Komatsu Excavator HB215LC-2 Hybrid service & repair manual

Description Komatsu Excavator HB215LC-2 Hybrid service & repair manual

Komatsu Hydraulic Excavator HB215LC-2 Hybrid pdf workshop service & repair manual

Serial numbers:
K60001 and up
50001 and up

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

SERVICE MANUAL CONTENT:
Index and foreword
Foreword, safety and general information
Important safety notice (Hybrid)
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code (Hybrid)
Precautions when performing operation
Practical use of KOMTRAX
Handling hybrid components and high voltage wiring harness
Standard tightening torque table
List of abbreviation
Conversion table

Specification
Specification drawing
Working range drawings
Weight table
Table of fuel, coolant, and lubricants

Structure and function
Engine and cooling system
Engine related parts
VFT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDOC muffler
Cooling system
Hybrid system
Outline of hybrid system
Configuration of hybrid system
Protective function of hybrid component
Protection function for workers when disassembling hybrid component
Cooling system of hybrid component
Interlock function
Motorgenerator
Electric swing motor
Electric control unit
High voltage wiring harness (power cable)
Water pump
Power train
Power train system
Swing circle
Swing machinery with swing brake
Final drive
Undercarriage and frame
Track frame and idler cushion
Hydraulic system
Hydraulic component layout
Valve control
Hydraulic tank
CLSS
Main pump
Pilot oil filter
Control valve
Travel motor
PPC valve
Solenoid valve
Attachment circuit selector valve (for low pressure circuit)
Center swivel joint
Accumulator
ATT EPC valve assembly
Return oil filter
Quick coupler control valve
Work equipment
Work equipment shim
Bucket play adjustment shim
Cab and its attachments
Cab mount and cab tipping stopper
ROPS cab
Electrical system
Electrical control system
Machine monitor system
KOMTRAX system
Sensor
Auto grease system

Standard value tables
Standard service value table
Standard value table for engine
Standard value table for machine
Standard value table for electrical system

Testing and adjusting
Related information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Testing engine speed
Testing boost pressure
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing fuel pressure
Testing fuel discharge, return and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling noinjection cranking operation
Testing and adjusting air conditioner compressor belt tension
Replacing fan belt
Hybrid system
Precautions related to hybrid equipment
Bleeding air from hybrid cooling system
Testing water pressure of hybrid coolant
Testing swing parking brake
Cleaning and replacing oil filter of electric swing motor
Power train
Testing swing circle bearing clearance
Undercarriage and frame
Testing and adjusting track tension
Hydraulic system
Releasing remaining pressure from hydraulic circuit
Testing oil pressure of control circuit
Testing and adjusting oil pressure in work equipment and travel circuits
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing outlet pressure of solenoid valve
Testing PPC valve outlet pressure
Adjusting play of work equipment and swing PPC valves
Measuring and adjusting quick coupler control valve output pressure
Testing pump swash plate sensor
Isolating the parts causing hydraulic drift in work equipment
Testing oil leakage
Bleeding air from hydraulic circuit
Cab and its attachments
Testing cab tipping stopper
Adjusting mirrors
Electrical system
Special functions of machine monitor
KOMTRAX terminal startup procedure
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service

Troubleshooting
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Checks before troubleshooting
Inspection procedure before troubleshooting
Preparation for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Diagnostic procedure for wiring harness open circuit of pressure sensor system
Connector list and layout
Connector contact identification
Tbranch box and Tbranch adapter table
Fuse location table
Failure codes table
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)
Troubleshooting for hybrid systems (Y mode)

Disassembly and assembly
Related information on disassembly and assembly
How to read this manual
Precautions related to hybrid equipment
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of supply pump assembly
Removal and installation of 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, motorgenerator, and main pump assembly
Removal and installation of fan belt
Removal and installation of starting motor
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of fuel cooler assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Removal and installation of KDOC assembly
Removal and installation of KCCV assembly
Removal and installation of air cleaner assembly
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
Hybrid system
Draining coolant, refilling with coolant, and bleeding air for hybrid system
Removal and installation of hybrid radiator assembly
Removal and installation of hybrid water pump assembly
Removal and installation of inverter assembly
Removal and installation of inverter and capacitor assembly
Procedure for draining and refilling generator lubricating oil
Removal and installation of tandem pump assembly
Removal and installation of motorgenerator and housing assembly
Removal and installation of electric swing motor assembly
Power train system
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of final drive
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
Removal and installation of sprocket
Removal and installation of idler and idler cushion assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of idler cushion assembly
Disassembly and assembly of track roller assembly
Disassembly and assembly of carrier roller assembly
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 control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve
Disassembly and assembly of travel PPC valve assembly
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 cab glass (adhered 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 operator's seat
Removal and installation of seat belt
Removal and installation of front wiper assembly
Electrical system
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser assembly
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 pump swash plate sensor
Removal and installation of mass air flow and temperature sensor
Removal and installation of KOMTRAX terminal assembly

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

Appendix
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Air conditioner condenser
Sunlight sensor
Outer temperature sensor (outside air temperature sensor)
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Parts and connectors layout
Testing air leakage (duct)
Testing with selfdiagnosis function
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart
Information in troubleshooting table
Failure code list related to air conditioner
A-1 Troubleshooting for power supply system (Air conditioner does not operate)
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
A-4 Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil
Desiccant replacement

Diagrams and drawings
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram

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