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Komatsu HB215LC-2 Shop Manual
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Komatsu HB215LC-2 Shop Manual

Hydraulic excavator
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SEN06488-01
HYDRAULIC
HB215LC
-2
EXCAVATOR
50001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu HB215LC-2

  • Page 1 SEN06488-01 HYDRAULIC HB215LC EXCAVATOR 50001 SERIAL NUMBERS and up...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 SHOP MANUAL HYDRAULIC EXCAVATOR HB215LC-2 Model Serial Number HB215LC-2 50001 and up 00 Index and foreword 1 00 Index and foreword HB215LC-2 00-1 Find manuals at https://best-manuals.com...
  • Page 4 Water pump........................10-38 Power train..........................10-39 Power train system......................10-39 Swing circle ........................10-41 Swing machinery with swing brake ..................10-42 Final drive ......................... 10-44 Undercarriage and frame......................10-46 Track frame and idler cushion ..................... 10-46 00-2 HB215LC-2 Find manuals at https://best-manuals.com...
  • Page 5 Precautions related to hybrid equipment ................30-37 Bleeding air from hybrid cooling system ................30-38 Testing water pressure of hybrid coolant................30-40 Testing swing parking brake ....................30-42 Cleaning and replacing oil filter of electric swing motor ............30-43 00-3 HB215LC-2 Find manuals at https://best-manuals.com...
  • Page 6 Failure code [879EMC] Ventilation Damper Abnormality ............40-127 Failure code [879FMC] Air Mix Damper Abnormality ............40-128 Failure code [879GKX] Refrigerant Abnormality ..............40-129 Failure code [989L00] Engine Controller Lock Caution1............40-130 Failure code [989M00] Engine Controller Lock Caution2............40-131 00-4 HB215LC-2 Find manuals at https://best-manuals.com...
  • Page 7 Failure code [CA559] Rail Press Low Error................. 40-218 Failure code [CA689] Eng Ne Speed Sensor Error .............. 40-220 Failure code [CA691] Intake Air Temp Sens High Error ............40-222 Failure code [CA692] Intake Air Temp Sens Low Error............40-224 00-5 HB215LC-2 Find manuals at https://best-manuals.com...
  • Page 8 Failure code [DA2RKR] CAN1 Discon (Pump Con) ............. 40-311 Failure code [DAF0MB] Monitor ROM Abnormality.............. 40-312 Failure code [DAF0MC] Monitor Error ................40-313 Failure code [DAF8KB] Camera Power Supply Short Circuit ..........40-314 Failure code [DAF9KQ] Model Selection Abnormality ............40-316 00-6 HB215LC-2 Find manuals at https://best-manuals.com...
  • Page 9 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ..........40-436 Failure code [DXE4KB] Attachment Flow EPC Short Circuit..........40-438 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ..........40-440 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ..........40-442 00-7 HB215LC-2 Find manuals at https://best-manuals.com...
  • Page 10 Failure code [GA1YNS] Booster Inductor Overheat ............. 40-541 Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ........40-542 Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat ..........40-543 Failure code [GA22NS] Booster IGBT Junction Overheat ............ 40-544 00-8 HB215LC-2 Find manuals at https://best-manuals.com...
  • Page 11 E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...... 40-618 E-16 Hybrid temperature monitor lights up in red while engine is running ......40-619 E-17 Engine oil pressure monitor lights up in red while engine is running ......40-621 HB215LC-2 00-9...
  • Page 12 E-59 Travel is not displayed correctly with monitoring function ..........40-674 E-60 Service is not displayed correctly with monitoring function ........... 40-675 E-61 Attachment hydraulic circuit cannot be changed............40-678 E-62 KOMTRAX system does not operate normally ............40-679 Troubleshooting of hydraulic and mechanical system (H-mode) ..........40-680 00-10 HB215LC-2...
  • Page 13 S-12 Fuel consumption is excessive .................. 40-762 S-13 Oil is in coolant (or coolant spurts or coolant level goes down)........40-763 S-14 Oil pressure drops ....................40-764 S-15 Fuel mixes into engine oil..................40-765 S-16 Water mixes into engine oil (milky) ................40-766 HB215LC-2 00-11...
  • Page 14 Removal and installation of electric swing motor assembly ..........50-131 Power train system ......................... 50-136 Removal and installation of travel motor and final drive assembly ......... 50-136 Disassembly and assembly of final drive ................50-137 Removal and installation of swing motor and swing machinery assembly ......50-146 00-12 HB215LC-2...
  • Page 15 Swing machinery with swing brake ..................60-6 Final drive ........................... 60-8 Sprocket..........................60-10 Undercarriage and frame......................60-12 Track frame and idler cushion ..................... 60-12 Idler ..........................60-14 Track roller ........................60-16 Carrier roller ........................60-17 Track shoe ........................60-18 Hydraulic system ........................60-24 HB215LC-2 00-13...
  • Page 16 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ......................80-71 A-4 Troubleshooting for FRESH/RECIRC air changeover ............80-73 Troubleshooting with gauge pressure................... 80-75 Connection of service tool....................80-78 Precautions for disconnecting and connecting air conditioner piping ........80-80 00-14 HB215LC-2...
  • Page 17 Symbols in hydraulic circuit diagram ..................90-3 Hydraulic circuit diagram....................... 90-7 Electric circuit diagram ......................90-13 Symbols in electric circuit diagram ..................90-13 Electrical circuit diagram ..................... 90-17 Electrical circuit diagram of air conditioner unit..............90-47 Index..................................1 HB215LC-2 00-15...
  • Page 18 • Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require use of special tools designed by Komatsu for special purposes.
  • Page 19 Operate the hoist or crane slowly tracks to prevent the machine from moving. to prevent the component from hitting any other HB215LC-2 00-17...
  • Page 20 • Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. 00-18 HB215LC-2...
  • Page 21 • After finishing the work, stop the hoist at the • Do not lift up the load at an angle. specified position and raise the hook to at least 2 Precautions for slinging down m above the floor. Do not leave the sling installed to the hook. HB215LC-2 00-19...
  • Page 22 Precautions for air conditioner piping For tightening torques, see Others, • When installing the air conditioner hoses, be "Precautions for disconnection and connection careful to prevent dirt, dusts and water from of air conditioner piping" (Chapter 80). entering into them. 00-20 HB215LC-2...
  • Page 23 • Fire around the machine due to highly heated materials to a safe place before starting. exhaust gas Some machines are equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying soot in exhaust gas. Its exhaust...
  • Page 24 • As for rubber, plastics, or parts (hoses, cables, and wiring harnesses, etc.) which contain those materials, ask the industrial waste treatment firms for their disposals in accordance with the local regulations. 00-22 HB215LC-2...
  • Page 25 • Some attachments and optional parts described in this shop manual may not be arranged for certain areas. Contact your Komatsu distributor if one or some of them are required. • Materials and specifications are subject to change without notice.
  • Page 26 Unit • In this shop manual, the units are indicated with International System of units (SI). • For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }. 00-24 HB215LC-2...
  • Page 27 • The dimensions of parts change because of the of new products or equivalent are called the wear or deformation while they are used. When "standard value", which is indicated by a range the dimension changes exceeding certain value, or a target value. HB215LC-2 00-25...
  • Page 28 "allowable interference". • The allowable interference shows the repair limit of the part of smaller tolerance. • The parts whose interferences are out of the allowable interference must be replaced or repaired. 00-26 HB215LC-2...
  • Page 29 • If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel. Precautions for replacing fuel filter cartridge • Be sure to use the Komatsu genuine fuel filter cartridge. • The common rail fuel injection system (CRI)
  • Page 30 Foreword, safety and general information Handling of intake system parts (PC220-A900-2A4-K-00-A) (Rev.2013/10) • The Komatsu Variable Geometry Turbocharger consists of more precise parts (variable mechanism) than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the air intake system.
  • Page 31 If the old oil is left in the system, the contaminant and sludge in the oil mix with the new oil and shorten the life of the new hydraulic oil. HB215LC-2 00-29...
  • Page 32 The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment can not remove. So, it is an extremely effective device. 00-30 HB215LC-2...
  • Page 33 3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the (Fig. 3) rubber cap will move approximately 3.5mm toward the hose, however, it is not a problem. a Since some hydraulic oil flows out, prepare an oil container. HB215LC-2 00-31...
  • Page 34 (Fig. 9) 2. While keeping the condition of Step 1, turn lever (8) to the right (clockwise). (Fig. 7) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (7) to disconnect it. (Fig. 8) 00-32 HB215LC-2...
  • Page 35 (10) straight until it hits contact surface (b) of the hexagonal portion on the male side. (Fig. 3. While keeping the conditions of Steps 1 and 2, pull out whole body (9) to disconnect it. (Fig. 12) HB215LC-2 00-33...
  • Page 36 The corroded or oxidized harness may be broken. contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times. 00-34 HB215LC-2...
  • Page 37 If any oil or grease, mud or dirt is stuck to the connector, wipe it off with a dry cloth or HB215LC-2 00-35...
  • Page 38 If the connector cannot be corrected easily, remove the clamp and adjust the position. Connecting connectors 1. Check the connector visually. 00-36 HB215LC-2...
  • Page 39 3. Perform a continuity test on the connector. After drying, leave wiring harness disconnected and perform a continuity test to check for any short circuits between pins caused by water. a After the connector is completely dried, blow the contact restorer and reassemble them. HB215LC-2 00-37...
  • Page 40 1. Insert the connector securely until a click is (FRAMATOME-24) heard. Disconnection Pull lock type 1. Slide down lock (red) (L1). (PACKARD-2) Disconnection 1. Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward. 00-38 HB215LC-2...
  • Page 41 [1] since you cannot insert your fingers. While pushing up lock (C) of the connector Connection with flat-head screwdriver [1], pull out 1. Insert the connector securely until a click is connector (3) in the direction of the arrow. heard. HB215LC-2 00-39...
  • Page 42 Housing (H1) is left on the wiring harness in a place where it is exposed to rain. side. • Do not place the controller on oil, water, or soil, or in a place that can be heated to a high 00-40 HB215LC-2...
  • Page 43 If there is any value change on the multimeter, there may be a defective contact in the circuit. HB215LC-2 00-41...
  • Page 44 For mid- to small-size appliance wire for excavators CAVS automobile (nominal No. 1.25 and lower) (Type 2) Heat- General wiring for extremely resistant low- cold weather specification Heat-resistant cross- voltage wire -50 to +110 linked polyethylene Wiring at high-temperature place automobile 00-42 HB215LC-2...
  • Page 45 Annealed copper for Conductor electric appliance Shielded For general signal wiring Soft polyvinyl chloride Insulator braided cable CAVS- -30 to +60 Sn plated, annealed, (nominal size: 0.5, 3 cores) Shield automobiles braided copper wire Soft polyvinyl chloride Sheath HB215LC-2 00-43...
  • Page 46 13.6 16.0 17.6 AVSS Standard (Table 4) Nominal No. 0.5f 0.75f 0.85 1.25f 1.25 Number of 7/round 11/round 16/round strands/ compression compression compression Diameter of strand Conductor Cross- sectional 0.56 0.88 1.29 area (mm d (approx.) CAVS Standard 00-44 HB215LC-2...
  • Page 47 20/0.18 Cross-sectional area (mm Core conductor 0.51 Outside diameter (mm) Strand diameter (mm) 0.12 Braided shield No. of wires/strands 5/16 Density (%) Min. 70 Sheath thickness (mm) Finished outside diameter (mm) a "f" of nominal No. denotes "flexible". HB215LC-2 00-45...
  • Page 48 Example) GW means that the background is "Green" and marking is "White". Types of circuits and color codes (Table 8) Type of wire AVS, AV, CAVS Charge Ground Start Light Instrument Signal Type of circuit Others 00-46 HB215LC-2...
  • Page 49 Disconnection of face seal type hoses and tubes Pipe joint side Hose side O-ring (3) Nominal No. Plug (1) Nut (2) 07376-70210 02789-00210 02896-11008 07376-70315 02789-00315 02896-11009 07376-70422 02789-00422 02896-11012 07376-70522 02789-00522 02896-11015 07376-70628 02789-00628 02896-11018 HB215LC-2 00-47...
  • Page 50 52.4 26.2 07371-31049 07378-11000 07000-13032 01643-51032 01044 51035 07379- 07372- 58.7 30.2 07371-31255 07378-11200 07000-13038 01643-51032 01250 51035 07379- 01010- 66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232 01260 81245 07379- 07372- 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232 01460 51240 00-48 HB215LC-2...
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50001