Komatsu Hydraulic Excavator HB205-1, HB215LC-1 Hybrid Repair Service Manual (SEN05393)
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator HB205-1, HB215LC-1 Hybrid, with technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator HB205-1, HB215LC-1 Hybrid workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,451 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN05393-04 - Hydraulic Excavator HB205-1, HB215LC-1 Hybrid Shop Manual.pdf
MAIN SECTIONS
COVER...1
00 Index and foreword...11
Table of Contents...12
Table of Contents...12
Foreword and general information...24
Safety notice...24
How to read the shop manual...29
Explanation of terms for maintenance standard...31
Handling of hydraulic components...33
Method of disconnecting and connecting push-pull type coupler...35
Handling of electric equipment...38
How to read electric wire code...48
Precautions when performing work...53
Handling of hybrid devices and high-voltage wirings...56
Standard tightening torque table...62
List of Abbreviation...66
Conversion table...70
01 Specifications...75
Specifications...77
Outline of hybrid system...77
Specification dimension drawing...78
Working range diagram...79
Specifications...80
Weight table...83
Table of fuel, coolant and lubricants...85
10 Structure and function...87
Engine and cooling system...89
Engine related parts...89
Cooling system...90
Hybrid relation...92
Configuration and safety functions of hybrid system...92
Cooling system of hybrid component...96
Motor-generator...98
Swing electric motor...99
Electric control unit...102
High-voltage wiring (power cable)...103
Water pump...104
Power train system...106
Power train...106
Swing circle...107
Swing machinery...108
Swing brake...110
Final drive...112
Undercarriage and frame...114
Track frame and idler cushion...114
Hydraulic system...116
Hydraulic components layout drawing...116
Valve control...118
Hydraulic tank...119
CLSS...120
Main pump...124
Control valve...146
Functions and operation by valve...158
Travel motor...195
PPC valve...205
Solenoid valve...224
Attachment circuit selector valve...226
Return oil filter...228
Center swivel joint...230
Accumulator...231
Electrical system...232
Electrical control system...232
Machine monitor system...262
KOMTRAX system...278
Sensors...280
20 Standard value table...287
Standard value table...289
Standard value table for engine...289
Standard value table for machine...290
30 Testing and adjusting...301
Tools for testing, adjusting and troubleshooting...304
Tools for testing, adjusting and troubleshooting...304
Engine and cooling system...309
Testing engine speed...309
Testing boost pressure...311
Checking exhaust gas color...312
Adjusting valve clearance...313
Testing compression pressure...315
Testing blowby pressure...318
Testing engine oil pressure...319
Handling fuel system parts...320
Releasing remaining pressure from fuel system...320
Testing fuel system pressure...321
Cylinder cut-out test mode operation...323
No injection cranking operation...323
Testing fuel delivery, return rate and leakage...324
Bleeding air from fuel circuit...328
Testing fuel circuit for leakage...329
Handling of controller high-voltage circuit...330
Testing and adjusting air conditioner compressor belt tension...331
Replacement of fan belt...332
Undercarriage and frame...333
Testing swing circle bearing clearance...333
Testing and adjusting track tension...334
Hydraulic system...337
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits...337
Testing source pressure of control circuit...340
Testing and adjusting oil pressure in pump PC control circuit...341
Testing and adjusting oil pressure in pump LS control circuit...344
Testing solenoid valve output pressure...348
Testing PPC valve output pressure...351
Adjusting play of work equipment and swing PPC valves...353
Checking parts which cause hydraulic drift of work equipment...354
Releasing remaining pressure from hydraulic circuit...356
Testing oil leakage...357
Bleeding air from each part...359
Cab and its attachments...361
Checking cab tipping stopper...361
Adjusting mirrors...362
Angle adjustment of rear view camera...365
Hybrid relation...366
Testing swing holding brake...366
Cleaning and replacement of oil filter of swing electric motor...367
Operation check of swing emergency stop switch...368
Electrical system...370
Special functions of machine monitor...370
Handling voltage circuit of engine controller...432
Precautions related to hybrid machines...433
Preparation work for troubleshooting of electrical system...434
Procedure for testing diodes...440
Pm Clinic...441
Pm Clinic service...441
40 Troubleshooting...447
General information on troubleshooting...456
Points to remember when troubleshooting...456
Sequence of events in troubleshooting...457
Checks before troubleshooting...458
Classification and procedures for troubleshooting...487
Failure codes table...490
Symptom and troubleshooting numbers...498
Information in troubleshooting table...501
Troubleshooting method for open circuit in wiring harness of pressure sensor system...503
Connector list and layout...505
Connection table for connector pin numbers...516
T- branch box and T- branch adapter table...552
Fuse location table...555
Troubleshooting by failure code...557
Failure code [989L00] Engine Controller Lock Caution 1...557
Failure code [989M00] Engine Controller Lock Caution 2...557
Failure code [989N00] Engine Controller Lock Caution 3...558
Failure code [AA10NX] Air Cleaner Clogging...559
Failure code [AB00KE] Charge Voltage Low...560
Failure code [B@BAZG] Eng Oil Press Low...562
Failure code [B@BAZK] Eng Oil Level Low...563
Failure code [B@BCNS] Eng Water Overheat...564
Failure code [B@BCZK] Eng Water Level Low...566
Failure code [B@HANS] Hyd Oil Overheat...568
Failure code [CA111] ECM Critical Internal Failure...569
Failure code [CA115] Eng Ne and Bkup Speed Sens Error...569
Failure code [CA122] Chg Air Press Sensor High Error...570
Failure code [CA123] Chg Air Press Sensor Low Error...572
Failure code [CA131] Throttle Sensor High Error...574
Failure code [CA132] Throttle Sensor Low Error...576
Failure code [CA144] Coolant Temp Sens High Error...578
Failure code [CA145] Coolant Temp Sens Low Error...580
Failure code [CA153] Chg Air Temp Sensor High Error...582
Failure code [CA154] Chg Air Temp Sensor Low Error...584
Failure code [CA155] Chg Air Temp High Speed Derate...586
Failure code [CA187] Sens Supply 2 Volt Low Error...588
Failure code [CA221] Ambient Press Sens High Error...590
Failure code [CA222] Ambient Press Sens Low Error...592
Failure code [CA227] Sens Supply 2 Volt High Error...594
Failure code [CA234] Eng Overspeed...594
Failure code [CA238] Ne Speed Sens Supply Volt Error...595
Failure code [CA271] IMV/PCV1 Short Error...596
Failure code [CA272] IMV/PCV1 Open Error...598
Failure code [CA322] Inj #1(L#1) Open/Short Error...600
Failure code [CA324] Inj #3(L#3) Open/Short Error...602
Failure code [CA331] Inj #2(L#2) Open/Short Error...604
Failure code [CA332] Inj #4(L#4) Open/Short Error...606
Failure code [CA342] Calibration Code Incompatibility...608
Failure code [CA351] Injectors Drive Circuit Error...609
Failure code [CA352] Sens Supply 1 Volt Low Error...610
Failure code [CA386] Sens Supply 1 Volt High Error...612
Failure code [CA428] Water in Fuel Sensor High Error...614
Failure code [CA429] Water in Fuel Sensor Low Error...616
Failure code [CA435] Eng Oil Press Sw Error...618
Failure code [CA441] Battery Voltage Low Error...620
Failure code [CA442] Battery Voltage High Error...622
Failure code [CA449] Rail Press Very High Error...623
Failure code [CA451] Rail Press Sensor High Error...624
Failure code [CA452] Rail Press Sensor Low Error...626
Failure code [CA488] Chg Air Temp High Torque Derate...628
Failure code [CA553] Rail Press High Error...629
Failure code [CA559] Supply Pump Press Low Error 1...630
Failure code [CA689] Eng Ne Speed Sensor Error...632
Failure code [CA731] Eng Bkup Speed Sens Phase Error...634
Failure code [CA757] All Continuous Data Lost Error...635
Failure code [CA778] Eng Bkup Speed Sensor Error...636
Failure code [CA1633] KOMNET Datalink Timeout Error...639
Failure code [CA2185] Throt Sens Sup Volt High Error...640
Failure code [CA2186] Throt Sens Sup Volt Low Error...641
Failure code [CA2249] Rail Press Very Low Error...642
Failure code [CA2311] IMV Solenoid Error...643
Failure code [CA2555] Grid Htr Relay Open Circuit Error...644
Failure code [CA2556] Grid Htr Relay Short Circuit Error...646
Failure code [D19JKZ] Personal Code Relay Abnormality...648
Failure code [D862KA] GPS Antenna Open Circuit...651
Failure code [DA22KK] Pump Solenoid Power Low Error...652
Failure code [DA25KP] 5V Sensor1 Power Abnormality...654
Failure code [DA26KP] 5V Sensor2 Power Abnormality...656
Failure code [DA29KQ] Model Selection Abnormality...658
Failure code [DA2RMC] CAN Discon (Pump Con Detected)...660
Failure code [DAF8KB] Camera Power Supply Short Circuit...666
Failure code [DAFGMC] GPS Module Error...668
Failure code [DAFRMC] CAN Discon (Monitor Detected)...669
Failure code [DGH2KB] Hyd Oil Sensor Short...676
Failure code [DHPAMA] Pump Press Sensor Abnormality...678
Failure code [DHPBMA] R Pump Press Sensor Abnormality...680
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality...682
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality...684
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality...686
Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open or short circuit...688
Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open or short circuit...690
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality...692
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality...694
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality...696
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit...698
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir...700
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir...702
Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor signal abnormality...704
Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor malfunction...705
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir...706
Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor signal abnormality...708
Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor malfunction...709
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir...710
Failure code [DW43KA] Travel Speed Sol Open Circuit...712
Failure code [DW43KB] Travel Speed Sol Short Circuit...714
Failure code [DW45KA] Swing holding brake solenoid valve open circuit40...716
Failure code [DW45KB] Swing holding brake solenoid valve short circuit40...719
Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop...722
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir...724
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit...726
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit...728
Failure code [DW91KA] Travel Junction Sol. Disc...730
Failure code [DW91KB] Travel Junction Sol. S/C...732
Failure code [DWA2KA] Attachment Sol Open Circuit...734
Failure code [DWA2KB] Attachment Sol Short Circuit...736
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit...738
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit...740
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit...742
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit...744
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit...746
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit...748
Failure code [DXE0KA] LS-EPC Sol Open Circuit...750
Failure code [DXE0KB] LS-EPC Sol Short Circuit...752
Failure code [DXE4KA] Service Current EPC Disc...754
Failure code [DXE4KB] Service Current EPC S/C...756
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit...758
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit...760
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit...762
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit...764
Failure code [DY20KA] Wiper Working Abnormality...766
Failure code [DY20MA] Wiper Parking Abnormality...768
Failure code [DY2CKA] Washer drive discon...770
Failure code [DY2CKB] Washer drive short...772
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit...774
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...776
Troubleshooting by failure code [GA****] (code display)...778
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices...778
Failure code [GA----] Hybrid devices monitoring items list and check sheet...805
Failure code [GA00NS] HYB devices overheat...809
Failure code [GA01KA] Power Cable Interlock Open Circuit...810
Failure code [GA02KZ] DC Line Open/Short Circuit...812
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster...813
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster...814
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster...815
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster...816
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster...817
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster...818
Failure code [GA09KP] Low DC SW Output Volt. After Booster...819
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster...820
Failure code [GA0BKZ] AC Line Open/Short Circuit...821
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure...822
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON...823
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF...824
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure...826
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure...828
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir...829
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure...829
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit...830
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit...830
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded...831
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure...831
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt...832
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure...832
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con...833
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction...833
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation...834
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled...834
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction...835
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure...835
Failure code [GA1FMA] Abnormal Swing Motor Driver...836
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU...836
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure...837
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal...837
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction...838
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded...838
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op...839
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled...839
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir...840
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir...840
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir...841
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir...841
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir...842
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat...845
Failure code [GA1SFS] Contactor Locked...846
Failure code [GA1SMC] Contactor Failure...846
Failure code [GA1TKP] Capacitor Low Output Voltage...847
Failure code [GA1TNS] Capacitor Overheat...848
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir...850
Failure code [GA1VFS] Capacitor Contactor Locked...852
Failure code [GA1VMC] Capacitor Contactor Failure...854
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ...855
Failure code [GA1YNS] Booster Inductor Overheat...856
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ...857
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat...858
Failure code [GA21KB] Booster IGBT Short Circuit...859
Failure code [GA22NS] Booster IGBT Junction Overheat...861
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sens.0 Opn/Short Cir...862
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir...862
Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality...863
Failure code [GA25NS] Gen. Motor Driver IGBT0 overheat...864
Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality...865
Failure code [GA26NS] Gen. Motor Driver IGBT1 overheat...866
Failure code [GA27KZ] DC before boosting sensor open or short circuit40-409...867
Failure code [GA28KZ] DC after boosting sensor open or short circuit...867
Failure code [GA60MC] Generator Motor Failure...868
Failure code [GA60MD] Gen. Mot. Defective Movement...869
Failure code [GA60N1] Generator Motor Overrun...870
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir...872
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat...874
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir...875
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir...876
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction...877
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir...877
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir...878
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction...878
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir...879
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir...880
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction...880
Failure code [GA70KB] HYB Swing Motor Short Circuit...881
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion...881
Failure code [GA70NS] HYB Swing Motor Overheat...882
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir...884
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction...886
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op...888
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ...888
Failure code [GAA100] Swing emergency stop switch operated...889
Failure code [GAA2KB] Swing Brake sol. Supply Line short cir...890
Troubleshooting of electrical system (E-mode)...892
E-1 Engine does not start (Engine does not crank)...892
E-2 Preheater does not operate...898
E-3 When starting switch is turned to ON position, machine monitor displays nothing...903
E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up...906
E-5 Precaution monitor lights up while engine is running...907
E-6 Emergency stop monitor lights up while engine is running...909
E-7 Fuel level gauge does not indicate properly...910
E-8 Engine coolant temperature gauge does not indicate properly...912
E-9 Hydraulic oil temperature gauge does not indicate properly...914
E-10 HYB system temperature gauge does not indicate properly...916
E-11 Displays on machine monitor are different from those for actual machine...918
E-12 Machine monitor does not display some items...918
E-13 Function switch does not work...918
E-14 Automatic warm-up system does not operate (in cold season)...919
E-15 Auto-decelerator does not operate normally...920
E-16 Working mode does not change...921
E-17 Travel speed does not change...922
E-18 Alarm buzzer does not stop sounding...923
E-19 When starting switch is at OFF position, service meter is not displayed...923
E-20 Machine monitor cannot be set in service mode...923
E-21 All of work equipment, swing, and travel mechanism do not move or are not locked...924
E-22 Swing holding brake does not operate properly...927
E-23 One-touch power max. function does not operate...930
E-24 Travel alarm does not sound or does not stop sounding...934
E-25 Horn does not sound or does not stop sounding...936
E-26 Windshield wiper and window washer do not operate...938
E-27 "BOOM LOWER" indicator is not displayed properly with monitoring function...940
E-28 "ARM OUT" indicator is not displayed properly with monitoring function...942
E-29 "ARM IN" indicator is not displayed properly with monitoring function...944
E-30 "BOOM RAISE" indicator is not displayed properly with monitoring function...944
E-31 "BUCKET CURL" indicator is not displayed properly with monitoring function...944
E-32 "BUCKET DUMP" indicator is not displayed properly with monitoring function...945
E-33 "SWING" indicator is not displayed properly with monitoring function...945
E-34 "TRAVEL" indicator is not displayed properly with monitoring function...946
E-35 "TRAVEL STEERING" indicator is not displayed properly with monitoring function...948
E-36 "SERVICE" indicator is not displayed properly with monitoring function...950
E-37 Attachment hydraulic circuit cannot be changed...952
E-38 KOMTRAX system does not operate properly...953
Troubleshooting of hydraulic and mechanical system (H-mode)...954
System diagram of hydraulic and mechanical system...954
Information in troubleshooting table (H mode)...956
H-1 Speed or power of all work equipment and travel is low...957
H-2 Engine speed lowers significantly or engine stalls...959
H-3 All work equipment and travel systems do not work...960
H-4 Unusual noise comes out from around hydraulic pump...960
H-5 Auto-decelerator does not operate...961
H-6 Fine control performance or response is low...961
H-7 Speed or power of boom is low...962
H-8 Speed or power of arm is low...963
H-9 Speed or power of bucket is low...964
H-10 Work equipment does not move in its single operation...964
H-11 Hydraulic drift of work equipment is large...965
H-12 Time lag of work equipment is large...967
H-13 When part of work equipment is relieved singly, other parts of work equipment move...967
H-14 Power maximizing function does not work...968
H-15 In combined operation of work equipment, speed of part loaded more is low...968
H-16 When machine swings and travels simultaneously, travel speed is low...968
H-17 Machine deviates during travel...969
H-18 Travel speed is low...970
H-19 Machine is not steered well or sterring power is low...971
H-20 Travel speed does not shift or travel speed is low or high...972
H-21 Travel system does not work (only one side)...973
H-22 Upper structure does not swing...974
H-23 Swing acceleration or swing speed of upper structure is low...974
H-24 Upper structure overruns remarkably when it stops swinging...974
H-25 Large shock is made when upper structure stops swinging...975
H-26 Large sound is made when upper structure stops swinging...975
H-27 Upper structure lowers largely by its own weight...975
Troubleshooting of engine (S-mode)...976
Method of using troubleshooting chart...976
S-1 Engine startability is poor...980
S-2 Engine does not start...981
S-3 Engine does not pick up smoothly...984
S-4 Engine stops during operations...985
S-5 Engine does not rotate smoothly...986
S-6 Engine lacks output (or lacks power)...987
S-7 Exhaust gas is black (incomplete combustion)...988
S-8 Oil consumption is excessive (or exhaust gas is blue)...989
S-9 Oil becomes contaminated quickly...990
S-10 Fuel consumption is excessive...991
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)...992
S-12 Oil pressure drops...993
S-13 Oil level rises (coolant or fuel in oil)...994
S-14 Coolant temperature rises too high (overheating)...995
S-15 Unusual noise is made...996
S-16 Vibration is excessive...997
Troubleshooting hybrid system (Y-mode)...998
Precautions related to hybrid machine...998
Y-1 Hybrid monitor does not go out...1000
Y-2 Upper structure does not swing...1002
Y-3 Swing acceleration or swing speed is low...1004
Y-4 Upper structure overruns largely when stop swinging...1005
Y-5 Large shock is made when upper structure stops swinging...1006
Y-6 Large unusual noise is made when upper structure stops swinging...1006
Y-7 Swing drift on a slope is large...1007
Y-8 Electric swing motor temperature increases abnormally...1008
Y-9 Motor-generator temperature increases abnormally...1010
Y-10 Inverter overheats...1011
Y-11 Capacitor overheats...1012
50 Disassembly and assembly...1013
General information on disassembly and assembly...1016
How to read Disassembly and Assembly...1016
Precautions related to hybrid machine...1018
Coating materials list...1019
Special tools list...1022
Sketches of special tools...1027
Engine and cooling system...1032
Removal and installation of fuel supply pump assembly...1032
Removal and installation of fuel injector assembly...1037
Removal and installation of cylinder head assembly...1044
Removal and installation of radiator assembly...1067
Removal and installation of hydraulic oil cooler assembly...1069
Removal and installation of aftercooler assembly...1071
Removal and installation of engine front seal...1074
Removal and installation of engine rear seal...1076
Removal and installation of fuel cooler assembly...1080
Removal (and installation) of engine, motor generator, and main pump assembly...1082
Removal and installation of fuel tank assembly...1098
Hybrid...1101
Draining adding coolant and bleeding air for hybrid system...1101
Removal and installation of hybrid radiator assembly...1105
Removal and installation of water pump assembly for hybrid system...1108
Removal and installation of inverter assembly...1111
Removal and installation of inverter and capacitor assembly...1115
Draining and adding generator lubricating oil...1120
Removal and installation of tandem pump assembly...1122
Removal and installation of motor-generator housing assembly...1125
Removal and installation of swing electric motor assembly...1134
Power train...1147
Removal and installation of final drive assembly...1147
Disassembly and assembly of final drive...1149
Removal and installation of sprocket...1158
Removal and installation of swing motor and swing machinery assembly50...1159
Disassembly and assembly of swing machinery assembly...1169
Removal and installation of swing circle assembly...1184
Undercarriage and frame...1185
Separation and connection of track shoe assembly...1185
Disassembly and assembly of idler...1188
Disassembly and assembly of idler cushion assembly...1191
Disassembly and assembly of track roller...1193
Disassembly and assembly of carrier roller...1195
Removal and installation of revolving frame assembly...1199
Removal and installation of counterweight assembly...1201
Hydraulic system...1203
Removal and installation of center swivel joint assembly...1203
Disassembly and assembly of center swivel joint assembly...1205
Removal and installation of hydraulic tank assembly...1207
Removal and installation of main pump assembly...1212
Removal and installation of main pump input shaft oil seal...1217
Removal and installation of control valve assembly...1218
Disassembly and assembly of control valve...1223
Disassembly and assembly of work equipment PPC valve assembly...1227
Disassembly and assembly of travel PPC valve...1229
Work equipment...1232
Removal and installation of work equipment assembly...1232
Disassembly and assembly of work equipment cylinder assembly...1235
Cab and its attachments...1241
Removal and installation of operator's cab assembly...1241
Removal and installation of operator's cab glass (adhered window glass)...1245
Removal and installation of front window assembly...1255
Removal and installation of floor frame assembly...1262
Removal and installation of air conditioner unit assembly...1267
Electrical system...1270
Removal and installation of engine controller assembly...1270
Removal and installation of pump controller assembly...1272
Removal and installation of machine monitor assembly...1275
Removal and installation of KOMTRAX terminal assembly...1277
60 Maintenance standard...1279
Engine and cooling system...1282
Engine mount...1282
Cooling system...1283
Power train...1285
Swing circle...1285
Swing machinery...1286
Swing brake...1288
Final drive...1290
Sprocket...1292
Undercarriage and frame...1294
Track frame and idler cushion...1294
Idler...1296
Track roller...1298
Carrier roller...1299
Track shoe...1300
Hydraulic system...1306
Main pump...1306
Control valve...1310
Travel motor...1319
Solenoid valve...1332
Attachment circuit selector valve...1333
Center swivel joint...1334
Work equipment...1336
Work equipment...1336
Dimension of work equipment...1338
Work equipment cylinder...1342
80 Appendix...1345
Air conditioner...1347
Precautions for refrigerant...1347
Air conditioner component...1348
Configuration and function of refrigeration cycle...1350
Outline of refrigeration cycle...1351
Air conditioner unit...1354
Air conditioner controller...1359
Compressor...1360
Condenser and Modulator...1361
Procedure for testing and troubleshooting...1362
Circuit diagram and arrangement of connector pins...1364
System diagram...1366
Detail of air conditioner unit...1368
Parts and connectors layout...1370
Testing air leakage (duct)...1374
Testing with self-diagnosis function...1375
Testing temperature control...1378
Testing vent (mode) changeover...1380
Testing FRESH/RECIRC air changeover...1383
Testing inner sensor...1385
Testing evaporator temperature sensor...1386
Testing sunlight sensor...1388
Testing (dual) pressure switch for refrigerant...1389
Testing relays...1391
Troubleshooting chart 1...1392
Troubleshooting chart 2...1394
Information in troubleshooting table...1396
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)...1397
Troubleshooting for compressor and refrigerant system (Air is not cooled)...1401
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)...1404
Troubleshooting for temperature control...1407
Troubleshooting for vent (mode) changeover...1410
Troubleshooting for FRESH/RECIRC air changeover...1412
Troubleshooting for temperature sensor system...1414
Troubleshooting with gauge pressure...1415
Connection of service tool...1418
Precautions for disconnecting and connecting air conditioner piping...1420
Handling of compressor oil...1422
Desiccant replacement procedure...1424
90 Diagrams and drawings...1427
Hydraulic circuit diagram...1429
Symbols used in hydraulic circuit diagrams...1429
Hydraulic circuit diagram...1433
Electrical circuit diagram...1434
Symbols used in electric circuit diagrams...1434
Electrical circuit diagram ...1438
Index...1444
