Komatsu Excavator HB205-1 HB215LC-1 Hybrid service & repair manual

Description Komatsu Excavator HB205-1 HB215LC-1 Hybrid service & repair manual

Komatsu Hydraulic Excavator HB205-1, HB215LC-1 Hybrid pdf workshop service & repair manual

Serial numbers:
1001 and up

Technical documentation, specifications, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

SERVICE MANUAL CONTENT:
Index and Foreword
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

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

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

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

Testing and adjusting
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

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
Troubleshooting by failure code [GA****] (code display)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)
Troubleshooting hybrid system (Y-mode)

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 motorgenerator assembly
Removal and installation of motorgenerator 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 assembly
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
Removal and installation of work equipment control lever 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

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
PPC valve
Solenoid valve
Attachment circuit selector valve
Center swivel joint
Work equipment
Work equipment
Dimension of work equipment
Work equipment cylinder

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
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

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

Engine SAA4D107E-1 workshop service repair manual