speed does not change while travel speed selection is changed .........................................................1236 E-36 Alarm buzzer does not stop sounding ..........................................................................................1237 E-37 Service meter is not displayed, while starting switch is in OFF position .....................................................1238 E-38 Service mode cannot be selected ..............................................................................................1239 E-39 None of work equipment, swing or travel works ................................................................................1240 E-40 Any of work equipment, swing and travel cannot be locked .....................................................................1242 E-41 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position .............................1244 E-42 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position ...............................1247 E-43 One-touch power maximizing function does not operate, or indicator is not displayed on monitor ...............................1249 E-44 One-touch power maximizing function cannot be canceled .......................................................................1251 E-45 Alarm does not sound during travel ...........................................................................................1252 E-46 Alarm does not stop sounding while machine is stopped ........................................................................1253 E-47 Horn does not sound ..........................................................................................................1254 E-48 Horn does not stop sounding ..................................................................................................1256 E-49 Wiper monitor does not light up, or does not go out, while wiper switch is operated ..........................................1257 E-50 Wiper does not operate while wiper switch is operated ........................................................................1258 E-51 Window washer does not operate while window washer switch is operated ........................................................1260 E-52 Boom LOWER is not displayed correctly with monitoring function ...............................................................1261 E-53 Arm OUT is not displayed correctly with monitoring function ..................................................................1262 E-54 Arm IN is not displayed correctly with monitoring function ...................................................................1263 E-55 Boom RAISE is not displayed correctly with monitoring function ...............................................................1264 E-56 Bucket CURL is not displayed correctly with monitoring function ..............................................................1265 E-57 Bucket DUMP is not displayed correctly with monitoring function ..............................................................1266 E-58 Swing is not displayed correctly with monitoring function ....................................................................1267 E-59 Travel is not displayed correctly with monitoring function ...................................................................1268 E-60 Service is not displayed correctly with monitoring function ..................................................................1269 E-61 Attachment hydraulic circuit cannot be changed ...............................................................................1272 E-62 KOMTRAX system does not operate normally .....................................................................................1273 Troubleshooting of hydraulic and mechanical system (H-mode) ...........................................................................1274 Information described in troubleshooting table (H-mode) ...........................................................................1274 System chart of hydraulic and mechanical systems ..................................................................................1275 Failure mode and cause table ......................................................................................................1277 H-1 All of work equipments and travel operations lack speed or power ..............................................................1283 H-2 Engine speed drops significantly or engine stalls .............................................................................1286 H-3 None of work equipment or travel works ........................................................................................1289 H-4 Unusual sound is heard from around hydraulic pump .............................................................................1290 H-5 Fine control performance or response is poor ..................................................................................1291 H-6 Boom speed or power is low ....................................................................................................1293 H-7 Arm speed or power is low .....................................................................................................1297 H-8 Bucket speed or power is low ..................................................................................................1302 H-9 Work equipment does not move in single operation ..............................................................................1305 H-10 Hydraulic drift of boom is large .............................................................................................1306 H-11 Hydraulic drift of arm is large ..............................................................................................1307 H-12 Hydraulic drift of bucket is large ...........................................................................................1308 H-13 Time lag of work equipment is large ..........................................................................................1309 H-14 When part of work equipment is relieved singly, other parts of work equipment move ...........................................1311 H-15 One-touch power maximizing function does not operate .........................................................................1312 H-16 In combined operation of work equipment, equipment having heavier load moves slower ..........................................1313 H-17 Machine does not travel straight .............................................................................................1314 H-18 Travel speed is slow .........................................................................................................1317 H-19 Machine is hard to steer or travel power is low ..............................................................................1320 H-20 Travel speed does not change, or travel speed is too slow or fast ............................................................1324 H-21 One of tracks does not run ...................................................................................................1325 H-22 Upper structure does not swing to the right or left ..........................................................................1327 H-23 Upper structure swings only to the right or left .............................................................................1328 H-24 Swing acceleration or swing speed is low in both directions (right and left) .................................................1329 H-25 Swing acceleration performance is poor or swing speed is slow in only one direction ..........................................1330 H-26 Upper structure overruns excessively when it stops swinging (both right and left) ............................................1331 H-27 Upper structure overruns excessively when it stops swinging (either right or left) ...........................................1332 H-28 Shock is large when upper structure stops swinging ...........................................................................1333 H-29 Large unusual noise is heard when upper structure stops swinging .............................................................1334 H-30 Swing drift on a slope is large while swing parking brake is applied .........................................................1335 H-31 Swing drift on a slope is large while swing parking brake is released ........................................................1336 H-32 Attachment hydraulic circuit cannot be changed while attachment is installed .................................................1337 H-33 Oil flow in attachment circuit cannot be controlled ..........................................................................1338 Troubleshooting of engine (S-mode) ....................................................................................................1339 Information mentioned in troubleshooting table (S mode) ...........................................................................1339 S-1 Engine does not crank when starting switch is turned to START position ........................................................1340 S-2 Engine cranks but no exhaust smoke comes out ..................................................................................1341 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ................................1342 S-4 Engine startability is poor ...................................................................................................1343 S-5 Engine does not pick up smoothly ..............................................................................................1345 S-6 Engine stops during operation .................................................................................................1347 S-7 Engine runs rough or is unstable ..............................................................................................1349 S-8 Engine lacks power ............................................................................................................1350 S-9 Exhaust smoke is black ........................................................................................................1352 S-10 Engine oil consumption is excessive ..........................................................................................1354 S-11 Oil becomes contaminated quickly .............................................................................................1355 S-12 Fuel consumption is excessive ................................................................................................1356 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .............................................................1357 S-14 Oil pressure drops ...........................................................................................................1358 S-15 Fuel mixes into engine oil ...................................................................................................1359 S-16 Water mixes into engine oil (milky) ..........................................................................................1360 S-17 Coolant temperature rises too high (overheating) .............................................................................1361 S-18 Unusual noise is heard .......................................................................................................1362 S-19 Vibration is excessive .......................................................................................................1363 S-20 Air cannot be bled from fuel circuit .........................................................................................1364 Troubleshooting for hybrid systems (Y mode) ...........................................................................................1365 Precautions related to hybrid equipment ...........................................................................................1365 Y-1 Hybrid monitor does not go out ................................................................................................1366 Y-2 Machine does not swing ........................................................................................................1367 Y-3 Swing acceleration or swing speed is low ......................................................................................1370 Y-4 Upper structure overruns excessively when it stops swinging ...................................................................1371 Y-5 Shock is large when upper structure stops swinging ............................................................................1372 Y-6 Large unusual noise is heard when upper structure stops swinging ..............................................................1373 Y-7 Swing drift on a slope is large ...............................................................................................1374 Y-8 Electric swing motor temperature increases abnormally .........................................................................1375 Y-9 Motor-generator temperature increases abnormally ..............................................................................1376 Y-10 Inverter temperature increases abnormally ....................................................................................1377 Y-11 Capacitor temperature increases abnormally ...................................................................................1378 50 Disassembly and assembly ...............................................................................................................1379 Table of contents .....................................................................................................................1380 Related information on disassembly and assembly .......................................................................................1382 How to read this manual ...........................................................................................................1382 Precautions related to hybrid equipment ...........................................................................................1384 Coating materials list ............................................................................................................1385 Special tools list ................................................................................................................1389 Sketches of special tools .........................................................................................................1394 Engine and cooling system .............................................................................................................1401 Removal and installation of supply pump assembly ..................................................................................1401 Removal and installation of injector assembly .....................................................................................1405 Removal and installation of cylinder head assembly ................................................................................1411 Removal and installation of radiator assembly .....................................................................................1429 Removal and installation of hydraulic oil cooler assembly .........................................................................1432 Removal and installation of aftercooler assembly ..................................................................................1435 Removal and installation of engine, motor-generator, and main pump assembly .......................................................1437 Removal and installation of fan belt ..............................................................................................1449 Removal and installation of starting motor ........................................................................................1452 Removal and installation of engine front oil seal .................................................................................1454 Removal and installation of engine rear oil seal ..................................................................................1457 Removal and installation of fuel cooler assembly ..................................................................................1460 Removal and installation of fuel tank assembly ....................................................................................1462 Removal and installation of engine hood assembly ..................................................................................1464 Removal and installation of KDOC assembly .........................................................................................1467 Removal and installation of KCCV assembly .........................................................................................1468 Removal and installation of air cleaner assembly ..................................................................................1474 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ........................................................1475 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .......................................................1477 Hybrid system .........................................................................................................................1480 Draining coolant, refilling with coolant, and bleeding air for hybrid system ......................................................1480 Removal and installation of hybrid radiator assembly ..............................................................................1484 Removal and installation of hybrid water pump assembly ............................................................................1487 Removal and installation of inverter assembly .....................................................................................1489 Removal and installation of inverter and capacitor assembly .......................................................................1492 Procedure for draining and refilling generator lubricating oil ....................................................................1497 Removal and installation of tandem pump assembly ..................................................................................1499 Removal and installation of motor-generator and housing assembly ..................................................................1502 Removal and installation of electric swing motor assembly .........................................................................1509 Power train system ....................................................................................................................1514 Removal and installation of travel motor and final drive assembly .................................................................1514 Disassembly and assembly of final drive ...........................................................................................1515 Removal and installation of swing motor and swing machinery assembly ..............................................................1524 Disassembly and assembly of swing machinery assembly ..............................................................................1528 Removal and installation of swing circle assembly .................................................................................1542 Undercarriage and frame ...............................................................................................................1543 Separation and connection of track shoe assembly ..................................................................................1543 Removal and installation of sprocket ..............................................................................................1546 Removal and installation of idler and idler cushion assembly ......................................................................1547 Disassembly and assembly of idler assembly ........................................................................................1548 Disassembly and assembly of idler cushion assembly ................................................................................1550 Disassembly and assembly of track roller assembly .................................................................................1552 Disassembly and assembly of carrier roller assembly ...............................................................................1554 Removal and installation of revolving frame assembly ..............................................................................1559 Removal and installation of counterweight assembly ................................................................................1561 Hydraulic system ......................................................................................................................1564 Removal and installation of center swivel joint assembly ..........................................................................1564 Disassembly and assembly of center swivel joint assembly ..........................................................................1567 Removal and installation of hydraulic tank assembly ...............................................................................1569 Removal and installation of main pump assembly ....................................................................................1572 Removal and installation of control valve assembly ................................................................................1576 Disassembly and assembly of control valve assembly ................................................................................1580 Disassembly and assembly of work equipment PPC valve ..............................................................................1586 Disassembly and assembly of travel PPC valve assembly .............................................................................1588 Work equipment ........................................................................................................................1590 Removal and installation of work equipment assembly ...............................................................................1590 Disassembly and assembly of work equipment cylinder assembly ......................................................................1593 Cab and its attachments ...............................................................................................................1600 Removal and installation of operator's cab assembly ...............................................................................1600 Removal and installation of operator cab glass (adhered glass) ....................................................................1605 Removal and installation of front window assembly .................................................................................1615 Removal and installation of floor frame assembly ..................................................................................1621 Removal and installation of air conditioner unit assembly .........................................................................1627 Removal and installation of operator's seat .......................................................................................1631 Removal and installation of seat belt .............................................................................................1633 Removal and installation of work equipment control lever assembly..................................................................1635 Removal and installation of front wiper assembly ..................................................................................1649 Electrical system .....................................................................................................................1656 Removal and installation of air conditioner compressor assembly ...................................................................1656 Removal and installation of air conditioner condenser assembly ....................................................................1658 Removal and installation of engine controller assembly ............................................................................1660 Removal and installation of pump controller assembly ..............................................................................1662 Removal and installation of machine monitor assembly ..............................................................................1665 Removal and installation of pump swash plate sensor ...............................................................................1667 Removal and installation of mass air flow and temperature sensor ..................................................................1668 Removal and installation of KOMTRAX terminal assembly .............................................................................1669 60 Maintenance standard ...................................................................................................................1671 Table of contents .....................................................................................................................1672 Engine and cooling system .............................................................................................................1673 Engine mount ......................................................................................................................1673 Cooling system ....................................................................................................................1674 Power train system ....................................................................................................................1675 Swing circle ......................................................................................................................1675 Swing machinery with swing brake ..................................................................................................1676 Final drive .......................................................................................................................1678 Sprocket ..........................................................................................................................1680 Undercarriage and frame ...............................................................................................................1682 Track frame and idler cushion .....................................................................................................1682 Idler .............................................................................................................................1684 Track roller ......................................................................................................................1686 Carrier roller ....................................................................................................................1687 Track shoe ........................................................................................................................1688 Hydraulic system ......................................................................................................................1694 Hydraulic tank ....................................................................................................................1694 Main pump .........................................................................................................................1695 Control valve .....................................................................................................................1696 Travel motor ......................................................................................................................1706 PPC valve .........................................................................................................................1709 Solenoid valve ....................................................................................................................1719 Attachment circuit selector valve (for high-pressure circuit) .....................................................................1720 Attachment circuit selector valve (for low-pressure circuit) ......................................................................1721 Center swivel joint ...............................................................................................................1722 Work equipment ........................................................................................................................1723 Work equipment ....................................................................................................................1723 Work equipment cylinder ...........................................................................................................1732 80 Appendix ...............................................................................................................................1735 Table of contents .....................................................................................................................1736 Air conditioner components ............................................................................................................1737 Precautions for refrigerant .......................................................................................................1737 Air conditioner component .........................................................................................................1738 Configuration and function of refrigeration cycle .................................................................................1741 Outline of refrigeration cycle ....................................................................................................1742 Air conditioner unit ..............................................................................................................1744 Dual pressure switch ..............................................................................................................1751 Air conditioner controller ........................................................................................................1752 Compressor ........................................................................................................................1753 Air conditioner condenser .........................................................................................................1754 Sunlight sensor ...................................................................................................................1756 Outer temperature sensor (outside air temperature sensor) .........................................................................1757 Procedure for testing and troubleshooting .........................................................................................1758 Circuit diagram and arrangement of connector pins .................................................................................1760 System diagram ....................................................................................................................1762 Parts and connectors layout .......................................................................................................1765 Testing air leakage (duct) ........................................................................................................1769 Testing with self-diagnosis function ..............................................................................................1772 Testing vent (mode) changeover ....................................................................................................1775 Testing FRESH/RECIRC air changeover ...............................................................................................1777 Testing sunlight sensor ...........................................................................................................1778 Testing (dual) pressure switch for refrigerant ....................................................................................1779 Testing relays ....................................................................................................................1780 Troubleshooting chart 1 ...........................................................................................................1781 Troubleshooting chart 2 ...........................................................................................................1782 Information in troubleshooting table ..............................................................................................1785 Failure code list related to air conditioner ......................................................................................1786 Failure code [879AKA] A/C Inner Sensor Open Circuit ...............................................................................1787 Failure code [879AKB] A/C Inner Sensor Short Circuit ..............................................................................1788 Failure code [879BKA] A/C Outer sensor Open Circuit ...............................................................................1789 Failure code [879BKB] A/C Outer sensor Short Circuit ..............................................................................1791 Failure code [879CKA] Ventilating Sensor Open Circuit .............................................................................1793 Failure code [879CKB] Ventilating Sensor Short Circuit ............................................................................1794 Failure code [879DKZ] Sunlight sensor Open or Short Circuit .......................................................................1795 Failure code [879EMC] Ventilation Damper Abnormality ..............................................................................1797 Failure code [879FMC] Air Mix Damper Abnormality ..................................................................................1798 Failure code [879GKX] Refrigerant Abnormality .....................................................................................1799 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ....................................................1800 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) .....................................................1802 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ............................................1805 A-4 Troubleshooting for FRESH/RECIRC air changeover ...............................................................................1807 Troubleshooting with gauge pressure ...............................................................................................1809 Connection of service tool ........................................................................................................1812 Precautions for disconnecting and connecting air conditioner piping ...............................................................1814 Handling of compressor oil ........................................................................................................1816 Desiccant replacement .............................................................................................................1818 90 Diagrams and drawings ..................................................................................................................1821 Table of contents .....................................................................................................................1822 Hydraulic circuit diagram .............................................................................................................1823 Symbols in hydraulic circuit diagram ..............................................................................................1823 Hydraulic circuit diagram..........................................................................................................1827 Electric circuit diagram ..............................................................................................................1833 Symbols in electric circuit diagram ...............................................................................................1833 Electrical circuit diagram.........................................................................................................1837 Electrical circuit diagram of air conditioner unit.................................................................................1867 INDEX......................................................................................................................................1869
DESCRIPTION:
KOMATSU HB215LC-2 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06488-11 – PDF DOWNLOAD
General precautions
• 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.
S.S 29/12/24
