Komatsu HB205-1, HB215LC-1 Hydraulic Excavator Shop Manual (1001 and up) - SEN05393-04

This complete service repair workshop manual PDF download for the HB205-1, HB215LC-1 Komatsu Hydraulic Excavator (S/N: 1001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu HB205-1 - S/N: 1001 and up
Komatsu HB215LC-1 - S/N: 1001 and up


TABLE OF CONTENTS :

- Index and foreword
- Specification
- Structure and function
- Standard value table
- Testing and adjusting
- Troubleshooting
- Disassembly and assembly
- Maintenance standard
- Appendix
- Diagrams and drawings
- Index


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN05393-04
Total Pages : 1451


This Komatsu HB205-1, HB215LC-1 Hydraulic Excavator Shop Manual has easy to read text sections with top quality diagrams and instructions. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.

This Manual covers all aspects of repair:
- Simply print out the pages you need or print the entire manual as a whole!!!
- Detailed substeps expand on repair procedure information.
- Notes, cautions and warnings throughout each chapter pinpoint critical information.
- Numbered instructions guide you through every repair procedure step by step.
- Bold figure number help you quickly match illustrations with instructions.
- Detailed illustrations, drawings and photos guide you through every procedure.
- Enlarged inset helps you identify and examine parts in detail.
- Numbered table of contents easy to use so that you can find the information you need fast.

-

00 Index and foreword
Table of Contents
Table of Contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of hydraulic components
Method of disconnecting and connecting push-pull type coupler
Handling of electric equipment
How to read electric wire code
Precautions when performing work
Handling of hybrid devices and high-voltage wirings
Standard tightening torque table
List of Abbreviation
Conversion table

01 Specifications
Specifications
Outline of hybrid system
Specification dimension drawing
Working range diagram
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure and function
Engine and cooling system
Engine related parts
Cooling system
Hybrid relation
Configuration and safety functions of hybrid system
Cooling system of hybrid component
Motor-generator
Swing electric motor
Electric control unit
High-voltage wiring (power cable)
Water pump
Power train system
Power train
Swing circle
Swing machinery
Swing brake
Final drive
Undercarriage and frame
Track frame and idler cushion
Hydraulic system
Hydraulic components layout drawing
Valve control
Hydraulic tank
CLSS
Main pump
Control valve
Functions and operation by valve
Travel motor
PPC valve
Solenoid valve
Attachment circuit selector valve
Return oil filter
Center swivel joint
Accumulator
Electrical system
Electrical control system
Machine monitor system
KOMTRAX system
Sensors

20 Standard value table
Standard value table
Standard value table for engine
Standard value table for machine

30 Testing and adjusting
Tools for testing, adjusting and troubleshooting
Tools for testing, adjusting and troubleshooting
Engine and cooling system
Testing engine speed
Testing boost pressure
Checking exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Handling fuel system parts
Releasing remaining pressure from fuel system
Testing fuel system pressure
Cylinder cut-out test mode operation
No injection cranking operation
Testing fuel delivery, return rate and leakage
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Handling of controller high-voltage circuit
Testing and adjusting air conditioner compressor belt tension
Replacement of fan belt
Undercarriage and frame
Testing swing circle bearing clearance
Testing and adjusting track tension
Hydraulic system
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits
Testing source pressure of control circuit
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing solenoid valve output pressure
Testing PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Checking parts which cause hydraulic drift of work equipment
Releasing remaining pressure from hydraulic circuit
Testing oil leakage
Bleeding air from each part
Cab and its attachments
Checking cab tipping stopper
Adjusting mirrors
Angle adjustment of rear view camera
Hybrid relation
Testing swing holding brake
Cleaning and replacement of oil filter of swing electric motor
Operation check of swing emergency stop switch
Electrical system
Special functions of machine monitor
Handling voltage circuit of engine controller
Precautions related to hybrid machines
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic
Pm Clinic service

40 Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Failure codes table
Symptom and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Connector list and layout
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Fuse location table
Troubleshooting by failure code
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@HANS] Hyd Oil Overheat
Failure code [CA111] ECM Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA324] Inj #3(L#3) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA332] Inj #4(L#4) Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA553] Rail Press High Error
Failure code [CA559] Supply Pump Press Low Error 1
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2555] Grid Htr Relay Open Circuit Error
Failure code [CA2556] Grid Htr Relay Short Circuit Error
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA25KP] 5V Sensor1 Power Abnormality
Failure code [DA26KP] 5V Sensor2 Power Abnormality
Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAFGMC] GPS Module Error
Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DGH2KB] Hyd Oil Sensor Short
Failure code [DHPAMA] Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality
Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open or short circuit
Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open or short circuit
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir
Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor signal abnormality
Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor malfunction
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir
Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor signal abnormality
Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor malfunction
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir
Failure code [DW43KA] Travel Speed Sol Open Circuit
Failure code [DW43KB] Travel Speed Sol Short Circuit
Failure code [DW45KA] Swing holding brake solenoid valve open circuit40
Failure code [DW45KB] Swing holding brake solenoid valve short circuit40
Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit
Failure code [DW91KA] Travel Junction Sol. Disc.
Failure code [DW91KB] Travel Junction Sol. S/C
Failure code [DWA2KA] Attachment Sol Open Circuit
Failure code [DWA2KB] Attachment Sol Short Circuit
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
Failure code [DXE0KA] LS-EPC Sol Open Circuit
Failure code [DXE0KB] LS-EPC Sol Short Circuit
Failure code [DXE4KA] Service Current EPC Disc.
Failure code [DXE4KB] Service Current EPC S/C
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKA] Washer drive discon
Failure code [DY2CKB] Washer drive short
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices
Failure code [GA----] Hybrid devices monitoring items list and check sheet
Failure code [GA00NS] HYB devices overheat
Failure code [GA01KA] Power Cable Interlock Open Circuit
Failure code [GA02KZ] DC Line Open/Short Circuit
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster
Failure code [GA09KP] Low DC SW Output Volt. After Booster
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster
Failure code [GA0BKZ] AC Line Open/Short Circuit
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure
Failure code [GA1FMA] Abnormal Swing Motor Driver
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op.
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir.
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir.
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir.
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir.
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat
Failure code [GA1SFS] Contactor Locked
Failure code [GA1SMC] Contactor Failure
Failure code [GA1TKP] Capacitor Low Output Voltage
Failure code [GA1TNS] Capacitor Overheat
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir.
Failure code [GA1VFS] Capacitor Contactor Locked
Failure code [GA1VMC] Capacitor Contactor Failure
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ.
Failure code [GA1YNS] Booster Inductor Overheat
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ.
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat
Failure code [GA21KB] Booster IGBT Short Circuit
Failure code [GA22NS] Booster IGBT Junction Overheat
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sens.0 Opn/Short Cir.
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir.
Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality
Failure code [GA25NS] Gen. Motor Driver IGBT0 overheat
Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality
Failure code [GA26NS] Gen. Motor Driver IGBT1 overheat
Failure code [GA27KZ] DC before boosting sensor open or short circuit40-409
Failure code [GA28KZ] DC after boosting sensor open or short circuit
Failure code [GA60MC] Generator Motor Failure
Failure code [GA60MD] Gen. Mot. Defective Movement
Failure code [GA60N1] Generator Motor Overrun
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir.
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir.
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir.
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction
Failure code [GA70KB] HYB Swing Motor Short Circuit
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion
Failure code [GA70NS] HYB Swing Motor Overheat
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir.
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ.
Failure code [GAA100] Swing emergency stop switch operated
Failure code [GAA2KB] Swing Brake sol. Supply Line short cir.
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)
E-2 Preheater does not operate
E-3 When starting switch is turned to ON position, machine monitor displays nothing
E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up.
E-5 Precaution monitor lights up while engine is running
E-6 Emergency stop monitor lights up while engine is running
E-7 Fuel level gauge does not indicate properly
E-8 Engine coolant temperature gauge does not indicate properly
E-9 Hydraulic oil temperature gauge does not indicate properly
E-10 HYB system temperature gauge does not indicate properly
E-11 Displays on machine monitor are different from those for actual machine
E-12 Machine monitor does not display some items
E-13 Function switch does not work
E-14 Automatic warm-up system does not operate (in cold season)
E-15 Auto-decelerator does not operate normally
E-16 Working mode does not change
E-17 Travel speed does not change
E-18 Alarm buzzer does not stop sounding
E-19 When starting switch is at OFF position, service meter is not displayed
E-20 Machine monitor cannot be set in service mode
E-21 All of work equipment, swing, and travel mechanism do not move or are not locked
E-22 Swing holding brake does not operate properly
E-23 One-touch power max. function does not operate
E-24 Travel alarm does not sound or does not stop sounding
E-25 Horn does not sound or does not stop sounding
E-26 Windshield wiper and window washer do not operate
E-27 "BOOM LOWER" indicator is not displayed properly with monitoring function
E-28 "ARM OUT" indicator is not displayed properly with monitoring function
E-29 "ARM IN" indicator is not displayed properly with monitoring function
E-30 "BOOM RAISE" indicator is not displayed properly with monitoring function
E-31 "BUCKET CURL" indicator is not displayed properly with monitoring function
E-32 "BUCKET DUMP" indicator is not displayed properly with monitoring function
E-33 "SWING" indicator is not displayed properly with monitoring function
E-34 "TRAVEL" indicator is not displayed properly with monitoring function
E-35 "TRAVEL STEERING" indicator is not displayed properly with monitoring function
E-36 "SERVICE" indicator is not displayed properly with monitoring function
E-37 Attachment hydraulic circuit cannot be changed
E-38 KOMTRAX system does not operate properly
Troubleshooting of hydraulic and mechanical system (H-mode)
System diagram of hydraulic and mechanical system
Information in troubleshooting table (H mode)
H-1 Speed or power of all work equipment and travel is low
H-2 Engine speed lowers significantly or engine stalls
H-3 All work equipment and travel systems do not work
H-4 Unusual noise comes out from around hydraulic pump
H-5 Auto-decelerator does not operate
H-6 Fine control performance or response is low
H-7 Speed or power of boom is low
H-8 Speed or power of arm is low
H-9 Speed or power of bucket is low
H-10 Work equipment does not move in its single operation
H-11 Hydraulic drift of work equipment is large
H-12 Time lag of work equipment is large
H-13 When part of work equipment is relieved singly, other parts of work equipment move
H-14 Power maximizing function does not work
H-15 In combined operation of work equipment, speed of part loaded more is low
H-16 When machine swings and travels simultaneously, travel speed is low
H-17 Machine deviates during travel
H-18 Travel speed is low
H-19 Machine is not steered well or sterring power is low
H-20 Travel speed does not shift or travel speed is low or high
H-21 Travel system does not work (only one side)
H-22 Upper structure does not swing
H-23 Swing acceleration or swing speed of upper structure is low
H-24 Upper structure overruns remarkably when it stops swinging
H-25 Large shock is made when upper structure stops swinging
H-26 Large sound is made when upper structure stops swinging
H-27 Upper structure lowers largely by its own weight
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Engine startability is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust gas is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust gas is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (coolant or fuel in oil)
S-14 Coolant temperature rises too high (overheating)
S-15 Unusual noise is made
S-16 Vibration is excessive
Troubleshooting hybrid system (Y-mode)
Precautions related to hybrid machine
Y-1 Hybrid monitor does not go out
Y-2 Upper structure does not swing
Y-3 Swing acceleration or swing speed is low
Y-4 Upper structure overruns largely when stop swinging
Y-5 Large shock is made when upper structure stops swinging
Y-6 Large unusual noise is made when upper structure stops swinging
Y-7 Swing drift on a slope is large
Y-8 Electric swing motor temperature increases abnormally
Y-9 Motor-generator temperature increases abnormally
Y-10 Inverter overheats
Y-11 Capacitor overheats

50 Disassembly and assembly
General information on disassembly and assembly
How to read Disassembly and Assembly
Precautions related to hybrid machine
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of fuel cooler assembly
Removal (and installation) of engine, motor generator, and main pump assembly
Removal and installation of fuel tank assembly
Hybrid
Draining adding coolant and bleeding air for hybrid system
Removal and installation of hybrid radiator assembly
Removal and installation of water pump assembly for hybrid system
Removal and installation of inverter assembly
Removal and installation of inverter and capacitor assembly
Draining and adding generator lubricating oil
Removal and installation of tandem pump assembly
Removal and installation of motor-generator housing assembly
Removal and installation of swing electric motor assembly
Power train
Removal and installation of final drive assembly
Disassembly and assembly of final drive
Removal and installation of sprocket
Removal and installation of swing motor and swing machinery assembly50
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Separation and connection of track shoe assembly
Disassembly and assembly of idler
Disassembly and assembly of idler cushion assembly
Disassembly and assembly of track roller
Disassembly and assembly of carrier roller
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of main pump assembly
Removal and installation of main pump input shaft oil seal
Removal and installation of control valve assembly
Disassembly and assembly of control valve
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve
Work equipment
Removal and installation of work equipment assembly
Disassembly and assembly of work equipment cylinder assembly
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator's cab glass (adhered window glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of pump controller assembly
Removal and installation of machine monitor assembly
Removal and installation of KOMTRAX terminal assembly

60 Maintenance standard
Engine and cooling system
Engine mount
Cooling system
Power train
Swing circle
Swing machinery
Swing brake
Final drive
Sprocket
Undercarriage and frame
Track frame and idler cushion
Idler
Track roller
Carrier roller
Track shoe
Hydraulic system
Main pump
Control valve
Travel motor
Solenoid valve
Attachment circuit selector valve
Center swivel joint
Work equipment
Work equipment
Dimension of work equipment
Work equipment cylinder

80 Appendix
Air conditioner
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Air conditioner controller
Compressor
Condenser and Modulator
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Detail of air conditioner unit
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
Testing temperature control
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing inner sensor
Testing evaporator temperature sensor
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information in troubleshooting table
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Troubleshooting for temperature control
Troubleshooting for vent (mode) changeover
Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting for temperature sensor system
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil
Desiccant replacement procedure

90 Diagrams and drawings
Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram
Electrical circuit diagram
Symbols used in electric circuit diagrams
Electrical circuit diagram

Index

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