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Related Manuals for Komatsu HB205 -1
Summary of Contents for Komatsu HB205 -1
- Page 1 SEN05393-06 HYDRAULIC HB205 EXCAVATOR HB215LC HB205- 1001 SERIAL NUMBERS and up HB215LC- 1001...
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- Page 3 Notice of revision Notice of revision HB205-1, HB215LC-1 0 0 - 1 6th revision 2017/04 The affected pages are indicated by the use of the Mark Indication Action required following marks. It is requested that necessary ac- Page to be newly added tions must be taken to these pages according to the list below.
- Page 4 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 10-83 10-135 10-187 30-27 (01) 10-84 10-136 10-188 30-28 (01) 10-85 10-137 10-189 30-29 (01) 10-86 10-138 10-190 30-30 (01) 10-87 10-139 10-191 30-31...
- Page 5 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 30-79 (01) 30-131 (01) 40-37 (01) 40-89 (01) 30-80 (01) 30-132 (01) 40-38 (01) 40-90 (01) 30-81 (01) 30-133 (01) 40-39 (01) 40-91 (01)
- Page 6 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 40-139 (01) 40-191 (01) 40-243 (01) 40-295 (01) 40-140 (01) 40-192 (01) 40-244 (01) 40-296 (01) 40-141 (01) 40-193 (01) 40-245 (01) 40-297 (01)
- Page 7 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 40-345 (06) 40-393-2 (03) 40-439 (01) 40-491 (01) 40-346 (01) 40-394 (03) 40-440 (01) 40-492 (01) 40-347 (06) 40-395 (01) 40-441 (01) 40-493 (01)
- Page 8 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 40-543 (01) 50-41 (01) 50-93 (01) 50-139 (01) 40-544 (01) 50-42 (01) 50-94 (01) 50-140 (01) 40-545 (01) 50-43 (01) 50-95 (01) 50-141 (04)
- Page 9 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 50-185 (01) 50-237 (01) 60-35 80-21 (01) 50-186 (01) 50-238 (01) 60-36 80-22 (01) 50-187 (01) 50-239 (01) 60-37 80-23 (01) 50-188 (01) 50-240...
- Page 10 Notice of revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page number number number number 80-73 (01) 80-74 (01) 80-75 (01) 80-76 (01) 80-77 (01) 80-78 (01) 80-79 (01) 80-80 (01) 80-81 (01) 80-82 (01) 90-1 90-2 90-3 90-4...
- Page 11 HB205-1, HB215LC-1 0 0 - 1 HYDRAULIC EXCAVATOR HB205-1 HB215LC-1 Machine model Serial number HB205-1 1001 and up HB215LC-1 1001 and up 00 Index and foreword 3 0 - 1 HB205-1, HB215LC-1 00-1...
- Page 12 Table of Contents Table of Contents 00 Index and Foreword Table of Contents........................00- Table of Contents......................... 00- Foreword and general information ..................00- Safety notice ........................00- How to read the shop manual ....................00- Explanation of terms for maintenance standard ..............00- 11 Handling of hydraulic components..................
- Page 13 Table of Contents Control valve........................10- 58 Functions and operation by valve ..................10- 70 Travel motor......................... 10-107 PPC valve ..........................10-117 Solenoid valve ........................10-136 Attachment circuit selector valve ..................10-138 Return oil filter........................10-140 Center swivel joint........................ 10-142 Accumulator.........................
- Page 14 Table of Contents Releasing remaining pressure from hydraulic circuit ............30- 56 Testing oil leakage ....................... 30- 57 Bleeding air from each part....................30- 59 Cab and its attachments ......................30- 61 Checking cab tipping stopper....................30- 61 Adjusting mirrors ........................30- 62 Angle adjustment of rear view camera.................
- Page 15 Table of Contents Failure code [CA154] Chg Air Temp Sensor Low Error............40- 136 Failure code [CA155] Chg Air Temp High Speed Derate ............ 40- 138 Failure code [CA187] Sens Supply 2 Volt Low Error ............40- 140 Failure code [CA221] Ambient Press Sens High Error ............40- 142 Failure code [CA222] Ambient Press Sens Low Error ............
- Page 16 Table of Contents Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ......40- 236 Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality ......40- 238 Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open or short circuit 40- 240 Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open or short circuit...
- Page 17 Table of Contents Failure code [GA00NS] HYB devices overheat ..............40- 359 Failure code [GA01KA] Power Cable Interlock Open Circuit ..........40- 360 Failure code [GA02KZ] DC Line Open/Short Circuit............40- 362 Failure code [GA04KG] Abnormal DC HW Volt. Before Booster......... 40- 363 Failure code [GA05KG] Abnormal DC SW Volt.
- Page 18 Table of Contents Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ........40- 404-1 Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat..........40- 404-2 Failure code [GA21KB] Booster IGBT Short Circuit............. 40- 404-3 Failure code [GA22NS] Booster IGBT Junction Overheat ........... 40- 405 Failure code [GA23KZ] Gen.
- Page 19 Table of Contents E-18 Alarm buzzer does not stop sounding................. 40- 465 E-19 When starting switch is at OFF position, service meter is not displayed ....40- 465 E-20 Machine monitor cannot be set in service mode............40- 465 E-21 All of work equipment, swing, and travel mechanism do not move or are not locked . 40- 466 E-22 Swing holding brake does not operate properly............
- Page 20 Table of Contents S-2 Engine does not start ....................40- 523 S-3 Engine does not pick up smoothly................. 40- 526 S-4 Engine stops during operations..................40- 527 S-5 Engine does not rotate smoothly................... 40- 528 S-6 Engine lacks output (or lacks power) ................40- 529 S-7 Exhaust gas is black (incomplete combustion) .............
- Page 21 Table of Contents Draining and adding generator lubricating oil ..............50- 108 Removal and installation of tandem pump assembly ............50- 110 Removal and installation of motor-generator housing assembly ......... 50- 113 Removal and installation of swing electric motor assembly..........50- 122 Power train..........................
- Page 22 Table of Contents Undercarriage and frame ......................60- 16 Track frame and idler cushion....................60- 16 Idler ............................60- 18 Track roller ........................... 60- 20 Carrier roller ......................... 60- 21 Track shoe ........................... 60- 22 Hydraulic system........................60- 28 Main pump ........................... 60- 28 Control valve ........................
- Page 23 Table of Contents Troubleshooting for temperature sensor system ..............80- 70 Troubleshooting with gauge pressure.................. 80- 71 Connection of service tool ....................80- 74 Precautions for disconnecting and connecting air conditioner piping ........80- 76 Handling of compressor oil ....................80- 78 Desiccant replacement procedure ..................
- Page 24 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 25 Foreword and general information Safety notice 2) Locate a place in the repair workshop to keep 3. Preparation work tools and removed parts. Always keep the 1) Before adding oil or making any repairs, park tools and parts in their correct places. Always the machine on a hard and level ground, and keep the work area clean and make sure that apply the parking brake and chock the...
- Page 26 Foreword and general information Safety notice 6) When removing a cover which is under 5. Precautions for slinging work and making internal pressure or under pressure by a signals spring, always leave two bolts in diagonal 1) Only one appointed worker must make positions.
- Page 27 Foreword and general information Safety notice 13)When lowering a load, observe the following. When lifting down a load, stop it tempo- rarily at 30 cm above the floor, and then lower it slowly. Check that the load is stable, and then re- move the sling.
- Page 28 Foreword and general information Safety notice 15)After finishing the work, stop the hoist at the 2) Connection specified position and raise the hook to at 1] When installing the air conditioner circuit least 2 m above the floor. Do not leave the hoses and tubes, take care that dirt, dust, sling installed to the hook.
- Page 29 (Rev. 2010/03) Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol- ume of the engine model mounted on the machine.
- Page 30 Foreword and general information How to read the shop manual 2. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. 3. Filing method File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED PAGES.
- Page 31 Foreword and general information Explanation of terms for maintenance standard Explanation of terms for maintenance standard (Rev. 2010/03) The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the ma- chine maintenance work. The following terms are used to explain the criteria. 1.
- Page 32 Foreword and general information Explanation of terms for maintenance standard 4. Repair limit and allowable value or allowable dimension The dimension of a part changes because of wear and deformation while it is used. The limit of changed dimension is called the "re- pair limit".
- Page 33 Foreword and general information Handling of hydraulic components Handling of hydraulic components (Rev. 2010/03) With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil, or when disassembling or assembling hydraulic components.
- Page 34 Foreword and general information Handling of hydraulic components 5. Replacing hydraulic oil while its temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.
- Page 35 Foreword and general information Method of disconnecting and connecting push-pull type coupler Method of disconnecting and connecting push-pull type coupler (Rev. 2010/03) Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to release the remaining pressure in the hydraulic tank. Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
- Page 36 Foreword and general information Method of disconnecting and connecting push-pull type coupler Type 2 1. Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise).
- Page 37 Foreword and general information Method of disconnecting and connecting push-pull type coupler Type 3 1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the...
- Page 38 Foreword and general information Handling of electric equipment Handling of electric equipment (Rev. 2010/03) To maintain the performance of the machine over a long period, and to prevent failures or other troubles be- fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be performed.
- Page 39 Foreword and general information Handling of electric equipment 3) Disconnections in wiring If the harness is pulled to disconnect the connector, or components are lifted with a crane with the harness still connected, or a heavy object hits the harness, the crimping of the connector may separate, or the soldering may be damaged, or the harness may be broken.
- Page 40 Foreword and general information Handling of electric equipment 3. Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
- Page 41 Foreword and general information Handling of electric equipment 2) Connecting connectors 1] Check the connector visually. Check that no oil, dirt, or water is stuck to connector pins (joint portion). Check that connector pins are free from deformation, defective contact, corrosion, or damage.
- Page 42 Foreword and general information Handling of electric equipment 3) Deutsch connector (DT 8-pin, 12-pin) Disconnection (Left of figure) Disconnection Connection (Example of While pressing locks (a) and (b), pull out the incomplete setting of female connector (2). (a)) Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks.
- Page 43 Foreword and general information Handling of electric equipment 4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pres- sure water or steam directly on the wiring harness.
- Page 44 Foreword and general information Handling of electric equipment 4. Handling of connectors used on engine a Mainly, following engines are object for following connectors. 95E-5 107E-1 114E-3 125E-5 140E-5 170E-5 12V140E-3 1) Slide, lock type (FRAMATOME-3, FRAM- 2) Pull lock type (PACKARD-2) ATOME-2) 95/107/114/125/140/170/12V140 Series 95/107/114/125/140/170/12V140 Series...
- Page 45 Foreword and general information Handling of electric equipment a If the lock is located on the underside, use 3) Push lock type (1) 95/107/114 series flat-head screwdriver [1] since you cannot Example) Fuel pressure sensor insert your fingers. common rail (BOSCH-03) While pressing up lock (C) of the connector with flat-head screwdriver [1], Disconnection...
- Page 46 Foreword and general information Handling of electric equipment 5) Push lock type (3) 6) Turn-housing type (Round green 95/125/140/170/12V140 series connector) 140 series Disconnection Example) Intake air pressure sensor in While pressing lock (E) of the connector, pull intake manifold. out connector (5) in the direction of the arrow.
- Page 47 Foreword and general information Handling of electric equipment 5. Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag.
- Page 48 Foreword and general information How to read electric wire code How to read electric wire code (Rev. 2010/11) Hybrid a The information about the wires unique to each hybrid machine model is described. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
- Page 49 Foreword and general information How to read electric wire code (Table 2) Using tempera- Type Symbol Material Example of use ture range (°C) Annealed copper wire for Conductor electric appliance Insulator Soft polyvinyl chloride Foil shielded Sn plated annealed copper For general signal wiring cable for AVSSCS...
- Page 50 Foreword and general information How to read electric wire code 2. Dimensions AVS, AV, AEX, AVSS (Table 3) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 65/0.32 strands/Diame- 41/0.32 ter of strand Conduc- Sectional area...
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