SEN05393-04

HYDRAULIC HB205 -1
EXCAVATOR
HB215LC -1
HB205- 1001
SERIAL NUMBERS and up
HB215LC- 1001
 1

Notice of revision

Notice of revision HB205-1, HB215LC-1 0 -1

4th revision 2013/03

The affected pages are indicated by the use of the Mark Indication Action required
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the Q Page to be newly added Add
list below.
q Page to be replaced Replace

( ) Page to be deleted Discard

List of revised pages

Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page
number number number number
q 1 (04) 00-25 10-1 10-41
q 2 (04) 00-26 10-2 10-42
q 3 (04) 00-27 10-3 10-43
q 4 (04) 00-28 10-4 10-44
q 5 (04) 00-29 10-5 10-45
q 6 (04) 00-30 10-6 10-46
q 7 (04) 00-31 10-7 10-47
q 8 (04) 00-32 10-8 10-48
00-1 00-33 10-9 10-49
00-2 (01) 00-34 10-10 10-50
00-3 (01) 00-35 10-11 10-51
00-3-1 (03) 00-36 (03) 10-12 (03) 10-52
00-3-2 (03) 00-37 (03) q 10-13 (04) 10-53
00-3-3 (03) 00-38 (03) Q 10-13-1 (04) 10-54
00-3-4 (03) 00-39 (03) Q 10-13-2 (04) 10-55
00-3-5 (03) 00-40 (03) 10-14 10-56
00-3-6 (03) 00-41 (03) 10-15 10-57
00-3-7 (03) 00-42 10-16 10-58
00-3-8 (03) 00-43 10-17 10-59
00-3-9 (03) 00-44 10-18 10-60
00-3-10 (03) 00-45 10-19 10-61
00-4 (03) 00-46 10-20 10-62
00-5 (03) 00-47 10-21 10-63
00-6 00-48 10-22 10-64
00-7 00-49 10-23 10-65
00-8 00-50 10-24 10-66
00-9 00-51 10-25 10-67
00-10 00-52 10-26 10-68
00-11 00-53 10-27 10-69
00-12 00-54 10-28 10-70
00-13 01-1 10-29 10-71
00-14 01-2 10-30 10-72
00-15 01-3 10-31 10-73
00-16 01-4 10-32 10-74
00-17 01-5 10-33 10-75
00-18 01-6 10-34 10-76
00-19 01-7 10-35 10-77
00-20 01-8 10-36 10-78
00-21 01-9 10-37 10-79
00-22 01-10 10-38 10-80
00-23 01-11 (03) 10-39 10-81
00-24 01-12 (03) 10-40 10-82

HB205-1, HB215LC-1 1
(04)
 2

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 (01)
10-88 10-140 10-192 30-32 (01)
10-89 10-141 10-193 30-33 (01)
10-90 10-142 10-194 30-34 (01)
10-91 10-143 10-195 30-35 (01)
10-92 10-144 10-196 30-36 (01)
10-93 10-145 10-197 30-37 (01)
10-94 10-146 10-198 30-38 (01)
10-95 10-147 20-1 (01) 30-39 (01)
10-96 10-148 20-2 (01) 30-40 (01)
10-97 10-149 20-3 (01) 30-41 (01)
10-98 10-150 20-4 (01) 30-42 (01)
10-99 10-151 20-5 (01) 30-43 (01)
10-100 10-152 20-6 (01) 30-44 (01)
10-101 10-153 20-7 (01) 30-45 (01)
10-102 10-154 20-8 (01) 30-46 (01)
10-103 10-155 (03) 20-9 (01) 30-47 (01)
10-104 10-156 20-10 (01) 30-48 (01)
10-105 10-157 20-11 (01) 30-49 (01)
10-106 10-158 20-12 (01) 30-50 (01)
10-107 10-159 20-13 (01) 30-51 (01)
10-108 10-160 20-14 (01) 30-52 (01)
10-109 10-161 30-1 (01) 30-53 (01)
10-110 10-162 30-2 (01) 30-54 (01)
10-111 10-163 30-3 (01) 30-55 (01)
10-112 10-164 30-4 (01) 30-56 (01)
10-113 10-165 (03) 30-5 (01) 30-57 (01)
10-114 10-166 30-6 (01) 30-58 (01)
10-115 10-167 30-7 (03) 30-59 (01)
10-116 10-168 30-8 (01) 30-60 (01)
10-117 10-169 30-9 (01) 30-61 (01)
10-118 10-170 30-10 (01) 30-62 (01)
10-119 10-171 30-11 (01) 30-63 (01)
10-120 10-172 30-12 (01) 30-64 (01)
10-121 10-173 30-13 (01) 30-65 (01)
10-122 10-174 30-14 (01) 30-66 (01)
10-123 10-175 30-15 (01) q 30-67 (04)
10-124 10-176 30-16 (01) 30-68 (03)
10-125 10-177 30-17 (01) 30-69 (01)
10-126 10-178 30-18 (01) 30-70 (01)
10-127 10-179 30-19 (01) 30-71 (01)
10-128 10-180 30-20 (01) 30-72 (01)
10-129 10-181 30-21 (01) 30-73 (01)
10-130 10-182 30-22 (01) 30-74 (01)
10-131 10-183 30-23 (01) 30-75 (01)
10-132 10-184 30-24 (01) 30-76 (01)
10-133 10-185 30-25 (01) 30-77 (01)
10-134 10-186 30-26 (01) 30-78 (01)

2 HB205-1, HB215LC-1
(04)
 3

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)
30-82 (01) 30-134 (01) 40-40 (01) 40-92 (01)
30-83 (01) 30-135 (01) 40-41 (01) 40-93 (01)
30-84 (01) 30-136 (01) 40-42 (01) 40-94 (01)
30-85 (01) 30-137 (01) 40-43 (01) 40-95 (01)
30-86 (01) 30-138 (01) 40-44 (03) 40-96 (01)
30-87 (01) 30-139 (01) 40-45 (03) 40-97 (01)
30-88 (01) 30-140 (01) 40-46 (03) 40-98 (01)
30-89 (01) 30-141 (01) 40-47 (03) 40-99 (01)
30-90 (01) 30-142 (01) 40-48 (03) 40-100 (01)
30-91 (03) 30-143 (01) 40-49 (03) 40-101 (01)
30-92 (03) 30-144 (01) 40-50 (03) 40-102 (01)
30-93 (01) 30-145 (01) 40-51 (03) 40-103 (01)
30-94 (01) 30-146 (01) 40-52 (01) 40-104 (01)
30-95 (01) 40-1 (01) 40-53 (01) 40-105 (01)
30-96 (01) 40-2 (03) 40-54 (01) 40-106 (01)
30-97 (01) 40-3 (03) 40-55 (01) 40-107 (01)
30-98 (01) 40-4 (03) 40-56 (01) 40-108 (01)
30-99 (01) 40-5 (03) 40-57 (01) 40-109 (01)
30-100 (01) 40-6 (03) 40-58 (01) 40-110 (01)
30-101 (01) 40-7 (03) 40-59 (01) 40-111 (03)
30-102 (01) 40-8 (03) 40-60 (01) 40-111-1 (03)
30-103 (01) 40-9 (01) 40-61 (01) 40-111-2 (03)
30-104 (01) 40-10 (01) 40-62 (01) 40-112 (01)
30-105 (01) 40-11 (01) 40-63 (01) 40-113 (01)
30-106 (01) 40-12 (01) 40-64 (01) 40-114 (01)
30-107 (01) 40-13 (01) 40-65 (01) 40-115 (01)
30-108 (01) 40-14 (01) 40-66 (01) 40-116 (03)
30-109 (01) 40-15 (01) 40-67 (01) 40-117 (01)
30-110 (01) 40-16 (01) 40-68 (01) 40-118 (01)
30-111 (01) 40-17 (01) 40-69 (01) 40-119 (01)
30-112 (01) 40-18 (01) 40-70 (01) 40-120 (01)
30-113 (01) 40-19 (01) 40-71 (01) 40-121 (01)
30-114 (03) 40-20 (01) 40-72 (01) 40-122 (01)
30-115 (01) 40-21 (01) 40-73 (01) 40-123 (01)
30-116 (01) 40-22 (01) 40-74 (01) 40-124 (01)
30-117 (01) 40-23 (01) 40-75 (01) 40-125 (01)
30-118 (01) 40-24 (01) 40-76 (01) 40-126 (01)
30-119 (01) 40-25 (01) 40-77 (01) 40-127 (01)
30-120 (01) 40-26 (01) 40-78 (01) 40-128 (01)
30-121 (01) 40-27 (01) 40-79 (01) 40-129 (01)
30-122 (01) 40-28 (01) 40-80 (01) 40-130 (01)
30-123 (03) 40-29 (01) 40-81 (01) 40-131 (01)
30-124 (01) 40-30 (01) 40-82 (01) 40-132 (01)
30-125 (01) 40-31 (01) 40-83 (01) 40-133 (01)
30-126 (01) 40-32 (01) 40-84 (01) 40-134 (01)
30-127 (01) 40-33 (01) 40-85 (01) 40-135 (01)
30-128 (01) 40-34 (01) 40-86 (01) 40-136 (01)
30-129 (01) 40-35 (01) 40-87 (01) 40-137 (01)
30-130 (01) 40-36 (01) 40-88 (01) 40-138 (01)

HB205-1, HB215LC-1 3
(04)
 4

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)
40-142 (01) 40-194 (01) 40-246 (01) 40-298 (01)
40-143 (01) 40-195 (01) 40-247 (01) 40-299 (01)
40-144 (01) 40-196 (01) 40-248 (01) 40-300 (01)
40-145 (01) 40-197 (01) 40-249 (01) 40-301 (01)
40-146 (01) 40-198 (01) 40-250 (01) 40-302 (01)
40-147 (01) 40-199 (01) 40-251 (01) 40-303 (01)
40-148 (01) 40-200 (01) 40-252 (01) 40-304 (01)
40-149 (01) 40-201 (01) 40-253 (01) 40-305 (01)
40-150 (01) 40-202 (01) 40-254 (01) 40-306 (01)
40-151 (01) 40-203 (01) 40-255 (01) 40-307 (01)
40-152 (01) 40-204 (01) 40-256 (01) 40-308 (01)
40-153 (01) 40-205 (01) 40-257 (01) 40-309 (01)
40-154 (01) 40-206 (01) 40-258 (01) 40-310 (01)
40-155 (01) 40-207 (01) 40-259 (01) 40-311 (01)
q 40-156 (04) 40-208 (01) 40-260 (01) 40-312 (01)
40-157 (01) 40-209 (01) 40-261 (01) 40-313 (01)
40-158 (01) 40-210 (01) 40-262 (01) 40-314 (01)
40-159 (01) 40-211 (01) 40-263 (01) 40-315 (01)
40-160 (01) 40-212 (01) 40-264 (01) 40-316 (01)
40-161 (01) 40-213 (01) 40-265 (01) 40-317 (01)
40-162 (01) 40-214 (01) 40-266 (01) 40-318 (01)
40-163 (01) 40-215 (01) 40-267 (01) 40-319 (01)
40-164 (01) 40-216 (01) 40-268 (01) 40-320 (01)
40-165 (01) 40-217 (01) 40-269 (01) 40-321 (01)
40-166 (01) 40-218 (01) 40-270 (01) 40-322 (01)
40-167 (01) 40-219 (01) 40-271 (01) 40-323 (01)
40-168 (01) 40-220 (01) 40-272 (01) 40-324 (01)
40-169 (01) 40-221 (01) 40-273 (01) 40-325 (01)
40-170 (01) 40-222 (01) 40-274 (01) 40-326 (01)
40-171 (01) 40-223 (01) 40-275 (01) 40-327 (01)
40-172 (01) 40-224 (01) 40-276 (01) 40-328 (01)
40-173 (01) 40-225 (01) 40-277 (01) 40-329 (01)
40-174 (01) 40-226 (01) 40-278 (01) 40-330 (01)
40-175 (01) 40-227 (01) 40-279 (01) 40-331 (01)
40-176 (01) 40-228 (01) 40-280 (01) 40-332 (03)
40-177 (01) 40-229 (01) 40-281 (01) q 40-333 (04)
40-178 (01) 40-230 (01) 40-282 (01) Q 40-333-1 (04)
40-179 (01) 40-231 (01) 40-283 (01) Q 40-333-2 (04)
40-180 (01) 40-232 (01) 40-284 (01) 40-334 (01)
40-181 (01) 40-233 (01) 40-285 (01) 40-335 (01)
40-182 (01) 40-234 (01) 40-286 (01) 40-336 (01)
40-183 (01) 40-235 (01) 40-287 (01) 40-337 (01)
40-184 (01) 40-236 (01) 40-288 (01) 40-338 (01)
40-185 (01) 40-237 (01) 40-289 (01) 40-339 (01)
40-186 (01) 40-238 (01) 40-290 (01) 40-340 (01)
40-187 (01) 40-239 (01) 40-291 (01) 40-341 (01)
40-188 (01) 40-240 (01) 40-292 (01) 40-342 (01)
40-189 (01) 40-241 (01) 40-293 (01) 40-343 (01)
40-190 (01) 40-242 (01) 40-294 (01) 40-344 (01)

4 HB205-1, HB215LC-1
(04)
 5

Notice of revision

Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page
number number number number
40-345 (01) 40-395 (01) 40-441 (01) 40-493 (01)
40-346 (01) 40-396 (03) 40-442 (01) 40-494 (01)
40-347 (01) 40-397 (01) 40-443 (01) 40-495 (01)
40-348 (01) 40-398 (03) 40-444 (01) 40-496 (01)
40-349 (01) 40-399 (03) 40-445 (01) 40-497 (01)
40-350 (01) 40-400 (03) 40-446 (01) 40-498 (01)
40-351 (01) 40-401 (01) 40-447 (01) 40-499 (01)
40-352 (01) 40-402 (01) 40-448 (01) 40-500 (01)
40-353 (01) 40-403 (03) 40-449 (01) 40-501 (01)
40-354 (01) 40-404 (03) 40-450 (01) 40-502 (01)
40-355 (01) 40-404-1 (03) 40-451 (01) 40-503 (01)
40-356 (01) 40-404-2 (03) 40-452 (01) 40-504 (01)
40-357 (01) 40-404-3 (03) 40-453 (01) 40-505 (01)
40-358 (01) 40-404-4 (03) 40-454 (01) 40-506 (01)
40-359 (03) 40-405 (03) 40-455 (01) 40-507 (01)
40-360 (01) 40-406 (03) 40-456 (01) 40-508 (01)
40-361 (01) 40-407 (03) 40-457 (01) 40-509 (01)
40-362 (03) 40-407-1 (03) 40-458 (01) 40-510 (01)
40-363 (01) 40-407-2 (03) 40-459 (01) 40-511 (01)
40-364 (01) 40-408 (03) 40-460 (01) 40-512 (01)
40-365 (01) 40-409 (03) 40-461 (01) 40-513 (01)
40-366 (01) 40-410 (03) 40-462 (01) 40-514 (01)
40-367 (01) 40-411 (01) 40-463 (01) 40-515 (01)
40-368 (01) 40-412 (01) 40-464 (01) 40-516 (01)
40-369 (01) 40-413 (01) 40-465 (01) 40-517 (01)
40-370 (01) 40-414 (03) 40-466 (01) 40-518 (01)
40-371 (01) 40-415 (03) 40-467 (01) 40-519 (01)
40-372 (01) 40-416 (03) 40-468 (01) 40-520 (01)
40-373 (01) 40-417 (01) 40-469 (01) 40-521 (01)
40-374 (01) 40-418 (01) 40-470 (01) 40-522 (01)
40-375 (01) 40-419 (01) 40-471 (01) 40-523 (01)
40-376 (01) 40-420 (01) 40-472 (01) 40-524 (01)
40-377 (01) 40-421 (01) 40-473 (01) 40-525 (01)
40-378 (01) 40-422 (01) 40-474 (01) 40-526 (01)
40-379 (01) 40-423 (03) 40-475 (01) 40-527 (01)
40-380 (01) 40-424 (03) 40-476 (01) 40-528 (01)
40-381 (01) 40-425 (03) 40-477 (01) 40-529 (01)
40-382 (01) 40-426 (03) 40-478 (01) 40-530 (01)
40-383 (01) 40-427 (03) 40-479 (01) 40-531 (01)
40-384 (01) 40-428 (03) 40-480 (01) 40-532 (01)
40-385 (03) 40-429 (01) 40-481 (01) 40-533 (01)
40-386 (01) 40-430 (01) 40-482 (01) 40-534 (01)
40-387 (01) 40-431 (01) 40-483 (01) 40-535 (01)
40-388 (01) 40-432 (01) 40-484 (01) 40-536 (01)
40-389 (01) 40-433 (01) 40-485 (01) 40-537 (01)
40-390 (01) 40-434 (01) 40-486 (01) 40-538 (01)
40-391 (01) 40-435 (01) 40-487 (01) 40-539 (01)
40-392 (03) 40-436 (01) 40-488 (01) 40-540 (01)
40-393 (03) 40-437 (01) 40-489 (01) 40-541 (01)
40-393-1 (03) 40-438 (01) 40-490 (01) 40-542 (01)
40-393-2 (03) 40-439 (01) 40-491 (01) 40-543 (01)
40-394 (03) 40-440 (01) 40-492 (01) 40-544 (01)

HB205-1, HB215LC-1 5
(04)
 6

Notice of revision

Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page
number number number number
40-545 (01) 50-43 (01) 50-95 (01) q 50-141 (04)
40-546 (01) 50-44 (01) 50-96 (01) q 50-142 (04)
40-547 (01) 50-45 (01) 50-97 (01) q 50-143 (04)
40-548 (01) 50-46 (01) 50-98 (01) q 50-144 (04)
40-549 (01) 50-47 (01) 50-99 (01) Q 50-144-1 (04)
40-550 (01) 50-48 (01) 50-100 (01) Q 50-144-2 (04)
40-551 (01) 50-49 (01) 50-101 (01) Q 50-144-3 (04)
40-552 (01) 50-50 (01) 50-102 (01) Q 50-144-4 (04)
40-553 (01) 50-51 (01) 50-103 (01) Q 50-144-5 (04)
40-554 (01) 50-52 (01) 50-104 (01) Q 50-144-6 (04)
50-1 (01) 50-53 (01) 50-105 (01) 50-145 (01)
50-2 (01) 50-54 (01) 50-106 (01) 50-146 (01)
50-3 (01) 50-55 (01) 50-107 (01) 50-147 (01)
50-4 (01) 50-56 (01) 50-108 (01) 50-148 (01)
50-5 (01) 50-57 (01) 50-109 (03) 50-149 (01)
50-6 (01) 50-58 (01) 50-110 (01) 50-150 (01)
50-7 (01) 50-59 (01) 50-111 (01) 50-151 (01)
50-8 (01) 50-60 (01) 50-112 (01) 50-152 (01)
50-9 (01) 50-61 (01) 50-113 (01) 50-153 (01)
50-10 (01) 50-62 (01) 50-114 (01) 50-154 (01)
q 50-11 (04) 50-63 (01) 50-115 (01) 50-155 (01)
q 50-12 (04) 50-64 (01) 50-116 (01) 50-156 (01)
50-13 (01) 50-65 (01) 50-117 (01) 50-157 (01)
50-14 (01) 50-66 (01) 50-118 (01) 50-158 (01)
50-15 (01) 50-67 (01) 50-119 (01) 50-159 (01)
50-16 (01) 50-68 (01) 50-120 (01) 50-160 (01)
50-17 (01) 50-69 (01) 50-121 (03) 50-161 (01)
50-18 (01) 50-70 (01) q 50-122 (04) 50-162 (01)
50-19 (01) 50-71 (01) q 50-123 (04) 50-163 (01)
50-20 (01) 50-72 (01) q 50-124 (04) 50-164 (01)
50-21 (01) 50-73 (01) q 50-125 (04) 50-165 (01)
50-22 (01) 50-74 (01) q 50-126 (04) 50-166 (01)
50-23 (01) 50-75 (01) q 50-127 (04) 50-167 (01)
50-24 (01) 50-76 (01) q 50-128 (04) 50-168 (01)
50-25 (01) 50-77 (01) Q 50-128-1 (04) 50-169 (01)
50-26 (01) 50-78 (01) Q 50-128-2 (04) 50-170 (01)
50-27 (01) 50-79 (01) Q 50-128-3 (04) 50-171 (01)
50-28 (01) 50-80 (01) Q 50-128-4 (04) 50-172 (01)
50-29 (01) 50-81 (01) Q 50-128-5 (04) 50-173 (01)
50-30 (01) 50-82 (01) Q 50-128-6 (04) 50-174 (01)
50-31 (01) 50-83 (01) 50-129 (01) 50-175 (01)
50-32 (01) 50-84 (01) 50-130 (01) 50-176 (01)
50-33 (01) 50-85 (01) 50-131 (01) 50-177 (01)
50-34 (01) 50-86 (01) 50-132 (01) 50-178 (01)
50-35 (01) 50-87 (01) 50-133 (01) 50-179 (01)
50-36 (01) 50-88 (01) 50-134 (01) 50-180 (01)
50-37 (01) 50-89 (01) 50-135 (01) 50-181 (01)
50-38 (01) 50-90 (03) 50-136 (01) 50-182 (01)
50-39 (01) 50-91 (03) 50-137 (01) 50-183 (01)
50-40 (01) 50-92 (03) 50-138 (01) 50-184 (01)
50-41 (01) 50-93 (01) 50-139 (01) 50-185 (01)
50-42 (01) 50-94 (01) 50-140 (01) 50-186 (01)

6 HB205-1, HB215LC-1
(04)
 7

Notice of revision

Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page
number number number number
50-187 (01) 50-239 (01) 60-37 80-23 (01)
50-188 (01) 50-240 (01) 60-38 80-24 (01)
50-189 (01) 50-241 (01) 60-39 80-25 (01)
50-190 (01) 50-242 (01) 60-40 80-26 (01)
50-191 (01) 50-243 (01) 60-41 80-27 (01)
50-192 (03) 50-244 (01) 60-42 80-28 (01)
50-193 (01) 50-245 (01) 60-43 80-29 (01)
50-194 (01) 50-246 (01) 60-44 80-30 (01)
50-195 (01) 50-247 (01) 60-45 80-31 (01)
50-196 (01) 50-248 (01) 60-46 80-32 (01)
50-197 (01) 50-249 (03) 60-47 80-33 (01)
50-198 (01) 50-250 (03) 60-48 80-34 (01)
50-199 (01) 50-251 (01) 60-49 80-35 (01)
50-200 (01) 50-252 (01) 60-50 80-36 (01)
50-201 (01) 50-253 (01) 60-51 80-37 (01)
50-202 (01) 50-254 (01) 60-52 80-38 (01)
50-203 (01) 60-1 60-53 80-39 (01)
50-204 (01) 60-2 60-54 80-40 (01)
50-205 (01) 60-3 60-55 80-41 (01)
50-206 (01) 60-4 60-56 80-42 (01)
50-207 (01) 60-5 60-57 80-43 (01)
50-208 (01) 60-6 60-58 80-44 (01)
50-209 (01) 60-7 60-59 80-45 (01)
50-210 (01) 60-8 60-60 80-46 (01)
50-211 (01) 60-9 60-61 80-47 (01)
50-212 (01) 60-10 60-62 80-48 (01)
50-213 (01) 60-11 60-63 80-49 (01)
50-214 (01) 60-12 60-64 80-50 (01)
50-215 (01) 60-13 60-65 80-51 (01)
50-216 (01) 60-14 60-66 80-52 (01)
50-217 (01) 60-15 80-1 (01) 80-53 (01)
50-218 (01) 60-16 80-2 (01) 80-54 (01)
50-219 (01) 60-17 80-3 (01) 80-55 (01)
50-220 (01) 60-18 80-4 (01) 80-56 (01)
50-221 (01) 60-19 80-5 (01) 80-57 (01)
50-222 (01) 60-20 80-6 (01) 80-58 (01)
50-223 (01) 60-21 80-7 (01) 80-59 (01)
50-224 (01) 60-22 80-8 (01) 80-60 (01)
50-225 (01) 60-23 80-9 (01) 80-61 (01)
50-226 (01) 60-24 80-10 (01) 80-62 (01)
50-227 (01) 60-25 80-11 (01) 80-63 (01)
50-228 (01) 60-26 80-12 (01) 80-64 (01)
50-229 (01) 60-27 80-13 (01) 80-65 (01)
50-230 (01) 60-28 80-14 (01) 80-66 (01)
50-231 (01) 60-29 80-15 (01) 80-67 (01)
50-232 (01) 60-30 80-16 (01) 80-68 (01)
50-233 (01) 60-31 80-17 (01) 80-69 (01)
50-234 (01) 60-32 80-18 (01) 80-70 (01)
50-235 (01) 60-33 80-19 (01) 80-71 (01)
50-236 (01) 60-34 80-20 (01) 80-72 (01)
50-237 (01) 60-35 80-21 (01) 80-73 (01)
50-238 (01) 60-36 80-22 (01) 80-74 (01)

HB205-1, HB215LC-1 7
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Notice of revision

Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page
number number number number
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
90-5
90-6
90-7
90-9
90-10
90-11
90-12
90-13
90-15
90-17
90-19
90-21
90-23
1 (01)
2 (03)
3 (03)
4 (03)
5 (03)
6 (03)
7 (03)
q Colophon (04)

8 HB205-1, HB215LC-1
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HB205-1, HB215LC-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 30-1

HB205-1, HB215LC-1 00-1

 2
Table of Contents

Table of Contents 2

00 Index and Foreword

Table of Contents.................................................................................................................... 00- 2 2
Table of Contents................................................................................................................. 00- 2 2
Foreword and general information .......................................................................................... 00- 4 4
Safety notice ........................................................................................................................ 00- 4 4
How to read the shop manual .............................................................................................. 00- 9 9
Explanation of terms for maintenance standard .................................................................. 00- 11 11
Handling of hydraulic components....................................................................................... 00- 13 13
Method of disconnecting and connecting push-pull type coupler ........................................ 00- 15 15
Handling of electric equipment............................................................................................. 00- 18 18
How to read electric wire code............................................................................................. 00- 28 28
Precautions when performing work...................................................................................... 00- 33 33
Handling of hybrid devices and high-voltage wirings ........................................................... 00- 36 36
Standard tightening torque table.......................................................................................... 00- 42 42
List of Abbreviation .............................................................................................................. 00- 46 46
Conversion table .................................................................................................................. 00- 50 50

01 Specifications
Specifications .......................................................................................................................... 01- 3 3
Outline of hybrid system ...................................................................................................... 01- 3 3
Specification dimension drawing.......................................................................................... 01- 4 4
Working range diagram........................................................................................................ 01- 5 5
Specifications....................................................................................................................... 01- 6 6
Weight table ......................................................................................................................... 01- 9 9
Table of fuel, coolant and lubricants .................................................................................... 01- 11 11

10 Structure and function

Engine and cooling system ..................................................................................................... 10- 3 4
Engine related parts............................................................................................................. 10- 3 4
Cooling system .................................................................................................................... 10- 4 5
Hybrid relation......................................................................................................................... 10- 6 7
Configuration and safety functions of hybrid system ........................................................... 10- 6 7
Cooling system of hybrid component................................................................................... 10- 10 11
Motor-generator ................................................................................................................... 10- 12 13
Swing electric motor............................................................................................................. 10- 13 14
Electric control unit............................................................................................................... 10- 14 15
High-voltage wiring (power cable)........................................................................................ 10- 15 16
Water pump ......................................................................................................................... 10- 16 17
Power train system ................................................................................................................. 10- 18 18
Power train........................................................................................................................... 10- 18 18
Swing circle.......................................................................................................................... 10- 19 19
Swing machinery.................................................................................................................. 10- 20 20
Swing brake ......................................................................................................................... 10- 22 22
Final drive ............................................................................................................................ 10- 24 24
Undercarriage and frame ........................................................................................................ 10- 26 26
Track frame and idler cushion.............................................................................................. 10- 26 26
Hydraulic system..................................................................................................................... 10- 28 28
Hydraulic components layout drawing ................................................................................. 10- 28 28
Valve control ........................................................................................................................ 10- 30 30
Hydraulic tank ...................................................................................................................... 10- 31 31
CLSS.................................................................................................................................... 10- 32 32
Main pump ........................................................................................................................... 10- 36 36

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Control valve........................................................................................................................ 10- 58 58

Functions and operation by valve ........................................................................................ 10- 70 70
Travel motor......................................................................................................................... 10-107 107
PPC valve ............................................................................................................................ 10-117 117
Solenoid valve ..................................................................................................................... 10-136 136
Attachment circuit selector valve ......................................................................................... 10-138 138
Return oil filter...................................................................................................................... 10-140 140
Center swivel joint................................................................................................................ 10-142 142
Accumulator......................................................................................................................... 10-143 143
Electrical system ..................................................................................................................... 10-144 144
Electrical control system ...................................................................................................... 10-144 144
Machine monitor system...................................................................................................... 10-174 174
KOMTRAX system............................................................................................................... 10-190 190
Sensors................................................................................................................................ 10-192 192

20 Standard value table

Standard value table ............................................................................................................... 20- 3 3
Standard value table for engine........................................................................................... 20- 3 3
Standard value table for machine ........................................................................................ 20- 4 4

30 Testing and adjusting

Tools for testing, adjusting and troubleshooting ..................................................................... 30- 4 4
Tools for testing, adjusting and troubleshooting .................................................................. 30- 4 4
Engine and cooling system ..................................................................................................... 30- 9 9
Testing engine speed .......................................................................................................... 30- 9 9
Testing boost pressure ........................................................................................................ 30- 11 11
Checking exhaust gas color................................................................................................. 30- 12 12
Adjusting valve clearance .................................................................................................... 30- 13 13
Testing compression pressure............................................................................................. 30- 15 15
Testing blowby pressure...................................................................................................... 30- 18 18
Testing engine oil pressure.................................................................................................. 30- 19 19
Handling fuel system parts .................................................................................................. 30- 20 20
Releasing remaining pressure from fuel system.................................................................. 30- 20 20
Testing fuel system pressure............................................................................................... 30- 21 21
Cylinder cut-out test mode operation................................................................................... 30- 23 23
No injection cranking operation ........................................................................................... 30- 23 23
Testing fuel delivery, return rate and leakage...................................................................... 30- 24 24
Bleeding air from fuel circuit ................................................................................................ 30- 28 28
Testing fuel circuit for leakage ............................................................................................. 30- 29 29
Handling of controller high-voltage circuit............................................................................ 30- 30 30
Testing and adjusting air conditioner compressor belt tension............................................ 30- 31 31
Replacement of fan belt....................................................................................................... 30- 32 32
Undercarriage and frame ........................................................................................................ 30- 33 33
Testing swing circle bearing clearance................................................................................ 30- 33 33
Testing and adjusting track tension ..................................................................................... 30- 34 34
Hydraulic system .................................................................................................................... 30- 37 37
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits ............ 30- 37 37
Testing source pressure of control circuit ............................................................................ 30- 40 40
Testing and adjusting oil pressure in pump PC control circuit ............................................. 30- 41 41
Testing and adjusting oil pressure in pump LS control circuit.............................................. 30- 44 44
Testing solenoid valve output pressure ............................................................................... 30- 48 48
Testing PPC valve output pressure ..................................................................................... 30- 51 51
Adjusting play of work equipment and swing PPC valves ................................................... 30- 53 53
Checking parts which cause hydraulic drift of work equipment ........................................... 30- 54 54

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Releasing remaining pressure from hydraulic circuit ........................................................... 30- 56 56

Testing oil leakage ............................................................................................................... 30- 57 57
Bleeding air from each part.................................................................................................. 30- 59 59
Cab and its attachments ......................................................................................................... 30- 61 61
Checking cab tipping stopper............................................................................................... 30- 61 61
Adjusting mirrors .................................................................................................................. 30- 62 62
Angle adjustment of rear view camera................................................................................. 30- 65 65
Hybrid relation......................................................................................................................... 30- 66 66
Testing swing holding brake ................................................................................................ 30- 66 66
Cleaning and replacement of oil filter of swing electric motor.............................................. 30- 67 67
Operation check of swing emergency stop switch ............................................................... 30- 68 68
Electrical system ..................................................................................................................... 30- 70 70
Special functions of machine monitor .................................................................................. 30- 70 70
Handling voltage circuit of engine controller ........................................................................ 30-132 132
Precautions related to hybrid machines............................................................................... 30-133 133
Preparation work for troubleshooting of electrical system ................................................... 30-134 134
Procedure for testing diodes ................................................................................................ 30-140 140
Pm Clinic ................................................................................................................................. 30-141 141
Pm Clinic service ................................................................................................................. 30-141 141

40 Troubleshooting
General information on troubleshooting .................................................................................. 40- 10 10
Points to remember when troubleshooting .......................................................................... 40- 10
Sequence of events in troubleshooting................................................................................ 40- 11
Checks before troubleshooting ............................................................................................ 40- 12
Classification and procedures for troubleshooting ............................................................... 40- 41
Failure codes table............................................................................................................... 40- 44
Symptom and troubleshooting numbers .............................................................................. 40- 52
Information in troubleshooting table..................................................................................... 40- 55
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 57
Connector list and layout ..................................................................................................... 40- 59
Connection table for connector pin numbers ....................................................................... 40- 70
T- branch box and T- branch adapter table ......................................................................... 40- 106
Fuse location table............................................................................................................... 40- 109
Troubleshooting by failure code.............................................................................................. 40-111 111
Failure code [989L00] Engine Controller Lock Caution 1 .................................................... 40- 111
Failure code [989M00] Engine Controller Lock Caution 2 ................................................... 40- 111
Failure code [989N00] Engine Controller Lock Caution 3.................................................... 40- 111-1
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40- 111-2
Failure code [AB00KE] Charge Voltage Low ....................................................................... 40- 112
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40- 114
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40- 115
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40- 116
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40- 118
Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40- 120
Failure code [CA111] ECM Critical Internal Failure ............................................................. 40- 121
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40- 121
Failure code [CA122] Chg Air Press Sensor High Error ...................................................... 40- 122
Failure code [CA123] Chg Air Press Sensor Low Error ....................................................... 40- 124
Failure code [CA131] Throttle Sensor High Error ................................................................ 40- 126
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40- 128
Failure code [CA144] Coolant Temp Sens High Error ......................................................... 40- 130
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40- 132
Failure code [CA153] Chg Air Temp Sensor High Error ...................................................... 40- 134

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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 ......................................................... 40- 144
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 146
Failure code [CA234] Eng Overspeed ................................................................................. 40- 146
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 147
Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40- 148
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40- 150
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................ 40- 152
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................ 40- 154
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................ 40- 156
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................ 40- 158
Failure code [CA342] Calibration Code Incompatibility ....................................................... 40- 160
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40- 161
Failure code [CA352] Sens Supply 1 Volt Low Error ........................................................... 40- 162
Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 164
Failure code [CA428] Water in Fuel Sensor High Error....................................................... 40- 166
Failure code [CA429] Water in Fuel Sensor Low Error........................................................ 40- 168
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40- 170
Failure code [CA441] Battery Voltage Low Error ................................................................. 40- 172
Failure code [CA442] Battery Voltage High Error ................................................................ 40- 174
Failure code [CA449] Rail Press Very High Error ................................................................ 40- 175
Failure code [CA451] Rail Press Sensor High Error ............................................................ 40- 176
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 178
Failure code [CA488] Chg Air Temp High Torque Derate ................................................... 40- 180
Failure code [CA553] Rail Press High Error ........................................................................ 40- 181
Failure code [CA559] Supply Pump Press Low Error 1....................................................... 40- 182
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 184
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 186
Failure code [CA757] All Continuous Data Lost Error ......................................................... 40- 187
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 188
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 191
Failure code [CA2185] Throt Sens Sup Volt High Error ...................................................... 40- 192
Failure code [CA2186] Throt Sens Sup Volt Low Error ....................................................... 40- 193
Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 194
Failure code [CA2311] IMV Solenoid Error.......................................................................... 40- 195
Failure code [CA2555] Grid Htr Relay Open Circuit Error ................................................... 40- 196
Failure code [CA2556] Grid Htr Relay Short Circuit Error ................................................... 40- 198
Failure code [D19JKZ] Personal Code Relay Abnormality .................................................. 40- 200
Failure code [D862KA] GPS Antenna Open Circuit............................................................. 40- 203
Failure code [DA22KK] Pump Solenoid Power Low Error ................................................... 40- 204
Failure code [DA25KP] 5V Sensor1 Power Abnormality ..................................................... 40- 206
Failure code [DA26KP] 5V Sensor2 Power Abnormality ..................................................... 40- 208
Failure code [DA29KQ] Model Selection Abnormality ......................................................... 40- 210
Failure code [DA2RMC] CAN Discon (Pump Con Detected) .............................................. 40- 212
Failure code [DAF8KB] Camera Power Supply Short Circuit .............................................. 40- 218
Failure code [DAFGMC] GPS Module Error ........................................................................ 40- 220
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40- 221
Failure code [DGH2KB] Hyd Oil Sensor Short .................................................................... 40- 228
Failure code [DHPAMA] Pump Press Sensor Abnormality.................................................. 40- 230
Failure code [DHPBMA] R Pump Press Sensor Abnormality .............................................. 40- 232
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ...................................................... 40- 234

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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... 40- 242
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality .................................... 40- 244
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality..................................... 40- 246
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ............................. 40- 248
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit.... 40- 250
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir ............................. 40- 252
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir ................................... 40- 254
Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor signal
abnormality .......................................................................................................................... 40- 256
Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor malfunction ..... 40- 257
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir .................................... 40- 258
Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor signal
abnormality .......................................................................................................................... 40- 260
Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor malfunction ....... 40- 261
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir ................................ 40- 262
Failure code [DW43KA] Travel Speed Sol Open Circuit...................................................... 40- 264
Failure code [DW43KB] Travel Speed Sol Short Circuit ...................................................... 40- 266
Failure code [DW45KA] Swing holding brake solenoid valve open circuit........................... 40- 268
Failure code [DW45KB] Swing holding brake solenoid valve short circuit........................... 40- 271
Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop............... 40- 274
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir ................................ 40- 276
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit .............................................. 40- 278
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit .............................................. 40- 280
Failure code [DW91KA] Travel Junction Sol. Disc............................................................... 40- 282
Failure code [DW91KB] Travel Junction Sol. S/C................................................................ 40- 284
Failure code [DWA2KA] Attachment Sol Open Circuit......................................................... 40- 286
Failure code [DWA2KB] Attachment Sol Short Circuit......................................................... 40- 288
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit..................................................... 40- 290
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit..................................................... 40- 292
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit......................................................... 40- 294
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit......................................................... 40- 296
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ........................................................ 40- 298
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ........................................................ 40- 300
Failure code [DXE0KA] LS-EPC Sol Open Circuit............................................................... 40- 302
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40- 304
Failure code [DXE4KA] Service Current EPC Disc.............................................................. 40- 306
Failure code [DXE4KB] Service Current EPC S/C............................................................... 40- 308
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ............................................. 40- 310
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ............................................. 40- 312
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit ................................................ 40- 314
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit................................................. 40- 316
Failure code [DY20KA] Wiper Working Abnormality............................................................ 40- 318
Failure code [DY20MA] Wiper Parking Abnormality ............................................................ 40- 320
Failure code [DY2CKA] Washer drive discon ...................................................................... 40- 322
Failure code [DY2CKB] Washer drive short......................................................................... 40- 324
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ..................................................... 40- 326
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...................................................... 40- 328
Troubleshooting by failure code [GA****] (code display)......................................................... 40-330 330
Precaution in hybrid device troubleshooting, and common troubleshooting procedures
for high voltage devices ....................................................................................................... 40- 330
Failure code [GA----] Hybrid devices monitoring items list and check sheet........................ 40- 355

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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. Before Booster ......................................... 40- 364
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster........................................... 40- 365
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster....................................... 40- 366
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster ........................................... 40- 367
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster ........................................... 40- 368
Failure code [GA09KP] Low DC SW Output Volt. After Booster ......................................... 40- 369
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster ......................................... 40- 370
Failure code [GA0BKZ] AC Line Open/Short Circuit ........................................................... 40- 371
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure ..................................................... 40- 372
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON ........................................... 40- 373
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF .......................................... 40- 374
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure ......................................... 40- 376
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure......................................... 40- 378
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir ..................................... 40- 379
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure ......................................... 40- 379
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit........................................... 40- 380
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit ............................................ 40- 380
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded ............................................... 40- 381
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure ......................................... 40- 381
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt ........................................ 40- 382
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure ................................. 40- 382
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. .................................. 40- 383
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction ........................................... 40- 383
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation ................................. 40- 384
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled........................................ 40- 384
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction ...................................... 40- 385
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure ....................................... 40- 385
Failure code [GA1FMA] Abnormal Swing Motor Driver ....................................................... 40- 386
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU .................................. 40- 386
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure ................................. 40- 387
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal................................... 40- 387
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction ...................................... 40- 388
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded ................................ 40- 388
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op........................................... 40- 389
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled..................................... 40- 389
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. ................................ 40- 390
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. ................................. 40- 390
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir................................. 40- 391
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir. ..................................... 40- 391
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir......................................... 40- 392
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat .............................................. 40- 393
Failure code [GA1SFS] Contactor Locked........................................................................... 40- 394
Failure code [GA1SMC] Contactor Failure .......................................................................... 40- 394
Failure code [GA1TKP] Capacitor Low Output Voltage....................................................... 40- 395
Failure code [GA1TNS] Capacitor Overheat ....................................................................... 40- 396
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir......................................... 40- 398
Failure code [GA1VFS] Capacitor Contactor Locked .......................................................... 40- 400
Failure code [GA1VMC] Capacitor Contactor Failure.......................................................... 40- 402
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. ..................................... 40- 403
Failure code [GA1YNS] Booster Inductor Overheat ............................................................ 40- 404

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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. Mot. Dr. Temp. Sens.0 Opn/Short Cir. .................................. 40- 406
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir. .................................. 40- 406
Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality........................................... 40- 407
Failure code [GA25NS] Gen. Motor Driver IGBT0 overheat ................................................ 40- 407-1
Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality........................................... 40- 407-2
Failure code [GA26NS] Gen. Motor Driver IGBT1 overheat ................................................ 40- 408
Failure code [GA27KZ] DC before boosting sensor open or short circuit ............................ 40- 409
Failure code [GA28KZ] DC after boosting sensor open or short circuit ............................... 40- 409
Failure code [GA60MC] Generator Motor Failure ................................................................ 40- 410
Failure code [GA60MD] Gen. Mot. Defective Movement..................................................... 40- 411
Failure code [GA60N1] Generator Motor Overrun ............................................................... 40- 412
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir. ...................................... 40- 414
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat ..................................... 40- 416
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir.................................... 40- 417
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir ..................................... 40- 418
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction ..................................... 40- 419
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.................................... 40- 419
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir ..................................... 40- 420
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction ..................................... 40- 420
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir.................................... 40- 421
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir. .................................... 40- 422
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction..................................... 40- 422
Failure code [GA70KB] HYB Swing Motor Short Circuit ...................................................... 40- 423
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion...................................... 40- 423
Failure code [GA70NS] HYB Swing Motor Overheat........................................................... 40- 424
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir................................... 40- 426
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction........................................ 40- 428
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.......................................... 40- 430
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. ...................................... 40- 430
Failure code [GAA100] Swing emergency stop switch operated ......................................... 40- 431
Failure code [GAA2KB] Swing Brake sol. Supply Line short cir. ......................................... 40- 432
Troubleshooting of electrical system (E-mode)....................................................................... 40-434 434
E-1 Engine does not start (Engine does not crank) ............................................................. 40- 434
E-2 Preheater does not operate........................................................................................... 40- 440
E-3 When starting switch is turned to ON position, machine monitor displays nothing ....... 40- 445
E-4 When starting switch is turned to ON position (with engine stopped), basic check
monitor lights up................................................................................................................... 40- 448
E-5 Precaution monitor lights up while engine is running .................................................... 40- 449
E-6 Emergency stop monitor lights up while engine is running ........................................... 40- 451
E-7 Fuel level gauge does not indicate properly.................................................................. 40- 452
E-8 Engine coolant temperature gauge does not indicate properly ..................................... 40- 454
E-9 Hydraulic oil temperature gauge does not indicate properly ......................................... 40- 456
E-10 HYB system temperature gauge does not indicate properly ....................................... 40- 458
E-11 Displays on machine monitor are different from those for actual machine.................. 40- 460
E-12 Machine monitor does not display some items ........................................................... 40- 460
E-13 Function switch does not work .................................................................................... 40- 460
E-14 Automatic warm-up system does not operate (in cold season)................................... 40- 461
E-15 Auto-decelerator does not operate normally ............................................................... 40- 462
E-16 Working mode does not change.................................................................................. 40- 463
E-17 Travel speed does not change .................................................................................... 40- 464

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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.......................................................... 40- 469
E-23 One-touch power max. function does not operate ...................................................... 40- 472
E-24 Travel alarm does not sound or does not stop sounding ............................................ 40- 476
E-25 Horn does not sound or does not stop sounding ........................................................ 40- 478
E-26 Windshield wiper and window washer do not operate ................................................ 40- 480
E-27 "BOOM LOWER" indicator is not displayed properly with monitoring function ........... 40- 482
E-28 "ARM OUT" indicator is not displayed properly with monitoring function .................... 40- 484
E-29 "ARM IN" indicator is not displayed properly with monitoring function ........................ 40- 486
E-30 "BOOM RAISE" indicator is not displayed properly with monitoring function.............. 40- 486
E-31 "BUCKET CURL" indicator is not displayed properly with monitoring function ........... 40- 486
E-32 "BUCKET DUMP" indicator is not displayed properly with monitoring function .......... 40- 487
E-33 "SWING" indicator is not displayed properly with monitoring function ........................ 40- 487
E-34 "TRAVEL" indicator is not displayed properly with monitoring function....................... 40- 488
E-35 "TRAVEL STEERING" indicator is not displayed properly with monitoring function ... 40- 490
E-36 "SERVICE" indicator is not displayed properly with monitoring function..................... 40- 492
E-37 Attachment hydraulic circuit cannot be changed......................................................... 40- 494
E-38 KOMTRAX system does not operate properly ............................................................ 40- 495
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40-496 496
Information in troubleshooting table (H mode)..................................................................... 40- 498
System diagram of hydraulic and mechanical system......................................................... 40- 496
H-1 Speed or power of all work equipment and travel is low ............................................... 40- 499
H-2 Engine speed lowers significantly or engine stalls........................................................ 40- 501
H-3 All work equipment and travel systems do not work ..................................................... 40- 502
H-4 Unusual noise comes out from around hydraulic pump................................................ 40- 502
H-5 Auto-decelerator does not operate ............................................................................... 40- 503
H-6 Fine control performance or response is low ................................................................ 40- 503
H-7 Speed or power of boom is low..................................................................................... 40- 504
H-8 Speed or power of arm is low ....................................................................................... 40- 505
H-9 Speed or power of bucket is low ................................................................................... 40- 506
H-10 Work equipment does not move in its single operation .............................................. 40- 506
H-11 Hydraulic drift of work equipment is large ................................................................... 40- 507
H-12 Time lag of work equipment is large ........................................................................... 40- 509
H-13 When part of work equipment is relieved singly, other parts of work equipment move 40- 509
H-14 Power maximizing function does not work .................................................................. 40- 510
H-15 In combined operation of work equipment, speed of part loaded more is low ............ 40- 510
H-16 When machine swings and travels simultaneously, travel speed is low ..................... 40- 510
H-17 Machine deviates during travel ................................................................................... 40- 511
H-18 Travel speed is low ..................................................................................................... 40- 512
H-19 Machine is not steered well or sterring power is low................................................... 40- 513
H-20 Travel speed does not shift or travel speed is low or high .......................................... 40- 514
H-21 Travel system does not work (only one side).............................................................. 40- 515
H-22 Upper structure does not swing .................................................................................. 40- 516
H-23 Swing acceleration or swing speed of upper structure is low ..................................... 40- 516
H-24 Upper structure overruns remarkably when it stops swinging .................................... 40- 516
H-25 Large shock is made when upper structure stops swinging ....................................... 40- 517
H-26 Large sound is made when upper structure stops swinging ....................................... 40- 517
H-27 Upper structure lowers largely by its own weight........................................................ 40- 517
Troubleshooting of engine (S-mode) ...................................................................................... 40-518 518
Method of using troubleshooting chart................................................................................. 40- 518
S-1 Engine startability is poor .............................................................................................. 40- 522

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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) ............................................................. 40- 530
S-8 Oil consumption is excessive (or exhaust gas is blue).................................................. 40- 531
S-9 Oil becomes contaminated quickly................................................................................ 40- 532
S-10 Fuel consumption is excessive.................................................................................... 40- 533
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) .................................. 40- 534
S-12 Oil pressure drops ....................................................................................................... 40- 535
S-13 Oil level rises (coolant or fuel in oil)............................................................................. 40- 536
S-14 Coolant temperature rises too high (overheating) ....................................................... 40- 537
S-15 Unusual noise is made ................................................................................................ 40- 538
S-16 Vibration is excessive.................................................................................................. 40- 539
Troubleshooting hybrid system (Y-mode) ............................................................................... 40-540 540
Precautions related to hybrid machine................................................................................. 40- 540
Y-1 Hybrid monitor does not go out ..................................................................................... 40- 542
Y-2 Upper structure does not swing..................................................................................... 40- 544
Y-3 Swing acceleration or swing speed is low ..................................................................... 40- 546
Y-4 Upper structure overruns largely when stop swinging................................................... 40- 547
Y-5 Large shock is made when upper structure stops swinging.......................................... 40- 548
Y-6 Large unusual noise is made when upper structure stops swinging ............................. 40- 548
Y-7 Swing drift on a slope is large ....................................................................................... 40- 549
Y-8 Electric swing motor temperature increases abnormally............................................... 40- 550
Y-9 Motor-generator temperature increases abnormally ..................................................... 40- 552
Y-10 Inverter overheats ....................................................................................................... 40- 553
Y-11 Capacitor overheats .................................................................................................... 40- 554

50 Disassembly and assembly

General information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4
Precautions related to hybrid machine................................................................................. 50- 6
Coating materials list............................................................................................................ 50- 7
Special tools list ................................................................................................................... 50- 10
Sketches of special tools ..................................................................................................... 50- 15
Engine and cooling system ..................................................................................................... 50- 20
Removal and installation of fuel supply pump assembly ..................................................... 50- 20
Removal and installation of fuel injector assembly .............................................................. 50- 25
Removal and installation of cylinder head assembly ........................................................... 50- 32
Removal and installation of radiator assembly .................................................................... 50- 55
Removal and installation of hydraulic oil cooler assembly................................................... 50- 57
Removal and installation of aftercooler assembly................................................................ 50- 59
Removal and installation of engine front seal ...................................................................... 50- 62
Removal and installation of engine rear seal ....................................................................... 50- 64
Removal and installation of fuel cooler assembly ................................................................ 50- 68
Removal (and installation) of engine, motor generator, and main pump assembly ............. 50- 70
Removal and installation of fuel tank assembly ................................................................... 50- 86
Hybrid...................................................................................................................................... 50- 89
Draining adding coolant and bleeding air for hybrid system ................................................ 50- 89
Removal and installation of hybrid radiator assembly.......................................................... 50- 93
Removal and installation of water pump assembly for hybrid system ................................. 50- 96
Removal and installation of inverter assembly..................................................................... 50- 99
Removal and installation of inverter and capacitor assembly .............................................. 50- 103

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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.............................................................................................................................. 50- 129
Removal and installation of final drive assembly ................................................................. 50- 129
Disassembly and assembly of final drive............................................................................. 50- 131
Removal and installation of sprocket ................................................................................... 50- 140
Removal and installation of swing motor and swing machinery assembly .......................... 50- 141
Disassembly and assembly of swing machinery assembly ................................................. 50- 145
Removal and installation of swing circle assembly.............................................................. 50- 160
Undercarriage and frame ........................................................................................................ 50- 161
Separation and connection of track shoe assembly ............................................................ 50- 161
Disassembly and assembly of idler ..................................................................................... 50- 164
Disassembly and assembly of idler cushion assembly ........................................................ 50- 167
Disassembly and assembly of track roller ........................................................................... 50- 169
Disassembly and assembly of carrier roller ......................................................................... 50- 171
Removal and installation of revolving frame assembly........................................................ 50- 175
Removal and installation of counterweight assembly .......................................................... 50- 177
Hydraulic system .................................................................................................................... 50- 179
Removal and installation of center swivel joint assembly .................................................... 50- 179
Disassembly and assembly of center swivel joint assembly................................................ 50- 181
Removal and installation of hydraulic tank assembly .......................................................... 50- 183
Removal and installation of main pump assembly............................................................... 50- 188
Removal and installation of main pump input shaft oil seal ................................................. 50- 193
Removal and installation of control valve assembly ............................................................ 50- 194
Disassembly and assembly of control valve ........................................................................ 50- 199
Disassembly and assembly of work equipment PPC valve assembly ................................. 50- 203
Disassembly and assembly of travel PPC valve.................................................................. 50- 205
Work equipment...................................................................................................................... 50- 208
Removal and installation of work equipment assembly ....................................................... 50- 208
Disassembly and assembly of work equipment cylinder assembly ..................................... 50- 211
Cab and its attachments ......................................................................................................... 50- 217
Removal and installation of operator's cab assembly.......................................................... 50- 217
Removal and installation of operator's cab glass (adhered window glass).......................... 50- 221
Removal and installation of front window assembly ............................................................ 50- 231
Removal and installation of floor frame assembly ............................................................... 50- 238
Removal and installation of air conditioner unit assembly ................................................... 50- 243
Electrical system ..................................................................................................................... 50- 246
Removal and installation of engine controller assembly...................................................... 50- 246
Removal and installation of pump controller assembly........................................................ 50- 248
Removal and installation of machine monitor assembly...................................................... 50- 251
Removal and installation of KOMTRAX terminal assembly ................................................. 50- 253

60 Maintenance standard
Engine and cooling system ..................................................................................................... 60- 4 4
Engine mount....................................................................................................................... 60- 4 4
Cooling system .................................................................................................................... 60- 5 5
Power train.............................................................................................................................. 60- 7 7
Swing circle.......................................................................................................................... 60- 7 7
Swing machinery ................................................................................................................. 60- 8 8
Swing brake ......................................................................................................................... 60- 10 10
Final drive ............................................................................................................................ 60- 12 12
Sprocket............................................................................................................................... 60- 14 14

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Undercarriage and frame ........................................................................................................ 60- 16 16

Track frame and idler cushion.............................................................................................. 60- 16 16
Idler ...................................................................................................................................... 60- 18 18
Track roller ........................................................................................................................... 60- 20 20
Carrier roller ......................................................................................................................... 60- 21 21
Track shoe ........................................................................................................................... 60- 22 22
Hydraulic system..................................................................................................................... 60- 28 28
Main pump ........................................................................................................................... 60- 28 28
Control valve ........................................................................................................................ 60- 32 32
Travel motor......................................................................................................................... 60- 41 41
PPC valve ............................................................................................................................ 60- 44 44
Solenoid valve...................................................................................................................... 60- 54 54
Attachment circuit selector valve ......................................................................................... 60- 55 55
Center swivel joint................................................................................................................ 60- 56 56
Work equipment...................................................................................................................... 60- 58 58
Work equipment................................................................................................................... 60- 58 58
Dimension of work equipment.............................................................................................. 60- 60 60
Work equipment cylinder ..................................................................................................... 60- 64 64

80 Appendix
Air conditioner ......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Air conditioner component ................................................................................................... 80- 4
Configuration and function of refrigeration cycle.................................................................. 80- 6
Outline of refrigeration cycle ................................................................................................ 80- 7
Air conditioner unit ............................................................................................................... 80- 10
Air conditioner controller ...................................................................................................... 80- 15
Compressor ......................................................................................................................... 80- 16
Condenser and Modulator ................................................................................................... 80- 17
Procedure for testing and troubleshooting ........................................................................... 80- 18
Circuit diagram and arrangement of connector pins ............................................................ 80- 20
System diagram ................................................................................................................... 80- 22
Detail of air conditioner unit ................................................................................................. 80- 24
Parts and connectors layout ................................................................................................ 80- 26
Testing air leakage (duct) .................................................................................................... 80- 30
Testing with self-diagnosis function ..................................................................................... 80- 31
Testing temperature control ................................................................................................. 80- 34
Testing vent (mode) changeover ......................................................................................... 80- 36
Testing FRESH/RECIRC air changeover ............................................................................ 80- 39
Testing inner sensor ............................................................................................................ 80- 41
Testing evaporator temperature sensor............................................................................... 80- 42
Testing sunlight sensor ........................................................................................................ 80- 44
Testing (dual) pressure switch for refrigerant ...................................................................... 80- 45
Testing relays....................................................................................................................... 80- 47
Troubleshooting chart 1 ....................................................................................................... 80- 48
Troubleshooting chart 2 ....................................................................................................... 80- 50
Information in troubleshooting table..................................................................................... 80- 52
Troubleshooting for power supply and CAN communication system (Air conditioner
does not operate)................................................................................................................. 80- 53
Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80- 57
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ......... 80- 60
Troubleshooting for temperature control.............................................................................. 80- 63
Troubleshooting for vent (mode) changeover ...................................................................... 80- 66
Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 68

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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 ....................................................................................... 80- 80

90 Diagrams and drawings

Hydraulic circuit diagram......................................................................................................... 90- 3 3
Symbols used in hydraulic circuit diagrams ......................................................................... 90- 3 3
Hydraulic circuit diagram ..................................................................................................... 90- 7 7
Electrical circuit diagram ......................................................................................................... 90- 9 7
Symbols used in electric circuit diagrams ............................................................................ 90- 9 7
Electrical circuit diagram...................................................................................................... 90- 13 9

Index ....................................................................................................................................... 1

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 4
Foreword and general information
Safety notice

Foreword and general information 4

Safety notice 4

HB205-1, HB215LC-1 (Rev. 2012/10)

Hybrid
Important safety notice

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.
The symbol mark "k" is indicated for such matters that require special precautions. The work indi-
cated with the warning mark should be performed according to the instructions with special attention
to the precautions. Should a hazardous situation occur or be anticipated during such work, be sure
to keep safe first and take every necessary measure.

1. Precautions peculiar to hybrid machine k 6. When handling hybrid devices or

1) Hybrid mark
k 1. This machine is equipped with the
hybrid system consisting of an electric
motor and a diesel engine. The above
Hybrid mark is attached to each expla-
nation peculiar to the hybrid system
(contents different from those for the
common diesel engine machine). Be
sure to read the Operation and Mainte-
nance Manual, "Introduction", "Out-
line of hybrid system" (Section 1),
"Safety", "Safety Precautions on Safe-
ty Indicators" (Section 2) and this
Shop Manual, "Handling of hybrid de-
vices and high-voltage wiring" and
"Items related to hybrid system" in
Structured and function to understand
the hybrid system.
k 2. The persons who engage in the in-
stalling or removing work of the hybrid
devices (motor-generator, capacitor,
inverter, swing electric motor) must
follow the local Industrial Safety and
Health Law concerning electricity.
k 3. Never disassemble the hybrid devic-
es mentioned above. The hybrid devic-
es and high-voltage wiring (orange
color) must be replaced by the unit.
k 4. When handling hybrid devices, be
sure to discharge the capacitor com-
pletely first. For details, see this man-
ual, "Handling of hybrid devices and
high-voltage wirings", "Discharge pro-
cedure for capacitor" or Testing and
adjusting, "Discharge" of capacitor".
k 5. When handling the hybrid devices
or high-voltage wirings, be sure to fol-
low "Handling of hybrid devices and
high-voltage wirings".
high voltage wirings, there is a proce-
dure to look into the charge level in-
spection window at the contactor box
above the capacitor and to check that
the LED display for capacitor charge
state indicates "UNCHARGED". Before
discharging capacitor, check display
function of this LED according to the
following procedure.
1] Both of two LEDs are lit 1 minute after
engine is started.
2] One LED is lit after turning the key to
the OFF position.
(One LED goes out by turning the key
to the OFF position.)
LED display function to show capaci-
tor charge state may be defective if the
above cannot be confirmed even when
any failure is not occurring in hybrid
system. In this case, replace the ca-
pacitor according to the following
"General precautions".
2. General precautions
k Inappropriate handling creates an ex-
treme danger. Read and understand what
is described in the Operation and Mainte-
nance Manual before operating the ma-
chine. Read and understand what is
described in this manual before starting
work.
1) Before performing any greasing or repairs,
read all the safety labels stuck to the
machine. For the locations of the safety
labels and detailed explanation of precau-
tions, see the Operation and Maintenance
Manual.

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 5
2) Locate a place in the repair workshop to keep
tools and removed parts. Always keep the
tools and parts in their correct places. Always
keep the work area clean and make sure that
there is no dirt, water, or oil on the floor.
Smoke only in the areas provided for
smoking. Never smoke while working.
3) When performing any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
q Always wear the safety glasses when hit-
ting parts with a hammer.
q Always wear the safety glasses when
grinding parts with a grinder, etc.
4) When performing any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform
your fellow workers before starting any step
of the operation. Before starting work, hang
UNDER REPAIR warning tag in the oper-
ator's compartment.
5) Only qualified workers must perform the work
and operation which require license or quali-
fication.
6) Keep all tools in good condition, learn the
correct way to use them, and use the proper
ones. Before starting work, thoroughly check
the tools, machine, forklift truck, service car,
etc.
7) If welding repairs are needed, always have a
trained and experienced welder perform the
work. When performing welding work, always
wear welding gloves, apron, shielding
goggles, cap and other clothes suited for
welding work.
8) Before starting work, warm up your body
thoroughly to start work under good condi-
tion.
9) Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition and at the provided
place.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signals
Prohibition of operation and handling by
5 unlicensed workers
6 Safety check before starting work
7 Wearing protective goggles (for cleaning or
grinding work)
8 Wearing shielding goggles and protectors (for
welding work)
9 Good physical condition and preparation
Precautions against work which you are not used
10 to or you are used to too much
HB205-1, HB215LC-1
(03)
Foreword and general information
Safety notice
3. Preparation work
1) Before adding oil or making any repairs, park
the machine on a hard and level ground, and
apply the parking brake and chock the
wheels or tracks to prevent the machine from
moving.
2) Before starting work, lower the work equip-
ment (blade, ripper, bucket, etc.) to the
ground. If this is not possible, insert the lock
pin or use blocks to prevent the work equip-
ment from falling. In addition, be sure to lock
all the control levers and hang warning tag on
them.
3) When disassembling or assembling, support
the machine with blocks, jacks, or stands
before starting the work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders
or steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
4. Precautions during work
1) Before disconnecting or removing compo-
nents for the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is shut down, so be careful
not to get scalded. Wait for the oil and coolant
to cool before performing any work on the oil
or water circuits.
3) Before starting work, shut down the engine.
When working on or around a rotating part, in
particular, shut down the engine. When
checking the machine without shutting down
the engine (measuring oil pressure, revolving
speed, temperature, etc.), take extreme care
not to get caught in rotating parts or moving
parts.
4) Before starting work, remove the cables from
the battery. Always remove the cable from
the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any other
part. Do not work with any part still raised by
the hoist or crane.
00-5
 6
Foreword and general information
Safety notice
6) When removing a cover which is under
internal pressure or under pressure by a
spring, always leave two bolts in diagonal
positions. Loosen those bolts gradually and
alternately to release the pressure, and then
remove the cover.
7) When removing components, be careful not
to break or damage the electrical wiring.
Damaged wiring may cause electrical fires.
8) When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it off immediately. Fuel or oil
on the floor can cause you to slip and can
even cause fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical
parts, in particular.
10)Be sure to assemble all parts again in their
original places. Replace any damaged parts
and parts which must not be reused with new
parts. When installing hoses and wires, be
sure that they will not be damaged by contact
with other parts when the machine is oper-
ated.
11)When installing high pressure hoses and
tubes, make sure that they are not twisted.
Damaged hoses and tubes are dangerous,
so be extremely careful when installing
hoses and tubes for high pressure circuits. In
addition, check that connections of them are
correct.
12)When assembling or installing parts, always
tighten them to the specified torques. When
installing protective parts such as guards, or
parts which vibrate violently or rotate at high
speeds, be particularly careful to check that
they are installed correctly.
13)When aligning two holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
14)When measuring hydraulic pressure, check
that the measuring tools are correctly
installed.
15)Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
16)If the engine is operated for a long time in a
place which is not ventilated well, you may
suffer from gas poisoning. Accordingly, open
the windows and doors to ventilate well.
00-6
5. Precautions for slinging work and making
signals
1) 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. The signaler must
always stand in front of the load and guide
the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight of
the load and method of slinging. If too thick
wire ropes are used to sling a light load, the
load may slip and fall.
6) Do not sling a load with one wire rope alone.
If it is slung so, It may rotate and may slip out
of the rope. Install two or more wire ropes
symmetrically.
k Slinging with one rope may cause
turning of the load during hoisting, un-
twisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dan-
gerous accident.
7) Limit the hanging angle to 60 degree, as a
rule.
Do not sling a heavy load with ropes forming
a wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angle. The table below
shows the variation of allowable load in kN
{kg} when hoisting is made with two ropes,
each of which is allowed to sling up to 9.8 kN
{1,000 kg} vertically, at various hanging
angles. When the two ropes sling a load verti-
cally, up to 19.6 kN {2,000 kg} of total weight
can be suspended. This weight is reduced to
9.8 kN {1,000 kg} when the two ropes make
a hanging angle of 120 degree. If the two
ropes sling a 19.6 kN {2,000 kg} load at a
lifting angle of 150 degree, each of them is
subjected to a force as large as 39.2 kN
{4,000 kg}.
HB205-1, HB215LC-1
 7
8) When installing wire ropes to an angular
load, apply pads to protect the wire ropes. If
the load is slippery, apply proper material to
prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire ropes,
chains, etc. to them with shackles, etc.
10)Apply wire ropes to the middle portion of the
hook.
q Slinging near the tip of the hook may
cause the rope to slip off the hook during
hoisting. The hook has the maximum
strength at the middle portion.
11)Do not use twisted or kinked wire ropes.
12)When lifting up a load, observe the following.
q Wind in the crane slowly until wire ropes
are stretched. When settling the wire
ropes with the hand, do not grasp them
but press them from above. If you grasp
them, your fingers may be caught.
q After the wire ropes are stretched, stop
the crane and check the condition of the
slung load, wire ropes, and pads.
q If the load is unstable or the wire rope or
chains are twisted, lower the load and lift
it up again.
q Do not lift up the load at an angle.
HB205-1, HB215LC-1
Foreword and general information
Safety notice
13)When lowering a load, observe the following.
q When lifting down a load, stop it tempo-
rarily at 30 cm above the floor, and then
lower it slowly.
q Check that the load is stable, and then re-
move the sling.
q Remove kinks and dirt from the wire
ropes and chains used for the sling work,
and put them in the specified place.
6. Precautions for using mobile crane
a Read the Operation and Maintenance Manu-
al of the crane carefully in advance and oper-
ate the crane safely.
7. Precautions for using overhead traveling
crane
k A hoist crane or similar device must be
used for lifting a heavy load (25 kg or
more). The weight of a part that is 25 kg or
more is indicated with the symbol "4" in
"Disassembly and assembly".
1) Before starting work, inspect the wire ropes,
brake, clutch, controller, rails, over wind stop
device, ground fault circuit interrupter, crane
collision prevention device, and power appli-
cation warning lamp, and check safety.
2) Observe the signals for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions of
the control buttons without fail.
5) Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and lift
up a load to a safe height.
10)Place the control switch in a position where it
will not be an obstacle to work and passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.
13)If the hoist stops because of a power failure,
turn the power switch OFF. When turning on
a switch which was turned OFF by the
ground fault circuit interrupter, check that the
devices related to that switch are not in oper-
ating condition.
14)If you find an obstacle around the hoist, stop
the operation.
00-7
 8
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. water, etc. will not enter them.
2] When connecting the air conditioner
8. Selecting wire ropes hoses and tubes, check that O-rings (1)
1) Select adequate ropes depending on the are fitted to their joints.
weight of parts to be hoisted, referring to the 3] Check that O-ring (1) is free from flaw and
table below. deterioration.
Wire ropes 4] When connecting the refrigerant piping,
(Standard "Z" twist ropes without galvanizing) apply compressor oil for refrigerant
(JIS G3525, No. 6, Type 6X37-A) (R134a) (DENSO: ND-OIL8, VALEO
Nominal diameter THERMAL SYSTEMS: ZXL100PG
Allowable load
of rope
(equivalent to PAG46)) to its O-rings.
mm kN ton
a Example of O-ring (Fitted to every
10 8.8 0.9
joint of hoses and tubes)
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
a The allowable load is one-sixth of the
breaking strength of the rope to be used
(Safety coefficient: 6).

9. Precautions for disconnecting and a For tightening torque, see the precau-
connecting hoses and tubes in an air condi- tions for installation in each section of
tioner circuit "Disassembly and assembly".
1) Disconnection
k Although the refrigerant (refrigerant
gas: R134a) used on the machine's air
conditioner is less destructive to the
ozone layer for environmentally friend-
liness, it is not allowed to be released
into the atmosphere as is. Whenever
disconnecting the air conditioner gas
circuit, be sure to recover the refriger-
ant gas to reuse it.
a Ask a qualified person for collection and
charge of the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight or your skin may be frozen.
Whenever recovering or adding refrig-
erant gas, you must put on safety
glasses, safety gloves and long
sleeved clothes.
The refrigerant gas must be recovered
and added by a qualified person.

00-8 HB205-1, HB215LC-1

 9
Foreword and general information
How to read the shop manual

How to read the shop manual 9

(Rev. 2010/03)

q 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.
q Materials and specifications are subject to change without notice.
q 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.

1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.

00. Index and foreword

This section contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.

01. Specification
This section explains the specifications of the machine.

10. Structure and function

This section explains the structure and function of each component. It serves not only to give an under-
standing for the structure of each component, but also serves as reference material for troubleshooting.

20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjust-
ing and to judge parts in troubleshooting.

30. Testing and adjusting

This section explains measuring tools and measuring methods for testing and adjusting, as well as the
adjusting method of each part. The standard values and judgment criteria for "Testing and adjusting" are
explained in "Standard value table".

40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.

50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and assem-
bling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.

60. Maintenance standard

This section gives maintenance standard values of each component. The maintenance standard sub-sec-
tion explains the criteria and remedies for disassembly and service.

80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.

90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.

HB205-1, HB215LC-1 00-9

 10
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.

q Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (01), (02), (03)...)

q Revisions
The revised pages are shown in the LIST OF REVISED PAGES.

4. Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.

Symbol Item Description

k
Special safety precautions which are necessary when performing work are
Safety
described.

Special technical precautions or other precautions for preserving standards which

a Caution
are necessary when performing work are described.

4
Weight of parts of component or parts are indicated. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc. are described.

3
Places that require special attention for tightening torque during assembly are
Tightening torque
indicated.

2 Coat Places to be coated with adhesives, etc. during assembly are indicated.

5 Oil, coolant Places where oil, etc. must be added, and capacity are indicated.

6 Drain Places where oil, etc. must be drained, and quantity to be drained are indicated.

5. Unit
In this shop manual, the units are indicated with International System of units (SI).
For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

00-10 HB205-1, HB215LC-1

 11
Foreword and general information
Explanation of terms for maintenance standard

Explanation of terms for maintenance standard 1

(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. Standard dimension and tolerance q When some parts are repaired, the value of
q To be accurate, the finished dimension of performance/function is set to the standard
parts is slightly different from one to another. value.
q To specify the finished dimension of a part, a
certain dimension is set for the part and an al-
lowable difference from that dimension is in-
dicated.
q The above dimension set is called the "stan-
dard dimension" and the range of difference
from the standard dimension is called the
"tolerance".
q The tolerance with the symbols of + or is in-
dicated on the right side of the standard di-
mension.

Example:
Standard dimension Tolerance
-0.022
120
-0.126
a The tolerance may be indicated in the text
and a table as [standard dimension (upper
limit of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)

q Usually, the dimension of a hole and the di-

mension of the shaft to be inserted into that
hole are indicated by the same standard di-
mension and different tolerances of the hole
and shaft. The tightness of fit is decided by
the tolerance.
q Indication of dimension of rotating shaft and
hole and their related drawing.
3. Standard interference
Example: q When the diameter of a hole of a part shown
Standard dimen- Tolerance in the given standard dimension and toler-
sion Shaft Hole ance table is smaller than that of the shaft to
-0.030 +0.046
60 be inserted, the difference between those di-
-0.076 0
ameters is called the "interference".
q The range (between A and B) from the differ-
2. Standard clearance and standard value ence (A) between the minimum dimension of
q The clearance made when new parts are as- the shaft and the maximum dimension of the
sembled is called the "standard clearance", hole to the difference (B) between the maxi-
which is indicated by the range from the min- mum dimension of the shaft and the mini-
imum clearance to the maximum clearance. mum dimension of the hole is the standard
q When some parts are repaired, the clearance interference.
is generally adjusted to the standard clear- q After repairing or replacing some parts, mea-
ance. sure the dimension of their hole and shaft
q The values indicating performance and func- and check that the interference is in the stan-
tion of new products or equivalent are called dard range.
the "standard value", which is indicated by a
range or a target value.

HB205-1, HB215LC-1 00-11

 12
Foreword and general information
Explanation of terms for maintenance standard

4. Repair limit and allowable value or allowable

dimension
q 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".
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value with which the
product can be used without causing a prob-
lem is called the "allowable value" or "allow-
able dimension".
q If a product deviates from the allowable val-
ue, it must be checked or repaired. However,
since most of the allowable values are esti-
mated from various tests or experiences in
most cases, it must be judged after consider-
ing the operating condition and customer's
requirement.

5. Allowable clearance
q Parts can be used until the clearance be-
tween them is increased to a certain limit.
The limit at which those parts cannot be used
is called the "allowable clearance".
q If the clearance between the parts exceeds
the allowable clearance, they must be re-
placed or repaired.

6. Allowable interference
q The allowable maximum interference be-
tween the hole of a part and the shaft of an-
other part to be assembled is called the
"allowable interference".
q The allowable interference shows the repair
limit of the part of smaller tolerance.
q If the interference between the parts exceeds
the allowable interference, they must be re-
placed or repaired.

00-12 HB205-1, HB215LC-1

 13
Foreword and general information
Handling of hydraulic components

Handling of hydraulic components 13

(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.

1. Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.

2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is
performed on hydraulic components in the field,
there is danger of dust entering the components.
It is also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be performed in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.

3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.

4. Preventing intrusion of foreign materials

during refilling operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has been collected during storage, so this is
an even more effective method.

HB205-1, HB215LC-1 00-13

 14
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. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
hole in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.

6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
performed twice. Primary flushing is performed
by use of flushing oil and secondary flushing is
performed by use of the specified hydraulic oil.

7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
perform oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment can remove the ultra fine
(about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.

00-14 HB205-1, HB215LC-1

 15
Foreword and general information
Method of disconnecting and connecting push-pull type coupler

Method of disconnecting and connecting push-pull type coupler 15

(Rev. 2010/03)
k Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the remaining pressure in the hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.

Type 1

1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
a Since some hydraulic oil flows out, pre-
pare an oil container.

2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose fitting in the adapter
on the other side perfectly, pull it back to
check the connecting condition (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormal-
ity, however.

HB205-1, HB215LC-1 00-15

 16
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). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)

2. Connection
q Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) con-
tacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 9)

00-16 HB205-1, HB215LC-1

 17
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
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)

2. Connection
q Hold the tightening portion and push body (9)
straight until sliding prevention ring (8) con-
tacts contact surface (b) of the hexagonal
portion at the male end. (Fig. 13)

HB205-1, HB215LC-1 00-17

 18
Foreword and general information
Handling of electric equipment

Handling of electric equipment 18

(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. This section deals particularly with correct repair procedures for mechatronics and is aimed at im-
proving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment".

Points to remember when handling electric equipment

1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harnesses
1) Defective contact of connectors (defective
contact between male and female connec-
tors)
Problems with defective contact are likely to
occur because the male connector is not
properly fitted into the female connector, or
because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and discon-
necting the connector about ten times.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are attached to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated and causes a
defective contact or the wire is broken.

00-18 HB205-1, HB215LC-1

 19
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.

4) High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to spray water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface of
the male and female pins, the oil will not let
the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the
connector, wipe it off with a dry cloth or blow
it to dry with compressed air and spray it with
electric contact cleaner.
a When wiping the joint portion of the con-
nector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the com-
pressed air completely before cleaning
with compressed air.

HB205-1, HB215LC-1 00-19

 20
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. For connectors
which have a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
a Never pull with one hand.

2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is in-
stalled.

qWhen removing a connector from a

clip, pull the connector in a parallel di-
rection to the clip for removing stop-
pers.
a If the connector is pried up and down
or to the left or right, the housing may
break.

3] Action to take after removing connectors

After removing a connector, cover it with
a vinyl bag to prevent the entry of dust,
dirt, oil, or water to the contact portion.
a If the machine is left disassembled for
a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.

00-20 HB205-1, HB215LC-1

 21
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.
Check that external surfaces of the
connectors are free from damage or
breakage.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the con-
nector and harness with a dryer, but
be careful not to make them too hot as
this will cause short circuits.
a If there is any damage or breakage,
replace the connector.
2] Fix the connector securely.
Position the connectors correctly, and
then fit them securely. For connectors
with the lock stopper, push in the
connector until the stopper clicks into
position.
3] Correcting protrusion of the boot and
misalignment of the wiring harness
For connectors fitted with the boot,
correct any extrusion of the boot. In addi-
tion, if the wiring harness is moved in
laying, or the clamp is out of position,
correct it to its right position.
a If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
q If the connector clamp is removed, be
sure to return it to its original position.
Check also that there are no loose
clamps.

HB205-1, HB215LC-1 00-21

 22
Foreword and general information
Handling of electric equipment

3) Deutsch connector (DT 8-pin, 12-pin)

Disconnection (Left of figure) q Disconnection q 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.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector (2)
while moving it up and down until the
locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
(1): Male connector
(2): Female connector
(a), (b): Locks

00-22 HB205-1, HB215LC-1

 23
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. If water gets directly on the
connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is the risk that
oil in the air may cause defective con-
tact, remove oil and water in the air
before starting air blow.

2] Dry the inside of the connector with a

dryer.
If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is
used in order not to make the connec-
tor or related parts too hot, as this will
cause deformation or damage to the
connector.

3] Perform a continuity test on the

connector.
After drying, leave the wiring harness
disconnected and perform a continuity
test to check for any short circuits
between pins caused by water.
a After completely drying the connector,
blow it with electric contact cleaner
and reassemble.

HB205-1, HB215LC-1 00-23

 24
Foreword and general information
Handling of electric equipment

4. Handling of connectors used on engine

a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3

1) Slide, lock type (FRAMATOME-3, FRAM- 2) Pull lock type (PACKARD-2)

ATOME-2) q 95/107/114/125/140/170/12V140 Series
q 95/107/114/125/140/170/12V140 Series q Various temperature sensors
q Various pressure sensors and NE Examples)
speed sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure sensor in intake Fuel temperature sensor: TFUEL
manifold: PIM (125/170/12V140 Oil temperature sensor: TOIL
series) Coolant temperature sensor: TWTR,
Oil pressure sensor: POIL etc.
(125/170/12V140 series)
Oil pressure switch (95/107/114 Disconnection
series) Disconnect the connector by pulling lock (B)
Ne speed sensor on flywheel housing: (on the wiring harness side) of connector (2)
NE (95/107/114/125/140/170/12V140 outward.
series)
Ambient pressure sensor: PAMB
(125/170/12V140 series)

Disconnection
1] Slide lock L1 to the right.
2] While pressing lock L2, pull out connector
(1) toward you.
a Even if lock L2 is pressed, connector
(1) cannot be pulled out toward you, if
part (A) does not float. In this case,
float part (A) with a small screwdriver
while pressing lock L2, and then pull
out connector (1) toward you.
Connection
Insert the connector straight until it "clicks".

Connection
Insert the connector straight until it "clicks".

00-24 HB205-1, HB215LC-1

 25
Foreword and general information
Handling of electric equipment

3) Push lock type (1) a If the lock is located on the underside, use
q 95/107/114 series flat-head screwdriver [1] since you cannot
Example) Fuel pressure sensor in insert your fingers.
common rail (BOSCH-03) While pressing up lock (C) of the
connector with flat-head screwdriver [1],
Disconnection pull out connector (3) in the direction of
While pressing lock (C), pull out connector the arrow.
(3) in the direction of the arrow.

q 114 series

Connection
Insert the connector straight until it "clicks".

q 107 series 4) Push lock type (2)

q 107/114 series
Example) Intake air pressure/tempera-
ture sensor in intake manifold (SUMI-
TOMO-04)

Disconnection
While pressing lock (D), pull out connector
(4) in the direction of the arrow.

Connection
Insert the connector straight until it "clicks".

HB205-1, HB215LC-1 00-25

 26
Foreword and general information
Handling of electric equipment

5) Push lock type (3) 6) Turn-housing type (Round green

q 95/125/140/170/12V140 series connector)
q 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. (CANNON-04): PIM, etc.
Example) Fuel pressure sensor in common
rail: PFUEL etc. (AMP-3)
Disconnection
1] Turn housing (H1) in the direction of the
arrow.
a When connector is unlocked, housing
(H1) becomes heavy to turn.
2] Pull out housing (H1) in the direction of
the arrow.
a Housing (H1) is left on the wiring har-
ness side.

Example) Injection pressure control valve of

fuel supply pump: PCV (SUMITOMO-2)

Connection
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of the
arrow until it "clicks".
Examples) Speed sensor of fuel supply
pump: G (SUMITOMO-3)
a Pull the connector straight up.

Connection
Insert the connector straight until it "clicks".

00-26 HB205-1, HB215LC-1

 27
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 the
controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in a place that can be heated to a high
temperature even for a short time. (Place it
on a suitable dry stand.)
6) Precautions when performing arc welding
When performing arc welding on the
machine body, disconnect all of the wiring
harness connectors connected to the
controller. Fit an arc welding ground to the
place close to the welding point.

6. Points to remember when troubleshooting

electric circuits
1) Be sure to turn the power OFF before discon-
necting or connecting connectors.
2) Before performing troubleshooting, check all
the related connectors for loose connection.
a Disconnect and connect the related con-
nectors several times to check.
3) Be sure to connect any disconnected
connectors before going on to the next step.
a If the power is turned ON with the connec-
tors still disconnected, unnecessary
warning will be displayed.
4) When performing troubleshooting of circuits
(measuring the voltage, resistance, conti-
nuity, or current), wag the related wiring
harnesses and connectors several times and
check that there is no change in the reading
of the tester.
a If there is any change, there may be de-
fective contact in the circuit.

HB205-1, HB215LC-1 00-27

 28
Foreword and general information
How to read electric wire code

How to read electric wire code 28

(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.
Example: AEX 0.85 L Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
of 0.85

Indicates color of wire by color code.

Color codes are shown in Table 3.

Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.

Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV, AVS, AVSS, and CAVS wires depend on size (nominal No.),
their symbols are not indicated on the diagram.)

1. Type, symbol, and material

AV, AVS and AVSS are different in only thickness and outside diameter of the cover. AEX is similar to AV
in thickness and outside diameter of AEX and different from AV, AVS and AVSS in material of the cover.
CAVS is circular compressed conductor in conductor and different appearance from AV and AVS.

(Table 1)
Using tempera-
Type Symbol Material Example of use
ture range (C)
Annealed copper for electric
Conductor
Low-voltage wire for appliance General wiring (Nominal
AV
automobile No. 5 and above)
Insulator Soft polyvinyl chloride
30 to +60
Annealed copper for electric AVS: General wiring (Nomi-
Thin-cover Conductor
AVS appliance nal No. 3 to 5)
low-voltage wire for
AVSS AVSS: General wiring
automobile Insulator Soft polyvinyl chloride
(Nominal No. 2)
Annealed copper for electric General wiring in extremely
Heat-resistant Conductor
appliance cold district, wiring at high
low-voltage wire for AEX 50 to +110
Heat-resistant crosslinked ambient temperature place
automobile Insulator
polyethylene
Compressed-conduct Annealed copper for electric
Conductor
or thin-cover appliance General wiring (Nominal
CAVS 30 to +60
low-voltage wire for Plasticized type polyvinyl No. 0.5 to 1.25)
Insulator
automobile chloride

00-28 HB205-1, HB215LC-1

 29
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 Drain wire 30 to +60
wire strand (nominal size: 0.5, double core)
automobiles
Shield Aluminum foil

Sheath Soft polyvinyl chloride

Annealed copper wire for
Conductor
electric appliances
Thin low-capacitance
Heat-resistant Insulator For signal wiring in high-tempera-
crosslinked polyethylene
low-voltage wire PEXBS 50 to +120 ture place
Sn plated, annealed, braided
for automobile Shield (nominal size: 0.5, 3 cores)
copper wire
Heat-resistant crosslinked
Sheath
polyethylene
Annealed copper wire for
Conductor
electric appliances
Braided shield Insulator Soft polyvinyl chloride
For general signal wiring
wire for CAVSBS 30 to +60
Sn plated, annealed, braided (nominal size: 0.5, 3 cores)
automobile Shield
copper wire
Sheath Soft polyvinyl chloride

HB205-1, HB215LC-1 00-29

 30
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) 2f 2 3f 3 5
Number of
strands/Diame- 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 41/0.32 65/0.32
ter of strand
Conduc- Sectional area
tor 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0

AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -

Cover D

AV Standard - - - - - - - 4.6

AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6

AVSS Standard - - - 2.7 2.7 - - -

Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diame- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
ter of strand
Conduc- Sectional area
tor 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6

AVS Standard - - - - - - - - -
Cover D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

AVSS Standard - - - - - - - - -

CAVS
(Table 4)
Nominal No. 0.5 0.85 1.25
16/Circular compres-
Number of strands 7/Circular compression 11/Circular compression
sion
Conductor Cross-sectional area
0.56 0.88 1.29
(mm2)
d (approx.) 0.9 1.1 1.4
Cover D CAVS Standard 1.6 1.8 2.1

00-30 HB205-1, HB215LC-1

 31
Foreword and general information
How to read electric wire code

AVSSCS PEXBS
(Table 5) (Table 6)
Nominal No. 0.5f Nominal No. 0.5f
Number of cores 2 Number of cores 3
Construction Construction
19/0.19 20/0.18
(No./mm) (No./mm)
Cross-sectional Cross-sectional
Core conductor 0.54 Core conductor 0.51
area (mm2) area (mm2)
Outside diameter Outside diameter
1.6 2.0
(mm) (mm)
Construction Strand diameter
20/0.18 0.12
(No./mm) (mm)
Drain wire Braided shield
Cross-sectional No. of wires/strands 5/16
0.51
area (mm2) Density (%) Min. 70
Aluminum foil thickness (mm) 0.03 Sheath thickness (mm) 0.5
Sheath thickness (mm) 0.5 Finished outside diameter (mm) 5.9
Finished outside diameter (mm) 4.3

f of nominal No. denotes flexible.

HB205-1, HB215LC-1 00-31

 32
Foreword and general information
How to read electric wire code

3. Color codes table

(Table 7)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: GW means that the background is Green and marking is White.

4. Types of circuits and color codes

(Table 8)
Type of wire AVS, AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch

00-32 HB205-1, HB215LC-1

 33
Foreword and general information
Precautions when performing work

Precautions when performing work 3

(Rev. 2010/07)
When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions giv-
en below.

1. Precautions for removal work

q If the coolant contains antifreeze, dispose of it correctly as chemicals.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Check the match marks showing the installation position, and put match marks in the necessary places
before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Attach the tags to wires and hoses to show their installation position to prevent any mistake when in-
stalling.
q Check the number and thickness of the shims, and keep them in a safe place.
q When slinging component, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly and alter-
nately.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Put the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376 - 70210 02789 - 20210
03 07376 - 70315 02789 - 20315
04 07376 - 70422 02789 - 20422
05 07376 - 70522 02789 - 20522
06 07376 - 70628 02789 - 20628
10 07376 - 71034 07221 - 21034
12 07376 - 71234 07221 - 21234

2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379 - 00400 07378 - 10400 07371 - 30400
05 07379 - 00500 07378 - 10500 07371 - 30500

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part No.
number D d L
06 07049 - 00608 6 5 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 29
27 07049 - 02734 27 22.5 34

HB205-1, HB215LC-1 00-33

 34
Foreword and general information
Precautions when performing work

2. Precautions for installation work

q Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
q Install the hoses without twisting or interference and fix them with intermediate clamps, if available.
q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean and degrease the part, and coat the threaded portion with two to
three drops of adhesive.
q When coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making
sure that the surface is free from dirt or damage.
q Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
q Coat the rotating parts and sliding parts with engine oil.
q When press-fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
q After installing the snap rings, check that the snap ring is settled in the ring groove completely.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
them securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When installing split flanges, fasten them uniformly and alternately to prevent excessive tightening on
one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, hydraulic
pumps and other hydraulic component removed for repair, be sure to bleed the air as follows:
1] Start and run the engine at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stop-
ping the piston at 100 mm off the end of its stroke.
3] Next, operate the hydraulic cylinder three to four times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions for completing work

1) Refilling of coolant, oil and grease
q If the coolant is drained, close the drain valve, and add coolant to the specified level. Run the engine
to circulate the coolant through the system. Then add the coolant again if necessary.
q If the hydraulic component is removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then add the oil again if necessary.
q If the hydraulic piping or hydraulic equipment are removed, be sure to bleed air from the system
after reassembling the parts, by referring to "Testing and adjusting".
q Supply the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.

2) Checking cylinder head and manifolds mountings for looseness

Check the cylinder head and intake and exhaust manifold mountings for looseness.
If any part is loosened, retighten it.
q For the tightening torques, see the "Disassembly and assembly".

3) Checking engine piping for damage and looseness

Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
If any part is loosened or damaged, retighten or repair it.

00-34 HB205-1, HB215LC-1

 35
Foreword and general information
Precautions when performing work

4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loosened, retighten it.
5) Checking muffler function
Check the muffler for unusual sound and sound different from that of a new muffler.
If any unusual sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".

HB205-1, HB215LC-1 00-35

 36
Foreword and general information
Handling of hybrid devices and high-voltage wirings

Handling of hybrid devices and high-voltage wirings 36

(Rev. 2012/10)
Hybrid

k 1. In order to handle (such as install or remove) the hybrid devices (motor-generator, swing electric
motor, capacitor, inverter) and high-voltage wirings, you must follow the local Industrial Safety
and Health Law concerning electricity. If you touch a device or a wiring carelessly, you may get an
electric shock and may be injured seriously since high-voltage may be stored in that device.
Never disassemble the hybrid devices or high-voltage wirings. If the devices are disassembled
carelessly, their quality assurance will be lost and a serious trouble may occur.

1. Motor-generator 4. Inverter (control unit)

2. High-voltage wirings (orange) 5. Cooling system
3. Capacitor 6. Swing electric motor

k 2. The hybrid devices and high-voltage wirings (wound with orange conduits) must be replaced by
the assembly.
k 3. When testing, servicing or replacing a hybrid device or a high-voltage wiring, discharge the ca-
pacitor in advance. (For details, see the latter half of this manual)
k 4. The machine is equipped with the capacitor discharge system. If it breaks down, discharge the
capacitor with the capacitor discharger.
k 5. Handling of inverter and capacitor
1) Handling of inverter and capacitor
Handle the inverter and capacitor with extreme care since they have microcomputers and elec-
tronic control circuits in them.
2) Precautions when performing arc welding
When performing arc welding on the body for repair of the machine etc., disconnect all wiring
harness connectors and ground cable connected to the inverter and capacitor. Connect the arc
welding ground cable close to the welding point.

00-36 HB205-1, HB215LC-1

(03)
 37
Precautions for maintenance of hybrid system
Materials for handling hybrid devices and high-volt-
age wirings
(1) Insulating gloves (rubber gloves, etc.)
(2) Safety shoes (insulating type)
(3) Safety glasses
(4) ABC fire extinguisher
(5) Sealing tape (for insulation)
(6) Cloth (rag)
Take care of high voltage and high temperature
This machine has a high-voltage system and some
parts become very hot. Improper handling of it can
cause a serious personal injury such as getting an
electric shock or a burn. The handle-with-care labels
are attached to the hybrid devices and orange
high-voltage wirings. Handle correctly according to
the directions in those labels.
Never disassemble the hybrid devices and
high-voltage wirings (orange).
Precautions for ordinary testing and service
Never disassemble the hybrid devices (motor-
generator, swing electric motor, capacitor, inverter)
and high-voltage wirings (orange).
When the hybrid devices need to be tested, re-
moved and reinstalled, work according to the follow-
ing procedure.
1. Procedure for removing hybrid devices and
high-voltage wirings and testing connection
terminals
1) Put the machine indoors so that the
high-voltage wiring terminals and hybrid
devices etc. to be removed will not be
exposed to rain, dust, etc.
2) Discharge the capacitor according to the
Capacitor discharge procedure described
after.
3) Perform the testing and service with the key
switch OFF.
4) Put on insulating gloves, safety glasses and
safety shoes (insulating type).
HB205-1, HB215LC-1
(03)
Foreword and general information
Handling of hybrid devices and high-voltage wirings
5) Look into the charge level inspection window
at the contactor box above the capacitor.
Check that the LED display for capacitor
charge state indicates "UNCHARGED", then
remove one-touch connector of capacitor.
If it doesn't indicate "UNCHARGED", leave it
until LED goes out. (Leave it for maximum 14
days.)
Clearly write "Do not discharge" on sealing
tape with a marker and stick it on the capac-
itor body.
6) Ensure that the each hybrid device case is
grounded securely to the machine. Check
the continuity between the machine frame
and the hybrid device with a circuit tester.
If the hybrid device case is not grounded, fix
the ground cable securely when performing
step 1) of the reinstallation procedure.
7) Remove the terminal mounting bolt of each
high-voltage wiring and remove the
connector terminal.
8) Measure the voltage between each terminal
of the hybrid device and its case.
1] If the voltage between each terminal and
the case is 30 V or below (safety voltage),
you can remove the hybrid device.
However, do not touch the terminal and
the case simultaneously even at this time.
2] If the above voltage is not below 30 V,
wait for a while until it decreases below 30
V. (If the inverter is normal, no voltage is
applied.)
9) Stick a sealing tape etc. to the connector
insertion hole on each hybrid device side for
insulation.
10) Wrap the connector terminal in a vinyl sheet
etc. to protect it from dirt and then wind a
sealing tape etc. further for insulation.
11) Remove the hybrid device.
2. Reinstallation
1) Install the hybrid device.
2) Thoroughly wipe the connector mounting
face of each hybrid device, thinly apply
grease to the connector sealing rubber, and
insert the connector terminal fully.
3) Fix the connector terminal with the specified
M6 bolt to 8.8 10.8 Nm {0.9 1.1 kgm}.
4) Install the capacitor one-touch connector.
00-37
 38
Foreword and general information
Handling of hybrid devices and high-voltage wirings

treme care for safety.

1) Put on insulating gloves (rubber gloves etc.),
safety glasses and safety shoes (insulating
Precautions when machine tips over or hybrid
type).
device is broken
2) Be sure to stop the engine so that a high
When the machine tips over or any hybrid device or
voltage will not be applied to the hybrid
high-voltage wiring (orange) is broken in an acci-
devices.
dent, if you touch them carelessly, you may be in-
3) Lift up the machine above the water with
jured seriously.
another machine.
In such a case, observe the following items and
4) Discharge the capacitor with the capacitor
work with extreme care for safety.
discharger.
1) When servicing, be sure to stop the engine
5) Remove the capacitor one-touch connector.
so that a high voltage will not be applied to
6) Look into the charge state inspection window
the hybrid devices.
at the contactor box above the capacitor, and
2) If a fire breaks out on the machine, put it out
check that the LED display for capacitor state
with the "ABC fire extinguisher" (for both oil
indicates "UNCHARGED".
and electric fires).
If it doesn't indicate "UNCHARGED", leave it
It is rather dangerous to try to extinguish a
until LED goes out. (Leave it for maximum 14
fire with a small amount of water. When extin-
days.)
guishing with water, splash a large quantity
Clearly write "Do not discharge" on sealing
of water from a hydrant etc.
tape with a marker and stick it on the capac-
3) Put on insulating gloves (rubber gloves etc.),
itor body.
safety glasses and safety shoes (insulating
7) Perform testing, service, removal, etc. of the
type).
hybrid devices according to steps 5) and
4) Raise the machine with another machine and
after in "Precautions for ordinary testing and
move it to a safe place.
service" described above.
5) Do not touch a bare wire which is unknown if
it is a high-voltage wiring. If it is obliged or
Precautions in cold weather
possible for you to touch such a wire, put on
q In a cold weather the upper structure swings at
insulating gloves, ensure that the voltage
the normal speed but the work equipment speed
between the wire and the machine body is
and travel speed become slower than at the nor-
below 30 V (safety voltage), and then insu-
mal temperature, thus the machine does not
late the wire with a sealing tape.
move as the operator expects. Warm up the ma-
6) Remove the capacitor one-touch connector.
chine sufficiently since it may collide with an ob-
7) Discharge the capacitor with the capacitor
stacle.
discharger.
q If it is required to move the machine before
8) Look into the charge state inspection window
warming it up, fully recognize the difference of
at the contactor box above the capacitor, and
the movement of the machine and work equip-
check that the LED display for capacitor state
ment in work equipment operation, travel opera-
indicates "UNCHARGED".
tion, and swing operation, then operate the
If it doesn't indicate "UNCHARGED", leave it
machine carefully.
until LED goes out. (Leave it for maximum 14
days.)
Procedure for discharging capacitor
Clearly write "Do not discharge" on sealing
If the hybrid system is normal, the capacitor can be
tape and stick it on the capacitor body.
discharged by operating the machine monitor. In this
9) Perform testing, service, removal, etc. of the
case, the charge in the capacitor is consumed by the
hybrid devices according to steps 6) and
motor-generator. Accordingly, when the hybrid sys-
after in "Precautions for ordinary testing and
tem is stopped, the capacitor cannot be discharged
service" described above.
with the machine monitor, depending on the type of
If the capacitor case is broken, take extreme
the occurring error (see the table described later). In
care not to touch the cells directly.
this case, the capacitor must be discharged with the
special capacitor discharger.
Precautions when submerged
a Even if an error disables the machine monitor
If the hybrid devices are submerged, they may mal-
from discharging the capacitor, the machine
function and can cause a trouble and the machine
monitor screen can "change to the screen for
may not be operated safely. If you touch the ma-
discharging and perform the discharge opera-
chine carelessly, you may get an electric shock and
tion". However, do not perform the discharge op-
may be injured seriously. In such a case, observe
eration.
the following items and test and service with ex-

00-38 HB205-1, HB215LC-1

(03)
 39
a You cannot swing the upper structure while the
capacitor is being discharged but you can oper-
ate the work equipment. Take care.
1. Turn the key switch ON, start the engine, and set
the engine speed to low idle.
2. While pressing machine monitor switch "4", input
"1+2+3" to enter the service mode.
3. Select "08 Discharge capacitor" in the service
menu and press "F6".
HB205-1, HB215LC-1
(03)
Foreword and general information
Handling of hybrid devices and high-voltage wirings
4. Press "F1" to start discharging.
Since the charge in the capacitor is consumed
through the motor-generator by this operation,
the engine speed increases temporarily. This is
normal.
5. Wait for approximately 20 minutes. If the
message "Capacitor charge ratio 0%" is
displayed, discharging is finished.
00-39
 40
Foreword and general information
Handling of hybrid devices and high-voltage wirings

6. Look into the charge level inspection window at the contactor box above the capacitor and check that the
capacitor charge level indicator LED indicates discharged.
The capacitor is discharged completely now.
a If the capacitor charge ratio does not decrease in 5 minutes, or if the LED does not indicate "UN-
CHARGED" when the capacitor charge ratio is "0%", or "Completed" is not indicated and LED doesn't
indicate "UNCHARGED" when 30 minutes passed after starting discharge, the capacitor is not dis-
charged for some reason. In this case, immediately stop discharging the capacitor with the machine
monitor, and then use the special capacitor discharger.
a If the capacitor is not discharged after discharging by capacitor discharger, leave it until LED lamp goes
out. (Leaving period: maximum 14 days) Stick a piece of sealing tape to the capacitor body and write
down "Discharge is not available" with a felt-tip pen.
a If LED lamp lights up again after discharging and leaving, perform the discharge from Step 1 again, or
leave it until LED lamp goes out. (Leaving period: maximum 14 days)

7. Turn the key switch to the OFF position to stop the engine completely.
a If key switch operation such as the following is performed, capacitor performs electric charge again.
Do not perform the following operation.
q After turning key switch to the OFF position, turn the key switch to the ON position before the engine
stops completely.
q After turning key switch to the OFF position and the engine stops completely, turn key switch to the
ON position to start the engine.

00-40 HB205-1, HB215LC-1

(03)
 41
Foreword and general information
Handling of hybrid devices and high-voltage wirings

a Even if the capacitor charge ratio is 0, the capacitor voltage has not decreased to 0 V perfectly. Be-
cause of the characteristics of the capacitor, its voltage tends to increase again a little to 0 30 V after
it is discharged. Accordingly, take extreme care when disconnecting the connector or performing other
service work.

Errors that disable machine monitor from discharging capacitor

Errors shown in the table below disable machine monitor from discharging capacitor.
Even if an error disables the machine monitor from discharging the capacitor, the machine monitor screen can
"change to the screen for discharging and perform the discharge operation". However, do not perform the dis-
charge operation.
Capacitor discharge with machine monitor cannot be performed when the following errors are indicated.

Errors related to high-voltage circuit Errors related to motor-generator circuit

Failure Failure
Failure name Failure name
code code
GA00NS HYB Equipment Overheat GA17KR Gen. Mot. Drv. Communication Failure
GA02KZ DC Line Open & Short Circuit GA17KZ Gen. Motor Driver Open/Short Circuit
GA01KA Power Cable Interlock Open Circuit GA17MB Gen. Mot. Drv. Function Degraded
GA04KG Abnormal DC HW Volt. Before Booster GA19KK Gen. Mot. Drv. Sub-CPU Low Sup. Volt.
GA05KG Abnormal DC SW Volt. Before Booster GA19KR Gen. Motor Driver Sub-CPU Comm. Failure
GA05KP Low DC SW Output Volt. Bef. Booster GA19KT Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.
GA06KZ DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster GA19MA Gen. Mot. Drv. Sub-CPU Malfunction
GA08KG Abnorm. DC HW Volt. After Booster GA19MC Gen. Mot. Drv. Sub-CPU Defect. Operation
GA09KG Abnorm. DC SW Volt. After Booster GA19NA Gen. Mot. Drv. Sub-CPU Start Disabled
GA09KP Low DC SW Output Volt. After Booster GA1BMA Gen. Mot. Dr. DC Vlt. Sens. Malfunction
GA0AKZ DC Vlt. Sen. Op./Shrt cir. Aft. booster GA25MA Gen. Motor Driver IGBT0 Abnormality
GA12NK HYB Cont. Pow. Suppl. Not Turn. ON GA26MA Gen. Motor Driver IGBT1 Abnormality
GA12NL HYB Cont. Pow. Suppl. Not Turn. OFF GA60N1 Generator Motor Overrun
GA18MC Gen. Mo.Dr. Excite. Pow. Sup. Failure GA62KY Gen. Mot. Ph-A Cur. Sen. Power Short Cir
GA1SFS Contactor Locked GA62KZ Gen. Mot. Ph-A Cur. Sen. Open/Short Cir
GA1SMC Contactor Failure GA62MA Gen. Mot. Ph-A Current Sen. Malfunction
GA1VMC Capacitor Contactor Failure GA63KY Gen. Mot. Ph-B Cur. Sen. Power Short Cir.
GA63KZ Gen. Mot. Ph-B Cur. Sen. Open/Short Cir.
GA63MA Gen. Mot. Ph-B Current Sen. Malfunction
GA64KY Gen. Mot. Ph-C Cur. Sen. Power Short Cir.
GA64KZ Gen. Mot. Ph-C Cur. Sen. Open/Short Cir.
GA64MA Gen. Mot. Ph-C Current Sen. Malfunction
GA70MD HYB Swing Motor Defective Stirr. Motion

HB205-1, HB215LC-1 00-41

(03)
 42
Foreword and general information
Standard tightening torque table

Standard tightening torque table 42

(Rev. 2010/03)
1. Table of tightening torques for bolts and nuts
a Unless otherwise specified, tighten metric nuts and bolts to the torque shown in the following table.

1) The following table applies to the bolts in Fig. A.

Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10(10) 11.8 14.7 1.2 1.5
8 13(12) 27 34 2.8 3.5
10 17(14) 59 74 6.0 7.5
12 19(17) 98 123 10.0 12.5
14 22 157 196 16 20
16 24 245 309 25 31.5
18 27 343 427 35 43.5
20 30 490 608 50 62
22 32 662 829 67.5 84.5
24 36 824 1,030 84 105
27 41 1,180 1,470 120 150
30 46 1,520 1,910 155 195
33 50 1,960 2,450 200 250
36 55 2,450 3,040 250 310
39 60 2,890 3,630 295 370
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.

2) The following table applies to the bolts in Fig. B.

Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0
8 12 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 17 74.5 90.2 7.6 9.2

Fig. A Fig. B

aValues with ( ) are applied to (*) marked bolt (flange bolt) as the width across flats.

00-42 HB205-1, HB215LC-1

 43
Foreword and general information
Standard tightening torque table

2. Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten split flanged bolts to the torque shown in the following table.
Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
10 14 59 74 6.0 7.5
12 17 98 123 10.0 12.5
16 22 235 285 23.5 29.5

3. Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten O-ring boss piping joints to the torque shown in the following table.
Thread diam- Width across
Tightening torque (Nm {kgm})
Nominal No. eter flats
mm mm Range Target
02 14 35 63 {3.5 6.5} 44 {4.5}
03, 04 20 Varies 84 132 {8.5 13.5} 103 {10.5}
depending on
05, 06 24 128 186 {13.0 19.0} 157 {16.0}
type of con-
10, 12 33 nector. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1,010 {76.0 103} 883 {90.0}

4. Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten O-ring boss plugs to the torque shown in the following table.
Thread diam- Width across
Tightening torque (Nm {kgm})
Nominal No. eter flats
mm mm Range Target
08 8 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}
10 10 17 9.8 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 {9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 127.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}

HB205-1, HB215LC-1 00-43

 44
Foreword and general information
Standard tightening torque table

5. Table of tightening torque for hoses (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a Apply the following torque when the threads are coated with engine oil (wetted).
Tightening torque (Nm {kgm}) Taper seal Face seal
Nominal Width Nominal No.
number of across Thread
Thread size Number of
hose flats (mm) Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 54 {3.5 5.5} 44 {4.5} 9/16 18UN 14.3
02 19
34 63 {3.5 6.5} 44 {4.5} 14
22 54 93 {5.5 9.5} 74 {7.5} 11/16 16UN 17.5
03
24 59 98 {6.0 10.0} 78 {8.0} 18
04 27 84 132 {8.5 13.5} 103 {10.5} 22 13/16 16UN 20.6
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1 14UNS 25.4
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1-3/16 12UN 30.2
(10) 41 177 245 {18.0 25.0} 216 {22.0} 33
(12) 46 197 294 {20.0 30.0} 245 {25.0} 36
(14) 55 246 343 {25.0 35.0} 294 {30.0} 42

6. Table of tightening torque for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Tightening torque (Nm {kgm}) Face seal
Outer diam- Width across
eter of pipe flats Nominal No. Thread diameter
(mm) (mm) Range Target Number of threads, (mm)
type of thread (Reference)
8 19 14 16 {1.4 1.6} 15 {1.5} 9/16 18UN 14.3
10 22 24 27 {2.4 2.7} 25.5 {2.6} 11/16 16UN 17.5
12 24 (27) 43 47 {4.4 4.8} 45 {4.6} 13/16 16UN 20.6
15 (16) 30 (32) 60 68 {6.1 6.8} 64 {6.5} 1 14UNS 25.4
22 (20) 36 90 95 {9.2 9.7} 92.5 {9.4} 1 3/16 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

00-44 HB205-1, HB215LC-1

 45
Foreword and general information
Standard tightening torque table

7. Table of tightening torque for 102, 107 and 114 engine series (bolts and nuts)
a Unless otherwise specified, tighten the metric bolts and nuts used for the 102, 107 and 114 engine se-
ries to the torque shown in the following table.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14

8. Table of tightening torque for 102, 107 and 114 engine series (eye joints)
a Unless otherwise specified, tighten the metric eye joints used for the 102, 107 and 114 engine series
to the torque shown in the following table.
Thread size Tightening torque
mm Nm kgm
6 82 0.81 0.20
8 10 2 1.02 0.20
10 12 2 1.22 0.20
12 24 4 2.45 0.41
14 36 5 3.67 0.51

9. Table of tightening torque for 102, 107 and 114 engine series (taper screws)
a Unless otherwise specified, tighten NPT screws used for the 102, 107 and 114 engine series to the
torque shown in the following table.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 2 1.53 0.20 51 0.51 0.10
1/8 20 2 2.04 0.20 15 2 1.53 0.20
1/4 25 3 2.55 0.31 20 2 2.04 0.20
3/8 35 4 3.57 0.41 25 3 2.55 0.31
1/2 55 6 5.61 0.61 35 4 3.57 0.41
3/4 75 8 7.65 0.82 45 5 4.59 0.51

HB205-1, HB215LC-1 00-45

 46
Foreword and general information
List of Abbreviation

List of Abbreviation 46

(Rev. 2010/03)
q This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline
of the meaning.
q Abbreviations that are used in general society may not be included.
q Special abbreviations that appear infrequently are marked in the text with an *.
q This list of abbreviations consists of two parts. The first part is a list of abbreviations used in the text of the
manual, and the second part is a list of abbreviations used in circuit diagrams.
List of abbreviations used in the shop manual
Purpose of use (major
Abbrevia-
Full Spelling applicable machine (*), or Explanation
tion
component/system)
With this function, when the tires skid (wheels stop
Travel and brake
A.B.S. Anti-skid Brake System rotating), the brakes are released, and when the
(HD, HM)
wheels start to rotate, the brakes are applied again.
Automatic Idling Setting
A.I.S.S. Engine This function automatically sets the idle speed.
System
Instead of a steering wheel, a lever is used to per-
Advanced Joystick Steer- Steering
A.J.S.S. form the steering operations as well as to shift gear
ing System (WA)
and change direction (forward or reverse).
When the machine is traveling downhill, if the
Automatic Retarder Accel- Travel and brake accelerator pedal is released, this function auto-
A.R.A.C.
erator Control (HD, HM) matically applies the retarder with a constant brak-
ing force.
When the machine is traveling downhill, if the
accelerator pedal is released, this function auto-
Automatic Retarder Speed Travel and brake
A.R.S.C. matically applies the retarder to ensure that the
Control (HD, HM)
machine speed does not accelerate above the
speed set by the operator.
When the rear wheels spin on soft ground sur-
Travel and brake
A.S.R. Automatic Spin Regulator faces, this function automatically uses the optimum
(HD, HM)
braking force to drive both wheels.
A device that can be fixed onto a machine in order
ATT. Attachment Work equipment
to enable it to do different jobs.
When the retarder is not being used, this valve
Brake Cooling oil control Brake
B.C.V. bypasses part of the brake cooling oil to reduce the
Valve (HD)
load on the hydraulic pump.
Communication and elec- Communications standard standardized as
C.A.N. Controller Area Network
tronic control ISO11898.
System that can simultaneously actuate multiple
Closed-center Load Sens-
C.L.S.S. Hydraulic actuators regardless of the load (provides better
ing System
ease of combined operation than O.L.S.S.).
Uses engine controller to perform electronic control
of supply pump, common rail, and injector. Func-
C.R.I. Common Rail Injection Engine
tions to maintain optimum fuel injection amount
and fuel injection timing.
Electronic control device that uses the signals from
E.C.M. Electronic Control Module Electronic control system the sensors on the machine to indicate to the actu-
ators the optimum actuation. (same as ECU)
Proportional electromagnetic valve that gradually
Electronic Control Modula- Transmission
E.C.M.V. increases oil pressure to engage clutch and
tion Valve (D, HD, WA, etc.)
reduces transmission shock.
System that ensures smooth high-speed travel by
Electronically Controlled Travel
E.C.S.S. using hydraulic spring effect of accumulator to
Suspension System (WA)
absorb vibration of machine during travel
Electronic control device that uses the signals from
E.C.U. Electronic Control Unit Electronic control system the sensors on the machine to indicate to the actu-
ators the optimum actuation. (same as ECM)
Functions to recirculate part of exhaust gas to com-
E.G.R. Exhaust Gas Recirculation Engine bustion chamber in order to reduce combustion
temperature, controls emission of Nox.

00-46 HB205-1, HB215LC-1

 47
Foreword and general information
List of Abbreviation

Purpose of use (major

Abbrevia-
Full Spelling applicable machine (*), or Explanation
tion
component/system)
System that allows data (filter, oil replacement
Equipment Management interval, malfunctions on machine, failure code,
E.M.M.S. Machine monitor
Monitoring System and failure history) from each sensor on the
machine to be checked on monitor.
Control system that moves an actuator in propor-
Electromagnetic Propor-
E.P.C. Hydraulic tion to the amperage of an electric current passing
tional Control
through the solenoid.
F-N-R Forward-Neutral-Reverse Operation Position of the gear shift lever or switch.
System that is used to determine the current loca-
Communication tion on the Earth of a ship, car, machine, etc. by
G.P.S. Global Positioning System
(KOMTRAX, VHMS) receiving the radio wave signals transmitted from
the navigation satellites.
Steering function that uses a combination of
Hydrostatic Steering Sys- Steering hydraulic motor and bevel shaft to control differ-
H.S.S.
tem (D) ence in travel speed of right and left tracks to turn
machine without using steering clutch.
Hydraulic transmission system that uses a combi-
Transmission
H.S.T. Hydro Static Transmission nation of hydraulic pump and hydraulic motor to
(D, WA)
shift gear steplessly without using gears.
Valve installed at inlet port of pump to adjust fuel
I.M.A. Inlet Metering Actuator Engine intake amount in order to control fuel discharge
amount of supply pump. Same as IMV.
Valve installed at inlet port of pump to adjust fuel
I.M.V. Inlet Metering Valve Engine intake amount in order to control fuel discharge
amount of supply pump. Described as IMV (IMA).
Image display device made up of a large number of
L.C.D. Liquid Crystal Display Machine monitor
pixels filled with liquid crystal.
Semiconductor element that emits light when the
L.E.D. Light Emitting Diode Electronic parts voltage is applied in forward direction, positive volt-
age to anode and negative voltage to cathode.
Function that senses differential pressure of pump
L.S. Load Sensing Hydraulic
and controls discharge amount according to load.
Service that allows transmission and reception of
Multimedia Messaging
M.M.S. Communication short messages consisting of characters or voice
Service
or images between cell phones.
Device actuated to open electric or hydraulic cir-
N.C. Normally Closed Electric and hydraulic
cuits that are normally closed if not actuated.
Device actuated to close electric or hydraulic cir-
N.O. Normally Open Electric and hydraulic
cuits that are normally open if not actuated.
Open-center Load Sens- Hydraulic system that can operate multiple actua-
O.L.S.S. Hydraulic
ing System tors at the same time, regardless of the load.
P.C. Pressure Control Hydraulic Controlling the oil pressure.
System in which a controller instantly analyses
Palm Command Control Steering data from each lever, pedal, and dial, and performs
P.C.C.S.
System (D) optimum electronic control of the engine and trans-
mission.
Valve installed at inlet port of pump to adjust fuel
P.C.V. Pump Control Valve Engine intake amount in order to control fuel discharge
amount of supply pump.
Proportional Pressure Control system that moves an actuator in propor-
P.P.C. Hydraulic
Control tion to the oil pressure.
Hydraulic
P.P.M. Piston Pump and Motor Piston pump and motor.
(D, PC, etc.)
P.T.O. Power Take Off Power transmission A device to take off power of the engine.
Power Tilt and power Pitch Work equipment Function that performs hydraulic control of the tilt
P.T.P.
dozer (D) and pitch of the bulldozer blade.

HB205-1, HB215LC-1 00-47

 48
Foreword and general information
List of Abbreviation

Purpose of use (major

Abbrevia-
Full Spelling applicable machine (*), or Explanation
tion
component/system)
International System of Units (abbreviated SI from
the French Le Systeme Internationale dUnites) is
the modern form of the metric system, and is the
Le Systeme International worlds most widely used system of measurement.
S.I. Unit
d Unites Therere seven base units: meter (m), kilogram
(kg), second (s), ampere (A), kelvin (K), candela
(cd), and mole (mol). The derived units include
Pascal (Pa), Newton (N), etc.
Solenoid is a loop of wire. However, as a matter of
fact in engineering, it refers to an actuator consists
of a solenoid and an iron core that is moved by the
SOL. Solenoid Electric
magnetic force when the solenoid is energized.
The word solenoid also often refers to a solenoid
valve.
T.W.V. Two Way Valve Hydraulic and electric Solenoid valve that switches over direction of flow.
Communications system that transmits machine
data, such as the present position of the machine,
Monitoring and communica- daily or aggregate hours of operation, fuel con-
Vehicle Health Monitoring
V.H.M.S. tion sumption, radiator coolant temperature, oil or filter
System
(D, HD, PC, WA: Large size) replacement interval, to make it possible to collect
and check this data from a distant place (Devel-
oped for use on large machines used in mines).
*: Code for machine family
D: bulldozer
HD: dump truck
HM: articulate dump truck
PC: hydraulic excavator
WA: wheel loader

00-48 HB205-1, HB215LC-1

 49
Foreword and general information
List of Abbreviation

List of abbreviations used in the circuit diagrams

Abbreviation Full Spelling
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
SW Switch
T/C Torque Converter
T/M Transmission

HB205-1, HB215LC-1 00-49

 50
Foreword and general information
Conversion table

Conversion table 50

(Rev. 2010/03)
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the meth-
od of using the conversion table, see the example given below.

Example: Method of using the conversion table to convert from millimeters to inches

1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from milli-
meters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2) Perform the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-50 HB205-1, HB215LC-1

 51
Foreword and general information
Conversion table

Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 52.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

HB205-1, HB215LC-1 00-51

 52
Foreword and general information
Conversion table

Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-52 HB205-1, HB215LC-1

 53
Foreword and general information
Conversion table

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408

100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119

150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830

200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542

HB205-1, HB215LC-1 00-53

 54
Foreword and general information
Conversion table

Temperature

Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-54 HB205-1, HB215LC-1

 0-1
HB205-1, HB215LC-1

HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1

Machine model Serial number

HB205-1 1001 and up
HB215LC-1 1001 and up

01 Specifications 30-1

HB205-1, HB215LC-1 01-1

 2
Contents

Contents 0-1

01 Specifications
Specifications.......................................................................................................................... 01- 3 3
Outline of hybrid system ...................................................................................................... 01- 3 3
Specification dimension drawing.......................................................................................... 01- 4 4
Working range diagram........................................................................................................ 01- 5 5
Specifications....................................................................................................................... 01- 6 6
Weight table ......................................................................................................................... 01- 9 9
Table of fuel, coolant and lubricants .................................................................................... 01- 11 11

01-2 HB205-1, HB215LC-1

 3
Specifications
Outline of hybrid system

Specifications 3

Outline of hybrid system 3

This machine is equipped with the hybrid system consisting of an electric motor and a diesel engine to reduce
fuel consumption.

Configuration of hybrid system

In the hybrid system of this machine, the high-voltage wirings connecting the hybrid devices of about 550 V
(motor-generator, swing electric motor, capacitor, inverter) and other devices and the cooling system become
high temperature in the machine operation.

1. Motor-generator (*1) 4. Inverter (control unit) (*1)

2. High-voltage wirings (orange) (*1) 5. Cooling system
3. Capacitor (*1) 6. Swing electric motor (*1)

*1: Indicates the high voltage (550 V) portions.

Low fuel consumption by hybrid system

q The upper structure is swung with the swing electric motor and the kinetic energy generated when the
swing brake operates is converted into electric energy and stored in the capacitor.
The stored electric energy is supplied to the swing electric motor when the upper structure is swung next
time.
q When the control lever is in neutral, the engine speed is decreased to the minimum to reduce fuel con-
sumption.
The engine speed is controlled according to the lever operation quantity, operation pattern and load so
that the fuel consumption efficiency will be kept best.

HB205-1, HB215LC-1 01-3

 4
Specifications
Specification dimension drawing

Specification dimension drawing 4

Item Unit HB205-1 HB215LC-1

A Overall length mm 9,425 9,425
B Overall height mm 2,970 2,970
C Overall width mm 2,800 3,080
D Shoe width mm 600 700
E Cab height mm 3,040 3,040
F Tail swing radius mm 2,750 2,750
G Overall track length mm 4,070 4,450
H Length of track on ground mm 3,275 3,655
Max. ground clearance mm 440 440

01-4 HB205-1, HB215LC-1

 5
Specifications
Working range diagram

Working range diagram 5

Item Unit HB205-1 HB215LC-1

A Max. digging reach mm 9,875 9,875
B Max. digging depth mm 6,620 6,620
C Max. digging height mm 10,000 10,000
D Max. vertical wall depth mm 5,980 5,980
E Max. dumping height mm 7,110 7,110
F Min. dumping height mm 2,645 2,645
G Max. reach at ground level mm 9,700 9,700

HB205-1, HB215LC-1 01-5

 6
Specifications
Specifications

Specifications 6

Machine model HB205-1 HB215LC-1

Serial number 1001 and up 1001 and up
Bucket capacity m3 0.9 0.9
Machine mass kg 19,800 21,200
Max. digging depth mm 6,620 6,620
Working ranges

Max. vertical wall depth mm 5,980 5,980

Max. digging reach mm 9,875 9,875
Max. reach at ground level mm 9,700 9,700
Max. digging height mm 10,000 10,000
Performance

Max. dumping height mm 7,110 7,110

Max. digging force 138.3 {14,100} 138.3 {14,100}
kN {kg}
(when power max. function is turned on) (149.1 {15,200}) (149.1 {15,200})
Swing speed rpm 12.4 12.4
Swing operation max. slope angle deg. 25 25
Travel speed km/h Lo: 3.0 Mi: 4.1 Hi: 5.5 Lo: 3.0 Mi: 4.1 Hi: 5.5
Gradeability deg. 35 35
Ground pressure (Standard shoe) kPa {kg/cm2} 46.1 {0.47} 44.1 {0.45}
Overall length mm 9,425 9,425
Overall width mm 2,800 3,080
Overall track width mm 2,800 3,080
Overall height (During transportation) (*) mm 3,040 (Cab height) 3,040
Machine body overall height (*) mm 3,040 (Cab height) 3,040
Ground clearance of upper structure
mm 1,085 1,085
Dimensions

bottom
Max. ground clearance mm 440 440
Tail swing radius mm 2,750 2,750
Min. swing radius of work equipment mm 3,040 3,040
Top height at min. swing radius of work
mm 8,005 8,005
equipment
Length of track on ground mm 3,275 3,655
Track gauge mm 2,200 2,380
Machine cab height mm 2,390 2,390
Width of standard shoe mm 600 700

*: Grouser height (26 mm) included.

01-6 HB205-1, HB215LC-1

 7
Specifications
Specifications

Machine model HB205-1 HB215LC-1

Serial number 1001 and up 1001 and up
Model SAA4D107E-1-A
4-cycle, water-cooled in-line, direct injection with
Type
turbocharger and air-cooled aftercooler
Number of cylinders bore x stroke mm 4 107 124
Piston displacement l {cc} 4.46 {4,460}
Rated horsepower kW/rpm {HP/rpm}
Net [ISO9249/JISD0006-1] 104/2,000 {139/2,000}
Performance
Engine

Gross [SAEJ1995] 110/2,000 {148/2,000}

Max. torque Nm/rpm {kgm/rpm} 573/1,700 {58.5/1,700}
High idle under no load rpm 2,060
Low idle under no load rpm 1,050, 700
Min. fuel consumption ratio g/kWh {g/HPh} 215 {155}
Starting motor 24 V, 5.5 kW
Alternator 24 V, 35 A
Battery 12 V, 110 Ah 2
Radiator type Corrugated aluminum, 5 array
Undercarriage

Carrier roller 2 on one side

Track roller 7 on one side 9 on one side

Assembly-type triple grosser Assembly-type triple grosser
Track shoe
45 on one side 49 on one side
Type and numbers Variable displacement piston type (HPV95 + 95) 2
Hydraulic
pump

Delivery l/min Piston: 219.5 2

Set pressure MPa {kg/cm2} Piston: 37.2 {380}

Control

Type and numbers 6-spool type: 1

valve

Operating method Hydraulic

Hydraulic system

Hydraulic cylinder Hydraulic

motor

Variable displacement piston type (HMV110ADT-2) 2

Travel motor
(with brake valve and parking brake)

Boom (*1) Arm (*1) (*2) Bucket

Type Double acting piston Double acting piston Double acting piston
Cylinder inner diameter mm 120 135 115
Piston rod diameter mm 85 95 80
Stroke mm 1,334.5 1,490 1,120
Max. pin-to-pin distance mm 3,204.5 3,565 2,800
Min. pin-to-pin distance mm 1,870 2,075 1,680
Hydraulic tank Closed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (CF40-1)

*1: Cushion is provided on the head side

*2: Cushion is provided on the bottom side

HB205-1, HB215LC-1 01-7

 8
Specifications
Specifications

Machine model HB205-1, HB215LC-1

Serial number 1001 and up
Type and
3-phase motor 1
quantity
Operating
Electric motor

Motor-generator 550V (DC)

voltage
Electrical equipment

Drive method Direct coupling with engine

Type and
3-phase motor 1
Swing electric quantity
motor Operating
550V (AC)
voltage
Type and
Control unit Inverter 1
quantity
Type and
Electric storage device Capacitor 1
quantity

01-8 HB205-1, HB215LC-1

 9
Specifications
Weight table

Weight table 9

k This weight table is prepared for your reference when handling or transporting the components.

Unit: kg
Machine model HB205-1, HB215LC-1
Serial number 1001 and up
Engine assembly 840 840
q Engine *1 452 452
q Motor-generator *1 225 225
q Hydraulic pump 152 152
Radiator and oil cooler assembly 158 158
Inverter *1 38 38
Capacitor *1 85 85
Hydraulic tank and filter assembly (Not including
123 123
hydraulic oil)
Fuel tank assembly (Not including fuel) 134 134
Revolving frame 1,803 1,803
Cab 480 480
Operator's seat 35 35
Counterweight 3,260 3,260
Swing machinery 229 229
Control valve 235 235
Swing electric motor *1 71 71
Travel motor 93 2 93 2
Center swivel joint 36 36
Track frame assembly (Not including piping) 4,264 4,862
q Track frame 2,260 2,649
q Swing circle 273 273
q Idler 101 2 101 2
q Idler cushion 118 2 129 2
q Carrier roller 14 4 14 4
q Track roller 36 14 36 18
q Final drive (including travel motor) 322 2 322 2
Track shoe assembly
q Standard triple shoe (600 mm) 1,215 2 1,325 2
q Standard triple shoe (700 mm) 1,405 2 1,530 2

HB205-1, HB215LC-1 01-9

 10
Specifications
Weight table

Unit: kg
Machine model HB205-1, HB215LC-1
Serial number 1001 and up
Boom assembly 1,393
Arm assembly 633
Bucket assembly 633
Boom cylinder assembly 173 2
Arm cylinder assembly 223
Bucket cylinder assembly 133
Link (large) assembly 83
Link (small) assembly 22 2
Boom pin 42 + 8 2 + 28 + 10 + 26
Arm pin 12 + 8
Bucket pin 20 2
Link pin 13 2

01-10 HB205-1, HB215LC-1

 11
Specifications
Table of fuel, coolant and lubricants

Table of fuel, coolant and lubricants 1

a For details of the notes (Note 1, Note 2... ) in the table, see Operation and Maintenance Manual.

q ASTM: American Society of Testing and Material

HB205-1, HB215LC-1 01-11

(03)
 12
Specifications
Table of fuel, coolant and lubricants

Unit: l
HB205-1, HB215LC-1
Refilling points
Specified capacity Refill capacity
Engine oil pan *1 20 18
Motor-generator case *1 6.5 6.0
Swing electric motor case *1 2.3 1.6
Swing machinery case *1 7.1 7.1
Final drive case
3.5 3.3
(each sides)
Hydraulic system 232 135
Fuel tank 400
Engine cooling system *1 17.3
Hybrid device cooling system *1 6.8 5.4

Note 1: The power train oil and engine oil are different from each other. Use oils recommended for them re-
spectively.
Note 2: When environment preservation is important in river works, marine and shore works, forest works,
etc., recommend use of bio hydraulic oil and bio grease.
Note 3: Hyper white grease (G0-T, G2-T) indicates high-performance white grease.
Recommend use of G0-T or G2-T in the following cases.
(1): Lubrication performance of grease is required to prevent the pins and bushings from creaking.
(2): Outside staining with black grease needs to be prevented.
Note 4: Do not use bio grease to the rolling bearings, including the swing bearing.

Features of grease (reference)

Rolling bearing
Item Heavy load Wear-resistant lubrication Heat-resistant Water-resistant Biodegradable Remarks
(fretting-resistant)
Non-black
Hyper White
w w w w w heavy duty
Grease
grease

Lithium
E Q w Q Q
grease
Synthetic
Bio grease E Q w Q w biodegradable
lithium grease
w: Excellent Q: Satisfactory E: Average : Low

Note 5: Super coolant

(1) Super Coolant has important functions as a corrosion inhibitor for the cooling system in addition to the
function of preventing freezing.
Use Super Coolant even in an area where freeze prevention is not required.
Do not recommend other coolants than Komatsu genuine Super Coolant (AF-NAC) in principle. Using another
coolant can cause critical failure to the cooling system including the engine.
(2) For the mixing proportion of Super Coolant and water, see Disassembly and assembly, "Draining, refilling
and air bleeding procedure for coolant in hybrid system".
When the machine is shipped, Super Coolant AF-NAC is added more than 30% unless otherwise specified.
Accordingly, its concentration does not need to be changed as long as the temperature does not decrease
below 10C.
If the temperature decreases below 10C, adjust the mixing proportion of Super Coolant and water according
to the mixing proportion table in Disassembly and assembly, "Draining, refilling and air bleeding procedure for
coolant in hybrid system".
(3) Be sure to keep the concentration of Super Coolant above 30% to maintain its corrosion inhibition ability.

01-12 HB205-1, HB215LC-1

(03)
 0-1
HB205-1, HB215LC-1

HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1

Machine model Serial number

HB205-1 1001 and up
HB215LC-1 1001 and up

10 Structure and function 30-1

HB205-1, HB215LC-1 10-1

 2
Contents

Contents 10-2

10 Structure and function

Engine and cooling system ..................................................................................................... 10- 3 3
Engine related parts............................................................................................................. 10- 3 3
Cooling system .................................................................................................................... 10- 4 4
Hybrid relation......................................................................................................................... 10- 6 6
Configuration and safety functions of hybrid system ........................................................... 10- 6 6
Cooling system of hybrid component................................................................................... 10- 10 10
Motor-generator ................................................................................................................... 10- 12 12
Swing electric motor............................................................................................................. 10- 13 13
Electric control unit............................................................................................................... 10- 14 14
High-voltage wiring (power cable)........................................................................................ 10- 15 15
Water pump ......................................................................................................................... 10- 16 16
Power train system ................................................................................................................. 10- 18 18
Power train........................................................................................................................... 10- 18 18
Swing circle.......................................................................................................................... 10- 19 19
Swing machinery.................................................................................................................. 10- 20 20
Swing brake ......................................................................................................................... 10- 22 22
Final drive ............................................................................................................................ 10- 24 24
Undercarriage and frame ........................................................................................................ 10- 26 26
Track frame and idler cushion.............................................................................................. 10- 26 26
Hydraulic system..................................................................................................................... 10- 28 28
Hydraulic components layout drawing ................................................................................. 10- 28 28
Valve control ........................................................................................................................ 10- 30 30
Hydraulic tank ...................................................................................................................... 10- 31 31
CLSS.................................................................................................................................... 10- 32 32
Main pump ........................................................................................................................... 10- 36 36
Control valve ........................................................................................................................ 10- 58 58
Functions and operation by valve ........................................................................................ 10- 70 70
Travel motor......................................................................................................................... 10-107 107
PPC valve ............................................................................................................................ 10-117 117
Solenoid valve...................................................................................................................... 10-136 136
Attachment circuit selector valve ......................................................................................... 10-138 138
Return oil filter...................................................................................................................... 10-140 140
Center swivel joint................................................................................................................ 10-142 142
Accumulator ......................................................................................................................... 10-143 143
Electrical system ..................................................................................................................... 10- 144 144
Electrical control system ...................................................................................................... 10-144 144
Machine monitor system ...................................................................................................... 10-174 174
KOMTRAX system............................................................................................................... 10-190 190
Sensors................................................................................................................................ 10-192 192

10-2 HB205-1, HB215LC-1

 3
Engine and cooling system
Engine related parts

Engine and cooling system 3

Engine related parts 3

1. Muffler Outline
2. Rear engine mount The motor-generator is mounted.
3. Front engine mount
4. Motor-generator ( )

HB205-1, HB215LC-1 10-3

 4
Engine and cooling system
Cooling system

Cooling system 4

10-4 HB205-1, HB215LC-1

 5
Engine and cooling system
Cooling system

1. Radiator outlet hose

2. Radiator cap for hybrid system ( )
3. Radiator
4. Air conditioner condenser
5. Radiator for hybrid system ( )
6. Fuel cooler
7. Reservoir tank
8. Aftercooler outlet tube
9. Shroud
10. Fan
11. Fan guard
12. Aftercooler
13. Oil cooler
14. Radiator cap
15. Radiator inlet hose

Specifications
Radiator: Corrugated aluminum 5-array
Oil cooler: CF40-1
Aftercooler: Corrugated aluminum
Fuel cooler: Drawn cup type
Radiator for hybrid system: Corrugated aluminum ( )

HB205-1, HB215LC-1 10-5

 6
Hybrid relation
Configuration and safety functions of hybrid system

Hybrid relation 6

Configuration and safety functions of hybrid system 6

Configuration of hybrid system

The high-voltage system of the hybrid system is not grounded and is insulated from the machine frame inside
the case of each hybrid device and the shield braid of the high-voltage wiring.
Therefore, you will not get an electric shock, unless you break the insulation of the high-voltage system and
touch the positive and negative sides simultaneously.
In addition, the case of each hybrid device and the shield braid are grounded to the machine frame through
flexible cables or other devices.

1. Motor-generator case
2. Engine
3. Motor-generator high-voltage portion
4. Connector
5. High-voltage wiring
6. Capacitor case
7. Inverter case
8. Swing electric motor case
9. Inverter high-voltage portion
10. Swing electric motor high-voltage portion
11. Capacitor high-voltage portion
12. Swing machinery
13. Machine frame
14. Flexible cable

a. Insulation
b. Shield braid

10-6 HB205-1, HB215LC-1

 7
Hybrid relation
Configuration and safety functions of hybrid system

Protection function of hybrid devices

To minimize breakage of the hybrid devices when electric leakage occurs, the inverter contains a ground leak-
age detector, which detects insulation deterioration of the high voltage device and a short circuit to the ma-
chine body and stops the components in the inverter (inverter unit, booster, driver).

Conditions for stopping whole hybrid system

1. When the temperature of the swing electric motor, motor-generator, inverter, or capacitor exceeds the
following system stop temperature
Example of corresponding failure code: [GA00NS] HYB Equipment Overheat
System stop temperature
Component name Portion name Monitoring item name
[C]
Swing electric motor Stator coil Swing electric motor coil temperature 160
Motor-generator Generator coil Motor-generator temperature 190
Booster transformer Booster inductor temperature 130
Booster IGBT junction* 135
Inverter Booster IGBT base Booster IGBT temperature 100
IGBT junction for PM* Swing inverter JCT temperature 135
IGBT junction for SR* Generator driver IGBT base temperature 100
Capacitor

The values of items marked with * are not measured but estimated from calculation.

2. When an overcurrent is detected in the swing electric motor or motor-generator (including breakage of a
fuse)
Or, when an abnormality is detected in the current sensor
Example of corresponding failure code: [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir
[GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction

3. When an overvoltage is detected in the high-voltage wiring

Or, when an abnormality is detected in the voltage sensor
Example of corresponding failure code: [GA08KG] Abnorm. DC HW Volt. After Booster
[GA0AKZ] DC Vlt. Sen. Op./Shrt cir. Aft. booster

4. When an abnormality is detected in the high-voltage wiring connector (open circuit, hot short circuit, or
ground fault in the interlock circuit)
Example of corresponding failure code: [GA01KA] Power Cable Interlock Open Circuit

5. When swing emergency stop switch is pressed

Example of corresponding failure code: [GAA100] Swing Emergency Stop Operation

6. When an earth leakage is detected

Example of corresponding failure code: [GA02KZ] DC Line Open & Short Circuit
[GA0BKZ] AC line Open & Short Circuit

7. When an abnormality is detected in the capacitor or in its high-voltage wiring (including wrong connection)
Example of corresponding failure code: [GA02KZ] DC Line Open & Short Circuit
[GA04KG] Abnormal DC HW Volt. Before Booster

HB205-1, HB215LC-1 10-7

 8
Hybrid relation
Configuration and safety functions of hybrid system

Protection function of hybrid devices

1. High voltage
2. Overcurrent
(swing electric motor, motor-generator)
3. Overcurrent (high-voltage line)
4. Defective connector
5. Emergency stop switch
6. Ground leakage detector (built-in inverter)
7. Fuse is broken when capacitor cable has short
circuit

10-8 HB205-1, HB215LC-1

 9
Hybrid relation
Configuration and safety functions of hybrid system

Safety functions when disassembling hybrid component

1. If the key switch is turned to the OFF position, each hybrid device is disconnected from the high voltage
power supply.
The 2 contactors for connecting the inverter and capacitor are opened and no power is supplied to the
capacitor. Electric charge in inverter is consumed by motor-generator when key is OFF. If motor-generator
stops its function due to error etc., electric charge is discharged by internal discharge resistor in a few
minutes.
2. Even if the key switch is ON, when a high-voltage wiring is removed, the interlock switch performs the
above disconnecting operation.
3. The capacitor can be discharged by consuming it in the motor-generator with the discharge function of the
monitor.

Since the electrode of the one-touch connector is protected with the insulator and waterproof seal and
cannot be touched easily, safety is secured even while there is charge left in the capacitor.

HB205-1, HB215LC-1 10-9

 10
Hybrid relation
Cooling system of hybrid component

Cooling system of hybrid component 10

Configuration of cooling system

1. Swing electric motor a. Passages of cooling and lubricating oil

2. Stator coil temperature b. Passage of coolant
3. Stator coil c. Temperature sensor
4. Radiator
5. Hybrid radiator
6. Engine
7. Motor-generator
8. Coil temperature
9. Pump
10. Rotor
11. Coil
12. Cooling and lubricating oil pumps
13. Inverter
14. Water pump
15. Inside of booster
16. Capacitor
17. Capacitor cell
18. Temperature of capacitor cell and bus bar
19. Oil cooler

10-10 HB205-1, HB215LC-1

 11
Hybrid relation
Cooling system of hybrid component

Interlock function
This function checks for a loose or disconnected connector in the high-voltage wiring (power cable) and out-
puts an error signal to the monitor and stops the hybrid system if it detects an abnormality.

The interlock circuit in the following figure is installed to the high-voltage wiring connectors of the
motor-generator, inverter, and swing electric motor. If any contact in the circuit is disconnected due to reverse
assemble of connector or coming off of connector, interlock function judges it as an abnormality and stops
hybrid system.
This function also checks the interlock circuit and stops the hybrid system if it detects abnormality in the circuit,
outputting the error signal similarly to the above.

The power cable connectors marked with a and connected to the inverter are also equipped with interlock
circuits, which check for loose or disconnected connectors.

Interlock circuit diagram

1. Swing electric motor 6. Interlock circuit

2. Disconnection of connector 7. Interlock output
3. Motor-generator 8. Interlock input
4. Inverter
5. Capacitor a. High-voltage wiring

HB205-1, HB215LC-1 10-11

 12
Hybrid relation
Motor-generator

Motor-generator 12

1. Generator 5. Oil feed pipe

2. Lubrication pump 6. Level gauge
(for motor-generator and swing electric motor) 7. Filter
3. Coolant pipe 8. Oil cooler
4. Coolant pipe

Function Specifications
q The motor-generator coverts the rotation and Model: ZG031
torque of the engine into electric power and sup- Lubricating oil:
plies it to the swing electric motor. Specified capacity: 6.5 l
q The motor-generator receives electric power Refill capacity: 6.0 l
from the capacitor and assists the engine output. Oil type: TO10
Weight: 229 kg

10-12 HB205-1, HB215LC-1

(03)
 13
Hybrid relation
Swing electric motor

Swing electric motor 13

Serial No.: 1001 2634

1. Swing electric motor 5. Coolant outlet

2. Oil filler plug 6. Lubricating oil inlet
3. Level gauge 7. Lubricating oil outlet
4. Coolant inlet 8. Lubricating oil drain

Function Specifications
q The swing electric motor converts the electric Model: ZM102
power supplied from the generator and capacitor Specified oil capacity: 2.3 l
into rotation and torque of the motor output shaft Refill capacity: 1.6 l
and transmits it to the swing machinery. Oil type: TO10
q The swing electric motor coverts the kinetic en- Weight: 71 kg
ergy of the upper structure into electric power
and supplies it to the capacitor.

HB205-1, HB215LC-1 10-13

(04)
 14
Hybrid relation
Swing electric motor

Serial No.: 2635 and up

A. Lubricating oil inlet 1. Swing electric motor

B. Coolant inlet 2. Oil filler and level gauge
C. Lubricating oil drain
D. Lubricating oil outlet
E. Coolant outlet

Function Specifications
q The swing electric motor converts the electric Model: ZM103
power supplied from the generator and capacitor Specified oil capacity: 2.5 l
into rotation and torque of the motor output shaft Refill capacity: 1.7 l
and transmits it to the swing machinery. Oil type: TO10
q The swing electric motor coverts the kinetic en- Weight: 65 kg
ergy of the upper structure into electric power
and supplies it to the capacitor.

10-13-1 HB205-1, HB215LC-1

(04)
 15
Hybrid relation
Swing electric motor

HB205-1, HB215LC-1 10-13-2

(04)
 14
Hybrid relation
Electric control unit

Electric control unit 14

1. Inverter 3. Mount rubber

2. Capacitor

Function Specifications
q Motor-generator control Inverter model: ZD110
q Swing motor control Fuse rating: 150 A
q Capacitor charge and discharge control Total weight: 123 kg
Inverter weight: 38 kg

10-14 HB205-1, HB215LC-1

 15
Hybrid relation
High-voltage wiring (power cable)

High-voltage wiring (power cable) 15

1. High-voltage wiring (motor-generator) A: Motor-generator

2. High-voltage wiring (motor-generator) B: Electric control unit
3. High-voltage wiring (swing electric motor) C: Swing electric motor
4. High-voltage wiring (capacitor)

Function Specifications
q The high-voltage wiring supplies high-voltage q Waterproof and shield structure
power.
q The high-voltage wiring connectors are distin-
guished with number of block wirings respective-
ly to prevent a wrong connection.
q Each high-voltage wiring connector is equipped
with an interlock switch. If the connector is dis-
connected, the switch is opened and the hybrid
system stops.

HB205-1, HB215LC-1 10-15

 16
Hybrid relation
Water pump

Water pump 16

1. Water pump

Function Specifications
q This pump starts when the key is turned to ON q Rated voltage: 24 V
position. q Rated ampere: 2.4 A
q This pump is driven with the electricity from the q Weight: 2.1 kg
battery.
q This pump circulates the coolant for the hybrid
components.
q This pump sucks in the coolant from the hybrid
component radiator and discharges it to the ca-
pacitor.

10-16 HB205-1, HB215LC-1

 17
Hybrid relation
Water pump

HB205-1, HB215LC-1 10-17

 18
Power train system
Power train

Power train system 18

Power train 18

1. Idler
2. Center swivel joint
3. Control valve
4. Final drive
5. Travel motor (HMV110ADT-2)
6. Hydraulic pump (HPV95 + 95)
7. Motor-generator ( )
8. Engine (SAA4D107E-1)
9. Travel speed solenoid valve
10. Swing brake solenoid valve
11. Swing electric motor (ZM102) ( )
12. Swing machinery
13. Swing circle

10-18 HB205-1, HB215LC-1

 19
Power train system
Swing circle

Swing circle 19

1. Swing circle inner race (No. of teeth: 96) a. Inner race soft zone "S" position
2. Ball b. Outer race soft zone "S" position
3. Swing circle outer race
Specifications
Reduction ratio 96/13 = 7.385
Grease G2-LI
Amount of filled grease (l) 14.6

HB205-1, HB215LC-1 10-19

 20
Power train system
Swing machinery

Swing machinery 20

10-20 HB205-1, HB215LC-1

 21
Power train system
Swing machinery

1. Swing pinion (No. of teeth: 13)

2. Cover
3. Plate
4. No. 3 sun gear
5. No. 3 planetary gear
6. No. 3 planetary carrier
7. No. 2 ring gear
8. No. 2 planetary carrier
9. No. 2 planetary gear
Specifications
Reduction ratio: ((17 + 58)/17) x ((18 + 58)/18) x ((16 + 62)/16) = 90.811

HB205-1, HB215LC-1 10-21

 22
Power train system
Swing brake

Swing brake 2

1. Case
2. No.1 planetary carrier
3. No.1 ring gear
4. No. 2 sun gear
5. No.1 planetary gear
6. Spring
7. No.1 sun gear
8. Brake piston
9. Brake gear
10. Brake plate
11. Brake disc

10-22 HB205-1, HB215LC-1

 23
Power train system
Swing brake

HB205-1, HB215LC-1 10-23

 24
Power train system
Final drive

Final drive 24

10-24 HB205-1, HB215LC-1

 25
Power train system
Final drive

1. Level plug
2. No. 1 planetary gear (No. of teeth: 42)
3. Drain plug
4. No. 1 sun gear (No. of teeth: 10)
5. No. 2 sun gear (No. of teeth: 21)
6. No. 1 planetary carrier
7. Cover
8. No. 2 planetary carrier
9. Gear hub (No. of teeth: 95)
10. Sprocket
11. Floating seal
12. Travel motor
13. No. 2 planetary gear (No. of teeth: 36)

Specifications
Reduction ratio: ((10 + 95)/10) x ((21 + 95)/21) + 1 = 57.000

HB205-1, HB215LC-1 10-25

 26
Undercarriage and frame
Track frame and idler cushion

Undercarriage and frame 26

Track frame and idler cushion 26

1. Idler q The dimensions and the number of track rollers

2. Track frame depend on the model, but the basic structure is
3. Carrier roller not different.
4. Final drive q Number of track rollers
5. Track roller
Model Q'ty (One side)
6. Track shoe
HB205-1 7
7. Center guard
HB215LC-1 9
8. Front guard

10-26 HB205-1, HB215LC-1

 27
Undercarriage and frame
Track frame and idler cushion

Standard shoe
Models
HB205-1 HB215LC-1
Item
Shoe width (mm) 600 700
Link pitch (mm) 190 190
Q'ty (One side) 45 49

HB205-1, HB215LC-1 10-27

 28
Hydraulic system
Hydraulic components layout drawing

Hydraulic system 28

Hydraulic components layout drawing 28

1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Right PPC valve
5. Hydraulic tank
6. Hydraulic oil filter
7. R.H. travel motor
8. Main pump
9. Control valve
10. Oil cooler
11. L.H. travel motor
12. Left PPC valve
13. Lock lever
14. Center swivel joint
15. Travel PPC valve
16. Accumulator
17. Solenoid valve assembly
17A. PPC lock solenoid valve
17B. 2-stage relief solenoid valve
17C. Swing brake solenoid valve
17D. Travel speed solenoid valve
17E. Travel junction solenoid valve

10-28 HB205-1, HB215LC-1

 29
Hydraulic system
Hydraulic components layout drawing

HB205-1, HB215LC-1 10-29

 30
Hydraulic system
Valve control

Valve control 30

1. Travel PPC valve 7. Control valve

2. L.H. travel lever 8. Junction box (equipped with pressure sensor
3. R.H. travel lever and pressure switch)
4. R.H. PPC valve 9. Accumulator
5. R.H. work equipment control lever 10. L.H. work equipment control lever
6. Solenoid block 11. L.H. PPC valve
12. Lock lever

10-30 HB205-1, HB215LC-1

 31
Hydraulic system
Hydraulic tank

Hydraulic tank 31

1. Hydraulic tank Specifications

2. Oil filler port cap
3. Filter element Hydraulic tank capacity (l) 190
4. Strainer Amount of oil in hydraulic tank
5. Bypass valve (l) 135
6. Suction strainer Relief valve opening pressure 16.7 6.9
7. Sight gauge (kPa {kg/cm2}) {0.17 0.07}
Suction valve opening pressure 0 0.49
(kPa {kg/cm2}) {0 0.005}
Bypass valve set pressure 0.15 0.03
(MPa {kg/cm2}) {1.5 0.3}

HB205-1, HB215LC-1 10-31

 32
Hydraulic system
CLSS

CLSS 32

Outline of CLSS

Features Configuration
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with variable capacity piston
tem, which has the following characteristics: pumps, control valves, and respective actuators.
q The hydraulic pump is configured with pump
q Fine control not influenced by load body, PC valve and LS valve.
q Controllability enabling digging even with fine
control
q Ease of compound operation ensured by flow di-
vider function using area of opening of spool dur-
ing compound operations
q Energy saving using variable pump control

10-32 HB205-1, HB215LC-1

 33
Basic principle
Pump swash plate angle control
q The pump swash plate angle (pump delivery) is
controlled so that LS differential pressure
(dPLS) (the difference between pump pressure
(PP) and control valve outlet port LS pressure
(PLS)) (load pressure of actuator) is constant.
q [LS differential pressure (dPLS) = Pump dis-
charge pressure (PP) LS pressure (PLS)]
HB205-1, HB215LC-1
Hydraulic system
CLSS
q The pump swash plate angle shifts toward the
maximum position if LS differential pressure
(dPLS) is lower than the set pressure of the LS
valve (when the actuator load pressure is high).
q If it becomes higher than the set pressure (when
the actuator load pressure is low), the pump
swash plate angle shifts toward the minimum po-
sition.
LS differential pressure (dPLS) and pump swash
plate angle
a For details of functions, see the Main pump
paragraph.
10-33
 34
Hydraulic system
CLSS

Pressure compensation control

q A pressure compensation valve is installed to

the outlet port side of the control valve to balance
the load.
q When actuators are operated together, the pres-
sure difference (dP) between the upstream (inlet
port) and downstream (outlet port) of the spool of
each valve becomes the same regardless the
size of the load (pressure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of opening
(S1) and (S2) of each valve.

10-34 HB205-1, HB215LC-1

 35
Hydraulic system
CLSS

System diagram

a The illustration shows the actuator (7) in the

merge mode with stroke end at the time of relief.

1. Front pump 9. LS circuit

2. Rear pump 10. Tank circuit
3. Main relief valve 11. Valve
4. Unload valve 12. Spring
5. Merge-divider valve 13. LS bypass valve
6. Control valve 14. LS valve
7. Actuator 15. PC valve
8. Pump circuit

HB205-1, HB215LC-1 10-35

 36
Hydraulic system
Main pump

Main pump 36

Type: HPV95+95

10-36 HB205-1, HB215LC-1

 37
Hydraulic system
Main pump

Outline
q This pump consists of two variable capacity
swash plate piston pumps, PC valve, LS valve,
and EPC valve.

IMF: Front PC mode selector current

IMR: Rear PC mode selector current
ISIG: LS set pressure selector current
PAF: Front pump delivery port
PAR: Rear pump delivery port
PBF: Pump pressure input port
PD1F: Case drain port
PD1R: Air bleeder
PD2F: Drain plug
PD2R: Drain plug
PENF: Front control pressure pickup port
PENR: Rear control pressure pickup port
PEPC: EPC source pressure port
PEPCC: EPC source pressure pickup port
PFC: Front pump discharge pressure pickup port
PLSF: Front load pressure input port
PLSFC: Front load pressure pickup port
PLSR: Rear load pressure input port
PLSRC: Rear load pressure pickup port
PMF: Front PC mode selector pressure pickup port
PMR: Rear PC mode selector pressure pickup port
PRC: Rear pump discharge pressure pickup port
PS: Pump suction port
PSIG: LS set selector pressure pickup port

1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve

HB205-1, HB215LC-1 10-37

 38
Hydraulic system
Main pump

1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve

10-38 HB205-1, HB215LC-1

 39
Hydraulic system
Main pump

Function
q The pump converts the engine torque transmit- q Cylinder block (7) seals the pressurized oil to
ted to its shaft into oil pressure and delivers pres- valve plate (8) and performs relative rotation.
surized oil corresponding to the load. q This surface is designed so that the oil pressure
q It is possible to change the discharge amount by balance is maintained at a suitable level.
changing the swash plate angle. q The oil inside the respective cylinder chambers
of cylinder block (7) is suctioned and discharged
Structure through valve plate (8).
q Cylinder block (7) is connected with shaft (1) on
spline (14).
q Shaft (1) is supported by front and rear bearings
(15).
q Tip of piston (6) is shaped as a concave sphere
and shoe (5) is caulked to it to form one unit.
q Piston (6) and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe (5)
is always pressed against this surface while slid-
ing in a circular movement.
q Rocker cam (4) conducts high pressure oil to the
cylindrical surface (B) with cradle (2), which is
secured to the case, and forms a static pressure
bearing with oil when it pivots.
q Piston (6) performs the reciprocation inside each
cylinder chamber of cylinder block (7).

HB205-1, HB215LC-1 10-39

 40
Hydraulic system
Main pump

Operation of pump
q Cylinder block (7) rotates together with shaft (1),
and shoe (5) slides on flat surface (A).
q When this happens, rocker cam (4) moves along
cylindrical surface (B), so angle (a) between cen-
ter line (X) of rocker cam (4) and the axis of cyl-
inder block (7) changes.
q (a) is named the swash plate angle.
q As center line (X) of rocker cam (4) matches the
axis of cylinder block (7) (swash plate angle (a)
= 0), the difference between volumes (E) and (F)
inside cylinder block (7) becomes 0.
q Suction and discharge of pressurized oil is not
performed in this stage. Namely pumping action
is not performed. (Actually, however, the swash
plate angle is not set to 0)

q With center line (X) of rocker cam (4) at a swash

plate angle (a) in relation to the axis of cylinder
block (7), flat surface (A) acts as a cam in rela-
tion to shoe (5).
q In this way, piston (6) slides on the inside of cyl-
inder block (7), so a difference between volumes
(E) and (F) is created inside cylinder block (7).
q Each piston (6) suctions and discharges the oil
by the amount (F) minus (E).
q As cylinder block (7) rotates and the volume of
chamber (E) decreases, the pressurized oil is
discharged.
q On the other hand, the volume of chamber (F) in-
creases and, in this process, the oil is suctioned.
(In the figure, chamber (F) is at the end of the
suction stroke and chamber (E) is at the end of
the discharge stroke.)

10-40 HB205-1, HB215LC-1

 41
Hydraulic system
Main pump

Control of delivery
q If the swash plate angle (a) increases, the differ-
ence between volumes (E) and (F) increases
and also pump delivery (Q) increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) performs linear reciprocation
according to the signal pressure from the PC
valve and LS valve.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) pivots on the surface
while rotating.
q The pressure receiving area of servo piston (12)
are not equal on the left side and right side. Main
pump discharge pressure (self pressure) (PP)
always applies to the pressure chamber of the
small diameter piston side.
q Output pressure (PEN) of the LS valve applies to
the chamber receiving the pressure at the large
diameter piston end.
q "The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end" and "the
ratio between the area receiving the pressure of
the small diameter piston and the large diameter
piston" control the movement of servo piston
(12).

HB205-1, HB215LC-1 10-41

 42
Hydraulic system
Main pump

LS valve

PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Sheet
PPL: Control pressure input port 6. Sleeve
PSIG: LS mode selector pilot port 7. Plug
8. Locknut

Function
q The LS (load sensing) valve detects the load of
the actuator and controls the discharge amount.
q This valve controls main pump delivery (Q) ac-
cording to differential pressure (dPLS) [=(PP)
(PLS)] (called the LS differential pressure) (be-
tween main pump discharge pressure (PP) and
control valve outlet port pressure (PLS).
q Main pump pressure (PP) and pressure (PLS)
(called the LS pressure) coming from the control
valve output, and pressure (PSIG) (called the LS
selector pressure) from the proportional solenoid
valve enter this valve.
q The relationship between the "LS differential
pressure (dPLS) between the main pump pres-
sure (PP) and LS pressure (PLS) [=(PP)
(PLS)]" and "the pump delivery (Q)" changes as
shown in the diagram according to LS selector
current (ISIG) of the LS-EPC valve.
q If (ISIG) changes from 0 A to 1 A, setting force of
the spring changes, too. As the result, the spec-
ified median of the pump delivery volume switch-
ing point changes as shown in the diagram. It will
change in the range of 0.27 to 1.7 MPa {2.78 to
17.75 kg/cm2}.

10-42 HB205-1, HB215LC-1

 43
Hydraulic system
Main pump

Operation
When the control valve is situated at neutral

q The LS valve is a 3-way selector valve, and pres- q Pump pressure (PP) is conducted to the large di-
sure (PLS) (LS pressure) from the inlet port of ameter end from the port (K).
the control valve applies to spring chamber (B) q The same pump pressure (PP) is conducted to
and main pump discharge pressure (PP) applies the small diameter end from the port (J).
to port (H) of sleeve (8). q According to the difference in the areas on servo
q The relation between the force resulting from piston (12), the pressure moves in such that the
this LS pressure (PLS), force of spring (4) and swash plate angle may be minimized.
the pump delivery pressure (self pressure) (PP)
determine the position of spool (6).
q However, magnitude of the output pressure
(PSIG) (called the LS selector pressure) of the
EPC valve for the LS valve entering port (G) also
changes the position of spool (6). (Setting force
of the spring is changed)
q Before the engine is started, servo piston (12) is
pushed to the left by the spring. (See the figure)
q If the control lever is in the neutral position when
the engine is started, LS pressure (PLS) will be
set to 0 MPa {0 kg/cm2}. (It is interconnected to
the drain circuit through the control valve spool)
q Spool (6) is pushed to the right, and port (C) and
port (D) will be connected.

HB205-1, HB215LC-1 10-43

 44
Hydraulic system
Main pump

Action for the direction of maximizing the pump delivery

q When the difference between the main pump q If the output pressure of the EPC valve for the LS
pressure (PP) and LS pressure (PLS), in other valve enters port (G), rightward force is generat-
words, LS differential pressure (dPLS) becomes ed on piston (7).
smaller (for example, when the area of opening q If piston (7) is pushed to the right, setting force of
of the control valve becomes larger and pump spring (4) is weakened, changing the LS differ-
pressure (PP) drops), spool (6) is pushed to the ential pressure (dPLS) [Difference between oil
left by the combined force of LS pressure (PLS) pressures (PLS) and (PP)] when ports (D) and
and the force of spring (4). (E) of spool (6) are connected.
q When spool (6) moves, port (D) and port (E) are
interconnected and connected with the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K) be-
comes drain pressure (PT). (The operation of the
PC valve is explained later.)
q The pressure at the large diameter end of servo
piston (12) becomes drain pressure (PT), and
pump pressure (PP) enters port (J) at the small
diameter end, so servo piston (12) is pushed to
the left side. Therefore, the swash plate is
moved in the direction to make the discharge
amount larger.

10-44 HB205-1, HB215LC-1

 45
Hydraulic system
Main pump

Action for the direction of minimizing the pump delivery

q When LS differential pressure (dPLS) increases

(for example, when the area of opening of the
control valve decreases and pump pressure
(PP) rises) because of the rightward move (it re-
duces pump delivery) of servo piston (12), pump
pressure (PP) pushes spool (6) to the right.
q When spool (6) moves, pump pressure (PP)
flows from port (C) to port (D) and from port (K),
it enters the large diameter end of the piston.
q Main pump pressure (PP) also enters port (J) of
the small diameter end of the piston, but be-
cause of the difference in area between the large
diameter end and the small diameter end on ser-
vo piston (12), it is pushed to the right. As the re-
sult, the servo piston (12) moves into the
direction of reducing the swash plate angle.
q As LS selector pressure (PSIG) is input to port
(G), setting force of spring (4) is reduced.

HB205-1, HB215LC-1 10-45

 46
Hydraulic system
Main pump

When servo piston is balanced

q Let us take the area receiving the pressure at the q Force of spring (4) is adjusted in such that the
large diameter end of the piston as (A1), the area position of the balanced stop of this spool (6)
receiving the pressure at the small diameter end may be determined when (PP) (PLS) = 1.7
as (A0), and the pressure flowing into the large MPa {17.75 kg/cm2} at the median of the speci-
diameter end of the piston as (PEN). fied value.
q If the main pump pressure (PP) of the LS valve q If (PSIG) [Output pressure of LS-EPC valve, 0 to
and the "combined force of spring (4) and LS 2.9 MPa {0 to 30 kg/cm2}] is input to port (G), the
pressure (PLS)" are balanced, and the relation- position of the balanced stop is changed in the
ship is (A0) x (PP) = (A1) x (PEN), servo piston range of (PP) (PLS) = 1.7 to 0.27 MPa {17.75
(12) will stop in that position. to 2.78 kg/cm2} in proportion to (PSIG) pressure.
q The swash plate of the pump will be held at the
intermediate position. [Spool (6) will be stopped
at a position where the distance of the opening
from port (D) to port (E) and the distance from
port (C) to port (D) is almost the same.]
q At this point, the relationship between the both
pressure receiving areas of servo piston (12) is
(A0) : (A1) = 3 : 5, so the pressure applied to the
both piston ends when it is balanced becomes
(PP) : (PEN) C 5 : 3.

10-46 HB205-1, HB215LC-1

 47
Hydraulic system
Main pump

PC valve

PA: Pump port 1. Plug

PA2: Pump pressure pilot port 2. Servo piston assembly
PDP: Drain port 3. Pin
PM: Mode selector pressure pilot port 4. Spool
PPL: Control pressure output port (to LS valve) 5. Retainer
6. Seat
7. Cover
8. Wiring

Function
q When the pump discharge pressure (PP1) q If the engine speed goes below the specified val-
(self-pressure) and (PP2) (other pump pressure) ue because of increased load, the controller
are high, the PC valve controls the pump so that sends a command current to PC-EPC valve so-
the volume of oil beyond the discharge pres- lenoid in order to reduce the swash plate angle
sure-based specific flow rate may not be con- in proportion to reduction in the engine speed.
ducted however you may increase the control
valve stroke. Namely it is intended at controlling
the horsepower for the pumps so that it may not
exceed the engine hosepower.
q If the pump discharge pressure (PP) increases
due to increased load during operation, this
valve decreases the pump delivery.
q And if the pump discharge pressure goes low, it
increases the pump delivery.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and the pump delivery (Q) will
become as shown in the diagram if the relation is
represented as the parameter of the current val-
ue (X) to be given to PC-EPC valve solenoid.
q The controller continues counting the actual en-
gine speed.
q If the engine speed is slowed down due to in-
creased load, the controller reduces the pump
delivery to recover the speed.

HB205-1, HB215LC-1 10-47

 48
Hydraulic system
Main pump

Operation
When pump controller is normal
When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low

Action of PC-EPC valve solenoid (1)

q Command current (X) is being sent to PC-EPC And for the rear pump pressure, the other
valve solenoid (1) from the pump controller. pump's pressure is that of the front pump.
q This command current (X) acts on PC-EPC
valve to output the signal pressure in order to
modify the force pushing piston (2).
q Spool (3) stops at a position where the combined
spool-pushing force is balanced by the setting
force of springs (4) and (6) as well as the pump
pressures (PP1) (self-pressure) and (PP2) (an-
other pump's pressure).
q The pressure [port (C) pressure] output from PC
valve is changed depending on the above posi-
tion.
q The size of command current (X) is determined
by the working item (lever operation), the select-
ed working mode, and the set value and actual
value of the engine speed.
a Other pumps pressure denotes the pressure of
the pump situated on the opposite side.
For the front pump pressure, the other pump's
pressure is that of the rear pump.

10-48 HB205-1, HB215LC-1

 49
Action of spring
q Load of springs (4) and (6) on the PC valve is de-
termined by the swash plate position.
q As servo piston (9) moves to right, spring (6) is
compressed.
q If the servo piston moves further to right, it will be
contacted against seat (5), and spring (6) will be
fixed (solid).
q After that, spring (4) alone will operate.
q The spring load is changed by servo piston (9)
as it extends or compresses springs (4) and (6).
q If the command current (X) to PC-EPC valve so-
lenoid (1) changes, so does the force pushing
piston (2).
q Spring force of springs (4) and (6) is also affect-
ed by the command current (X) to PC-EPC valve
solenoid.
q Port (C) of the PC valve is connected to port (E)
of the LS valve.
q Self-pressure (PP1) enters port (B) and the small
diameter end of servo piston (9), and other pump
pressure (PP2) enters port (A).
q When pump pressures (PP1) and (PP2) are
small, spool (3) will be positioned in the left side.
HB205-1, HB215LC-1
Hydraulic system
Main pump
q Ports (C) and (D) are connected, and the pres-
sure entering the LS valve becomes drain pres-
sure (PT).
q If port (E) and port (G) of the LS valve are con-
nected, the pressure entering the large diameter
end of the piston from port (J) becomes drain
pressure (PT), and servo piston (9) moves to the
left side.
q The pump delivery will be set to the increasing
trend.
q According to the move of servo piston (9),
springs (4) and (6) will be expanded and the
spring force decreases.
q As the spring force decreases, spool (3) moves
to the right, the connecting between port (C) and
port (D) is shut off and the pump discharge pres-
sure ports (B) and (C) are connected.
q As a result, the pressure on port (C) increases
and the pressure on the large diameter end of
the piston also increases. Thus, the leftward
move of servo piston (9) is stopped.
10-49
 50
Hydraulic system
Main pump

q Servo piston (9) stop position (= Pump delivery)

is decided by the position where the pushing
force generated from the pressures (PP1) and
(PP2) applied to spool (3), the pushing force of
the solenoid in PC-EPC valve generates and the
pushing force of springs (4) and (6) are bal-
anced.

10-50 HB205-1, HB215LC-1

 51
Hydraulic system
Main pump

When load on actuator is large and pump discharge pressure (PP) is high

Outline
q When the load is large and pump discharge
pressures (PP1) and (PP2) are high, the force
pushing spool (3) to the right becomes larger
and spool (3) will be moved to the position
shown in above figure.
q Part of the pressure to be conducted from port
(C) to LS valve flows from port (B) to port (C) and
(D) via LS valve. At the end of this flow, level of
this pressure becomes approximately half of
pump pressure (PP2).
q When spool (3) moves to the left, the openings
of port (C) and port (D) increase.
q As a result, the pressure on port (C) (= J) is de-
creased and the rightward move of servo piston
(9) is stopped.
q The position in which servo piston (9) stops at
this time is further to the right than the position
when pump pressures (PP1) and (PP2) are low.

Operation
q When port (E) and port (G) of the LS valve are
connected, this pressure from port (J) enters the
large diameter end of servo piston (9), and servo
piston (9) is stopped.
q If pump pressure (PP2) increases further and
spool (3) moves further to the right, pump pres-
sure (PP1) flows to port (C) and acts to make the
pump delivery the minimum.
q When servo piston (9) moves to the right,
springs (4) and (6) are compressed and push
back spool (3).

HB205-1, HB215LC-1 10-51

 52
Hydraulic system
Main pump

q The relationship between the average pump

pressure (PP1 + PP2)/2 and servo piston (9) in
terms of their positions can be represented by
the broken line in the figure because of the dou-
ble springs (4) and (6).
q The relationship between the average pump
pressure (PP1 + PP2)/2 and average pump de-
livery (Q) becomes as shown below.

q If command current (X) sent to PC-EPC valve

solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/2,
and pump delivery (Q) is proportional to the force
of the PC-EPC valve solenoid and moves in par-
allel.
q Namely, the force of PC-EPC valve solenoid (1)
is added to the pushing force to the right be-
cause of the pump pressure applied to the spool
(3), so the relationship between the average
pump pressure (PP1 + PP2)/2 and the pump de-
livery (Q) moves from (A) to (B) as the command
current (X) is increased.

10-52 HB205-1, HB215LC-1

 53
Hydraulic system
Main pump

As the emergency pump drive switch is turned "ON" due to failure of the pump controller
When the main pump is under light load

q If there is a failure in the pump controller, the

emergency pump drive switch is turned "ON" to
switch over the control to the resistor side.
q In this case, the power is directly supplied from
the battery. The current, however, is too large as
is, so the resistor is set in between to control the
current flowing to PC-EPC valve solenoid (1).
q The current becomes constant, so the force
pushing piston (2) is also constant.
q If the main pump pressures (PP1) and (PP2) are
low, the combined force of the pump pressure
and the PC-EPC valve solenoid (1) is weaker
than the spring set force, so spool (3) is bal-
anced at a position to the left.
q The port (C) is connected to the drain pressure
of the port (D), and the large diameter end of the
servo piston (9) also becomes the drain pressure
(PT) through the LS valve.
q Since the pressure on the small diameter end of
the piston high, servo piston (9) moves in the di-
rection to increase the delivery.

HB205-1, HB215LC-1 10-53

 54
Hydraulic system
Main pump

When the main pump is under heavy load

q If the emergency pump drive switch is in "ON" q The curve resulting when the emergency pump
position as in above, the command current (X) drive switch is ON is situated further to the left
sent to PC-EPC valve solenoid (1) becomes (B) than when the pump controller is normal (A).
constant.
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q If main pump pressures (PP1) and (PP2) in-
crease, spool (3) moves further to the right than
when the main pump load is light, and is bal-
anced at the position in the figure above.
q In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump delivery) and stops at a position
to the further to the right than when the load on
the pump is light.
q When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump delivery (Q) have a relationship as shown
with the curve in the figure corresponding to the
current sent to the PC-EPC valve solenoid
through the resistor.

10-54 HB205-1, HB215LC-1

 55
Hydraulic system
Main pump

LS (PC)-EPC valve

C: To LS (PC) valve
P: From self-pressure reducing valve
T: To tank

1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger

HB205-1, HB215LC-1 10-55

 56
Hydraulic system
Main pump

Function
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion.
q When it receives signal current (i) from the con-
troller, it generates the EPC output pressure in
proportion to the size of the signal, and outputs it
to the LS (PC) valve.
Operation
When signal current is 0 (coil is de-energized)
q When there is no signal current flowing from the
controller to coil (2), coil (2) is de-energized.
q Spool (5) is pushed to the left by spring (4).
q Port (P) closes and the pressurized oil from the
self-pressure reducing valve does not flow to the
LS (PC) valve.
q The pressurized oil from the LS (PC) valve is
drained to the tank through port (C) and port (T).

10-56 HB205-1, HB215LC-1

 57
When signal current is minute (coil is energized)
q When a minute signal current flows to coil (2),
coil (2) is energized, and a thrust toward the right
is generated on plunger (7).
q Rod (6) pushes spool (5) to the right, and pres-
surized oil flows from port (P) to port (C).
q Pressure on port (C) increases and the force to
act on spool (5) surface and the force of spring
(4) become larger than the thrust of plunger (7).
q Spool (5) is pushed to the left, and port (P) is
shut off from port (C).
q Port (C) and port (T) are connected.
q Spool (5) moves so that the thrust of plunger (7)
may be balanced with pressure of port (C) + the
force of spring (4).
q The circuit pressure between the EPC valve and
the LS (PC) valve is controlled in proportion to
the size of the signal current.
HB205-1, HB215LC-1
Hydraulic system
Main pump
When signal current is maximum (coil is ener-
gized)
q As the signal current flows to coil (2), coil (2) is
energized.
q When this happens, the signal current is at its
maximum, so the thrust of plunger (7) is also at
its maximum.
q Spool (5) is pushed toward right by rod (6).
q The maximum volume of pressurized oil flows
from port (P) to port (C), increasing the circuit
pressure across EPC valve and LS (PC) valve to
the maximum level.
q Since port (T) is closed, the pressurized oil does
not flow to the tank.
10-57
 58
Hydraulic system
Control valve

Control valve 58

Outline
q This control valve consists of a 6-spool valve
(one body composition) and a set of service
valve. A merge-divider valve, a back pressure
valve and a boom hydraulic drift prevention
valve are installed to it.
q The ports which are used on PC200-8 but not
used on this machine are not indicated.
q Since all the valves are assembled together with
connecting bolts and their passes are connected
to each other inside the assembly, the assembly
is compact and easy to maintain.
q With one spool provided for one work equip-
ment, this control valve is simple in construction.

A1: To bucket cylinder head P6: From boom PPC and EPC valves
A2: To L.H. travel motor P9: From R.H. travel PPC valve
A3: To boom cylinder bottom P10: From R.H. travel PPC valve
A5: To R.H. travel motor P11: From arm PPC and EPC valves
A6: To arm cylinder head P12: From arm PPC and EPC valves
A-1: To attachment 1 P-1: From service 1 and PPC valves
ATT: From attachment P-2: From service 1 and PPC valves
B1: To bucket cylinder bottom PLS1: To rear pump control
B2: To L.H. travel motor PLS2: To front pump control
B3: To boom cylinder head PLSC: LS pressure detection port
B5: To R.H. travel motor PP1: From front pump
B6: To arm cylinder bottom PP2: From rear pump
B-1: To attachment 1 PP2S: Pressure sensor mounting port
BP1: From LS select solenoid valve PPC: Pilot basic pressure detection port
BP5: From attachment selector solenoid valve PPS1: Pressure sensor mounting port
C: To tank PPS2: To front pump control
IS1: From controller PR: To solenoid valve, PPC valve, and EPC valve
IS2: From controller PST: From travel junction valve solenoid valve
P1: From bucket PPC and EPC valves PX1: From 2-stage relief solenoid valve
P2: From bucket PPC and EPC valves PX2: From 2-stage relief solenoid valve
P3: From L.H. travel PPC valve T: To tank
P4: From L.H. travel PPC valve T1: To tank
P5: From boom PPC and EPC valves TS: To tank

1. 6-spool valve 5. Merge-divider valve

2. Cover A 6. Boom hydraulic drift prevention valve
3. Cover B 7. Arm hydraulic drift prevention valve
4. Service valve 1 8. Arm quick return valve

10-58 HB205-1, HB215LC-1

 59
Hydraulic system
Control valve

General view
(if equipped with one attachment)

HB205-1, HB215LC-1 10-59

 60
Hydraulic system
Control valve

Sectional view
(1/5)

10-60 HB205-1, HB215LC-1

 61
Hydraulic system
Control valve

1. Pressure compensation valve (Arm IN)

2. Pressure compensation valve (R.H. travel FORWARD)
3. Pressure compensation valve (Boom RAISE)
4. Pressure compensation valve (L.H. travel FORWARD)
5. Pressure compensation valve (Bucket CURL)
6. Pressure compensation valve (Service 1)
7. Pressure compensation valve (Bucket DUMP)
8. Pressure compensation valve (L.H. travel REVERSE)
9. Pressure compensation valve (Boom LOWER)
10. Pressure compensation valve (R.H. travel REVERSE)
11. Pressure compensation valve (Arm OUT)
12. Main relief valve
13. Unload valve
14. Main relief valve
15. Spool (Service 1)
16. Spool (Bucket)
17. Spool (L.H. travel)
18. Spool (Boom)
19. Spool (R.H. travel)
20. Spool (Arm)

HB205-1, HB215LC-1 10-61

 62
Hydraulic system
Control valve

(2/5)

10-62 HB205-1, HB215LC-1

 63
Hydraulic system
Control valve

1. Suction valve (Arm IN)

2. Suction valve (R.H. travel FORWARD)
3. Suction valve (Boom LOWER)
4. Suction valve (L.H. travel FORWARD)
5. Safety-suction valve (Bucket CURL)
6. Safety-suction valve (Service 1)
7. 2-stage safety-suction valve (Service)
8. Safety-suction valve (Bucket DUMP)
9. Suction valve (L.H. travel REVERSE)
10. Safety-suction valve (Boom RAISE)
11. Suction valve (R.H. travel REVERSE)
12. Safety-suction valve (Arm OUT)
13. LS shuttle valve (Arm)
14. LS shuttle valve (R.H. travel)
15. LS shuttle valve (Boom)
16. LS shuttle valve (L.H. travel)
17. LS shuttle valve (Bucket)
18. LS shuttle valve (Service 1)
19. LS check valve
20. Pressure relief plug

HB205-1, HB215LC-1 10-63

 64
Hydraulic system
Control valve

(3/5)

10-64 HB205-1, HB215LC-1

 65
Hydraulic system
Control valve

1. Unload valve
2. Safety valve (Boom RAISE)
3. Main relief valve
4. Lift check valve

Arm valve
5. Arm check valve
6. LS shuttle valve
7. Quick return valve
8. Pressure compensation valve (OUT)
9. Spool
10. Safety-suction valve (OUT)
11. Back pressure valve
12. Regeneration circuit check valve
13. Suction valve (IN)
13A. Safety-suction valve (IN)
14. Pressure compensation valve (IN)

R.H. travel valve

15. LS shuttle valve
16. Pressure compensation valve (REVERSE)
17. Spool
18. Suction valve (REVERSE)
19. Suction valve (FORWARD)
20. Pressure compensation valve (FORWARD)

HB205-1, HB215LC-1 10-65

 66
Hydraulic system
Control valve

(4/5)

10-66 HB205-1, HB215LC-1

 67
Hydraulic system
Control valve

1. Return spring L.H. travel valve

2. Merge-divider valve (for LS)
3. Valve (Sequence valve)
4. Spring (Sequence valve)
5. Merge-divider valve (Main)
6. Return spring
Boom valve
7. Drift prevention valve
8. LS shuttle valve
9. Pressure compensation valve (RAISE)
10. Spool
11. Safety-suction valve (RAISE)
12. Regeneration circuit check valve
13. Suction valve (LOWER)
14. Pressure compensation valve (LOWER)
15. Merge-divider valve (travel junction valve)
16. Return spring
17. LS shuttle valve
18. Pressure compensation valve (REVERSE)
19. Spool
20. Suction valve (REVERSE)
21. Suction valve (FORWARD)
22. Pressure compensation valve (FORWARD)
Bucket valve
23. LS shuttle valve
24. Pressure compensation valve (DUMP)
25. Spool
26. Safety-suction valve (DUMP)
27. Safety-suction valve (CURL)
28. Pressure compensation valve (CURL)

HB205-1, HB215LC-1 10-67

 68
Hydraulic system
Control valve

(5/5)

Service valve 1
1. LS shuttle valve 5. Safety-suction valve
2. Pressure compensation valve 6. Unload valve
3. Spool 7. Main relief valve
4. 2-stage safety-suction valve 8. LS bypass plug

10-68 HB205-1, HB215LC-1

 69
Hydraulic system
Control valve

HB205-1, HB215LC-1 10-69

 70
Hydraulic system
Functions and operation by valve

Functions and operation by valve 70

Hydraulic circuit diagram and the name of valves

10-70 HB205-1, HB215LC-1

 71
Hydraulic system
Functions and operation by valve

1. Arm valve
2. R.H. travel valve
3. Boom valve
4. L.H. travel valve
5. Bucket valve
6. Service valve 1
7. Arm spool
8. R.H. travel spool
9. Boom spool
10. L.H. travel spool
11. Bucket spool
12. Service spool 1
13. Pressure compensation valve
14. Suction valve
15. Check valve (for boom regeneration circuit)
16. Check valve (for arm regeneration circuit)
17. EPC valve (for switching main spool of merge-divider valve)
18. EPC valve (for switching LS spool of merge-divider valve)
19. LS shuttle valve
20. Merge-divider valve
21. Arm quick return valve
22. Arm check valve (for central safety valve circuit)
23. Self-pressure reducing valve
24. Travel junction valve
25. Back pressure valve
26. Cooler check valve
27. Boom drift prevention valve
28. Main relief valve (bucket side)
Set pressure: 35.4 0.5 MPa {360.5 5 kg/cm2}
When digging force increased:
38.0 0.5 MPa {387 5 kg/cm2}
29. Main relief valve (arm side)
Set pressure: 35.4 0.5 MPa {360.5 5 kg/cm2}
When digging force increased:
38.0 0.5 MPa {387 5 kg/cm2}
30. Unload valve (bucket side)
Cracking pressure:
2.5 0.5 MPa {26 5 kg/cm2}
31. Unload valve (arm side)
Cracking pressure:
2.5 0.5 MPa {26 5 kg/cm2}
32. Safety-suction valve
Set pressure: 24.5 0.5 MPa {250 5 kg/cm2}
33. Safety-suction valve
Set pressure: 31.4 0.5 MPa {320 5 kg/cm2}
34. Safety-suction valve
Set pressure: 38.2 0.5 MPa {397 5 kg/cm2}
35. 2-stage safety-suction valve
Set pressure:
1 stage: 24.5 0.5 MPa {250 5 kg/cm2}
2 stage: 20.6 0.5 MPa {210 5 kg/cm2}

HB205-1, HB215LC-1 10-71

 72
Hydraulic system
Functions and operation by valve

Unload valve
When the unload valve is actuating

1. LS circuit 4. Tank circuit

2. Valve 5. Spring
3. Pump circuit

Function
q Drains an oil delivery for the portion of the mini-
mum pump swash plate angle while all control
valves are in the holding.
q The pump pressure will correspond to a set load
of spring (5) inside the valve (this pressure will
be P1).
q Since LS pressure is drained from the LS bypass
valve, LS pressure C tank pressure C 0 MPa {0
kg/cm2}.
Operation
q Pressure of pump circuit (3) is received by the
end of valve (2).
q Since the control valve is in neutral position,
pressure of LS circuit (1) is 0 MPa {0 kg/cm2}.
q Pressurized oil of pump circuit (3) stops at valve
(2), and the pressure rises as no relief is avail-
able.
q When this pressure becomes larger than the
force of spring (5), valve (2) moves to the left.
q Ports (b) and (c) are interconnected and the
pump pressure flows to tank circuit (4).
q The pressurized oil of LS circuit (1) passes from
orifice (a) through port (c) and is drained to the
tank circuit (4).
q When actuated, LS pressure C tank pressure.
q Since the pump discharge pressure LS circuit
pressure during unloading is larger than the
pump LS control pressure, the signal is output to
minimize the pump swash plate angle.

10-72 HB205-1, HB215LC-1

 73
q During operation (a work within a scope of dis-
charge by a minimum swash plate angle), the
discharge pressure for the portion of minimum
pump swash plate angle is set to LS pressure +
P1 pressure.
q LS control differential pressure (dPLS) of dis-
charge for the portion of minimum swash plate
angle will be equal to P1 pressure.
HB205-1, HB215LC-1
Hydraulic system
Functions and operation by valve
Operation of relief valve
q When the cylinder reaches the stroke end, the
main relief valve opens.
q The pump delivery (Q) is relieved to the tank.
(See the system diagram)
q The pump discharge pressure (PP) and LS pres-
sure (PLS) become approximately the same as
each has not flow at the upstream and down-
stream of the spool, and LS differential pressure
(dPLS) becomes 0 MPa {0 kg/cm2}.
q As LS differential pressure (dPLS) is lower than
the LS set pressure of LS valve, LS valve is ac-
tuated to maximize the pump swash plate angle.
q Mechanically, operation of PC valve have the
prevalence to that of LS valve.
q The pump is held at a minimum swash plate an-
gle by the cut-off function of PC valve.
10-73
 74
Hydraulic system
Functions and operation by valve

Introduction of LS pressure

1. Main pump
2. Main spool
3. Pressure compensation valve
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve

Function
q Introduces the upstream pressure (downstream
pressure of the spool meter-in) of pressure com-
pensation valve (3) and leads to LS shuttle valve
(7) as the LS pressure.
q Connected to actuator port (B) through valve (4),
and makes LS pressure C actuator load pres-
sure.
q Inlet pore (a) inside main spool (2) has a small
diameter concurrently serving as a throttle.

Operation
q When main spool (2) is operated, the pump pres-
sure enters port (c) through inlet pore (a) and is
led to the LS circuit.
q When the pump pressure rises to reach the load
pressure of port (B), check valve (5) opens.

10-74 HB205-1, HB215LC-1

 75
Hydraulic system
Functions and operation by valve

LS bypass valve

1. Main pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass valve
6. LS circuit

Function
q Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to pre-
vent a sudden change of hydraulic pressure.
q Bypass flow from LS bypass valve (5) causes a
pressure loss to be generated due to the circuit
resistance between throttle (c) of main spool (2)
and LS shuttle valve (4).
q Effective LS differential pressure drops to im-
prove a dynamic stability of the actuator.

HB205-1, HB215LC-1 10-75

 76
Hydraulic system
Functions and operation by valve

Pressure compensation valve

During independent operation and under maximum load pressure
(If the load pressure is higher than other work equipment during a combined operation)

1. Main pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve

Function q As principle, port (C) and spring chamber (E) are

q Pressure compensation valve works as the load
check valve.
q If the pump pressure (LS pressure) is lower than
the load at port (c), shuttle valve (3) in pressure
compensation valve piston (4) interconnects
spring chamber (E) and port (C).
q The force of spring (5) operates piston (4) and
valve (2) to the closing direction.
not interconnected in an integrated pressure
compensation valve.
q If high peak pressure is generated at port (C),
valve (7) does not collide with the valve cham-
ber.
q With a bucket valve, etc., port (C) and spring
chamber (E) are designed to interconnect before
valve (7) is seated.

Integrated pressure compensation valve

q High stress may occur when valve (2) collides
with valve chamber seat portion (C) if a high
peak pressure is generated in the actuator circuit
or repetitive peak pressure occurs continuously
(example: when using the breaker).
q To prevent this, a pressure compensation valve
with integrated valve (2) and piston (4) is used.
q With the present machine, this device is adopted
for the bucket valve (cylinder bottom) and the
service valve.

10-76 HB205-1, HB215LC-1

 77
Hydraulic system
Functions and operation by valve

When compensated
(If the load pressure is lower than other work equipment during a combined operation)

Function
q The pressure compensation valve closes under
LS pressure of port (D), and the spool meter-in
downstream pressure of port (B) becomes
equivalent to the maximum pressure of other
work equipment.
q Since the spool meter-in upstream pressure of
port (A) is the pump pressure, the spool meter-in
differential pressure [upstream pressure port (A)
pressure] downstream pressure [port (B) pres-
sure] becomes equivalent to all the spools in op-
eration.
q Pump flow is divided according to the ratio of the
meter-in opening area.

Operation
q Spring chamber (E) is interconnected to port (D).
q Piston (4) and valve (2) operate in the closing di-
rection (to the right) under the LS circuit pressure
from other work equipment of port (F).
q Valve upstream pressure (= spool meter-in
downstream pressure) of port (B) is controlled
with LS pressure.

HB205-1, HB215LC-1 10-77

 78
Hydraulic system
Functions and operation by valve

Pressure compensation valve area ratio

Function
q The state of division changes according to the
area ratio of pressure compensation portion (A1)
and (A2). Area ratio = (A2)/(A1)
q If area ratio = 1:
The spool meter-in downstream pressure will be
equal to the maximum load pressure, and the
pressure will be divided according to the opening
area ratio.
q If area ratio = 1 or over:
The spool meter-in downstream pressure will be
greater than the maximum load pressure, and
the pressure will be divided smaller than the
opening area ratio.
q If area ratio = 1 or under:
The spool meter-in downstream pressure will be
smaller than the maximum load pressure, and
the pressure will be divided greater than the
opening area ratio.

10-78 HB205-1, HB215LC-1

 79
Hydraulic system
Functions and operation by valve

Pressure compensation valve inner shuttle valve

If holding pressure at port (A) is larger than LS pressure in the spring chamber (B)

1. Main pump
2. Valve
3. Pressure compensation valve inner shuttle valve
4. Piston

Function
q Shuttle valve (3) is pushed to the right by port (A)
pressure and cuts off interconnection between
ports (A) and (C).
q Holding pressure at port (A) is led to the spring
chamber (B) to push piston (4) to the left so that
piston (4) and valve (2) will not be separated.

HB205-1, HB215LC-1 10-79

 80
Hydraulic system
Functions and operation by valve

In the case of travel

Outline
q Since no holding pressure is generated at port
(A) of the travel circuit, a pressure compensation
valve without shuttle valve (3) is adopted.

10-80 HB205-1, HB215LC-1

 81
Hydraulic system
Functions and operation by valve

Boom regeneration circuit

If the cylinder head pressure is lower than the bottom pressure (free fall, etc.)

1. Main pump 5. Suction valve

2. Boom spool 6. Check valve
3. Pressure compensation valve 7. LS shuttle valve
4. Safety-suction valve

Function
q Provides the regeneration circuit from the cylin-
der bottom to the cylinder head when the boom
is lowered and increases flow to the cylinder
head.
Operation
q If the cylinder head pressure is lower than the
bottom pressure, pressurized oil (A) from the cyl-
inder bottom flows to drain circuit (B) from the
notch of boom spool (2).
q On the other hand, remaining oil flows to regen-
eration circuit (C), opens check valve (6) and
flows to the cylinder head through circuit (D).
q Flow from regeneration circuit (C) and pump (1)
merges in circuit (E).

HB205-1, HB215LC-1 10-81

 82
Hydraulic system
Functions and operation by valve

If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)

Function
q Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.

10-82 HB205-1, HB215LC-1

 83
Hydraulic system
Functions and operation by valve

Arm regeneration circuit

If the cylinder head pressure is higher than the bottom pressure

1. Main pump 5. Suction valve

2. Arm spool 6. Check valve
3. Pressure compensation valve 7. LS shuttle valve
4. Safety-suction valve

Function
q During arm digging, regeneration circuit provid-
ed from the cylinder head to the bottom increas-
es the cylinder speed as the cylinder flow
involves the pump delivery plus regenerated
flow.
Operation
q If the cylinder head pressure is lower than the
bottom pressure, pressurized oil (A) from the cyl-
inder bottom flows to drain circuit (B) from the
notch of arm spool (2).
q On the other hand, remaining oil flows to regen-
eration circuit (C), opens check valve (6) and
flows to the cylinder bottom through circuit (D).
q Flow from regeneration circuit (C) and pump (1)
merges in circuit (E).

HB205-1, HB215LC-1 10-83

 84
Hydraulic system
Functions and operation by valve

If the cylinder head pressure is lower than the bottom pressure

Function
q Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.

10-84 HB205-1, HB215LC-1

 85
Hydraulic system
Functions and operation by valve

Merge-divider valve
When flows from the pumps merge [if merge-divider selector signals (IS1) and (IS2) are OFF]

1. Main spool 6. LS circuit (bucket side)

2. Spring 7. LS circuit (arm side)
3. LS spool 8. LS circuit (arm side)
4. Spring 9. EPC valve (for main spool)
5. LS circuit (bucket side) 10. EPC valve (for LS spool)

Function
q Merges pressurized oil (P1) and (P2) discharged
from the two pumps or divides (to respective
control valve group).
q Merges and divides LS circuit pressure.
Operation
q Since selector signal (IS1) is OFF, output pres-
sure from EPC valve is 0 MPa {0 kg/cm2}.
q Main spool (1) is pressed to the right by spring
(2) and ports (E) and (F) are interconnected.
q Merges pressurized oil (P1) and (P2) discharged
from the two pumps at ports (E) and (F) and
sends to necessary control valve.
q Since selector signal (IS2) is OFF for LS spool
(3), it is pressed to the right by spring (4), and
ports (A) (D) and ports (B) (C) are intercon-
nected.
q Forwards LS pressure led from respective con-
trol valve spools to LS circuits (5), (6), (7) and (8)
to all the pressure compensation valves.

HB205-1, HB215LC-1 10-85

 86
Hydraulic system
Functions and operation by valve

When flows from the pumps divide [if merge-divider selector signals (IS1) and (IS2) are ON]

Operation
q Selector signal (IS1) turns ON, and output pres-
sure from the EPC valve shifts main spool (1) to
the left, and ports (E) and (F) are divided.
q Pressurized oil discharged from the two pumps
are sent to respective control valves.
P1 pressure: To bucket, L.H. travel, and boom
P2 pressure: To swing, R.H. travel, and arm
q When selector signal (IS2) is turned ON, LS
spool (3) also shifts to the left under the output
pressure from the EPC valve, interconnects
ports (A) and (C) and divides other ports.
q Forwards LS pressure led from each control
valve spool to LS circuits (5), (6), (7) and (8) to
respective control valves.

10-86 HB205-1, HB215LC-1

 87
Hydraulic system
Functions and operation by valve

Self-pressure reducing valve

Function
q Reduces the discharge pressure of the main
pump and supplies it as control pressure for the
solenoid valves, EPC valves, etc.

Operation

While engine is stopped

q Poppet (11) is pressed by spring (12) against the
seat and port (PR) is not connected to (TS).
q Valve (14) is pressed by spring (13) against the
left side and port (P2) is connected to (TS).
q Valve (7) is pressed by spring (8) against the left
side and port (P2) is closed to (A2).

HB205-1, HB215LC-1 10-87

 88
Hydraulic system
Functions and operation by valve
During neutral and when load pressure (P2)
is low
a When load pressure (A2) is lower than self-pres-
sure reducing valve output pressure (PR)
q Valve (7) is pressed to the closing direction of
circuit between ports (P2) and (A2) by spring (8)
and under pressure (PR) (which is 0 MPa
{0 kg/cm2}).
q When pressurized oil flows in from port (P2), a
balance is reached due to [(fd area x P2 pres-
sure) = force of spring (8) + (fd area x PR pres-
sure)].
q Adjusts valve (7) opening to keep pressure (P2)
at a constant level over pressure (PR).
q When pressure (PR) rises above the set pres-
sure, poppet (11) opens.
q Pressurized oil flows from port (PR) to orifice (a)
in spool (14), then flows to seal drain port (TS)
from poppet (11) opening.
q Differential pressure is generated before and af-
ter orifice (a) in spool (14) and then spool (14)
moves to close the pass between ports (P2) and
(PR).
q Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the set
pressure) and supplied as pressure (PR).
10-88
When load pressure (P2) is high
q Load pressure (A2) increases with the operation
of digging, etc., and the pump delivery increases
accordingly.
q Pressure (P2) increases to [(fd area x P2 pres-
sure) > force of spring (8) + (fd area x PR pres-
sure)], and valve (7) moves to the right to the
stroke end.
q As a result, opening between ports (P2) and (A2)
increases, and the pass resistance reduces, re-
ducing the engine horsepower loss.
q When pressure (PR) rises above the set pres-
sure, poppet (11) opens.
q Pressurized oil flows from port (PR) to orifice (a)
in spool (14), then flows to seal drain port (TS)
from poppet (11) opening.
q Differential pressure is generated before and af-
ter orifice (a) in spool (14) and then spool (14)
moves to close the pass between ports (P2) and
(PR).
q Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the set
pressure) and supplied as pressure (PR).
HB205-1, HB215LC-1
 89
Hydraulic system
Functions and operation by valve

When abnormally high pressure is generated

q If pressure (PR) of self-pressure reducing valve
becomes abnormally high, ball (16) contracts
spring (15) and becomes separated from the
seat.
q Allows the pressurized oil to port (TS) from port
(PR) and lowers pressure (PR).
q Protects PPC valve, solenoid valve and other
devices from abnormal pressure.

HB205-1, HB215LC-1 10-89

 90
Hydraulic system
Functions and operation by valve

Travel junction valve

When pilot pressure is applied

Function
q This valve connects the L.H. and R.H. travel cir-
cuits through travel junction valve so that the hy-
draulic oil will be supplied evenly to both travel
motors to improve machine's straight travel per-
formance.
q When the machine is steered, outside pilot pres-
sure (PST) closes the travel junction valve to im-
prove steering performance.
Operation
q Pilot pressure from the travel junction solenoid
valve contracts spring (1), and travel junction
spool (2) moves to the left to the stroke end.
q Junction circuit between port (PTL) (L.H. travel
circuit) and port (PTR) (R.H. travel circuit) is
closed.

10-90 HB205-1, HB215LC-1

 91
When pilot pressure is not applied
Operation
q If pilot pressure (PST) from the solenoid valve is
0 MPa {0 kg/cm2}, travel junction spool (2) is
pressed by the force of spring (1) against the
right side and the pass between ports (PTL) and
(PTR) is open.
HB205-1, HB215LC-1
Hydraulic system
Functions and operation by valve
q If the oil flow rates to the L.H. and R.H. travel mo-
tors become different from each other, the oil
flows through the route between port (PTL), trav-
el junction spool (2), and port (PTR) so that the
oil flow rates to both motors will be equalized
again.
10-91
 92
Hydraulic system
Functions and operation by valve

Travel PPC shuttle valve

When travel lever is in neutral

Function
q Regulates flow to each cylinder by controlling
the stroke of each spool of the boom, arm, and
bucket using the pilot pressure of travel PPC
valve while climbing a steep grade, operating the
boom RAISE, arm IN and OUT, and bucket
CURL and Dump.
q When controlling the stroke of the boom, arm
and/or bucket, pilot pressure of travel PPC valve
passes through the circuit inside the control
valves to actuate the system.
Operation
q The oil in stroke regulation signal chamber (a) is
drained through orifices (5) and (6) of pistons (3)
and (4) in the travel spring case and the travel
PPC valve.
q When operated for boom RAISE (or arm IN and
OUT, bucket CURL and DUMP), spool (1)
moves to the left until it makes contact with the
end face of spring casing (2) (st0).

10-92 HB205-1, HB215LC-1

 93
Hydraulic system
Functions and operation by valve

When traveling

Operation
q If the right travel lever is set in the reverse (or for-
ward) direction, pilot pressure from the PPC
valve presses spool (7) to the left (or right).
q Spool (7) pushes piston (3) to close orifice (5)
and shut off stroke regulation signal chamber (a)
and the drain circuit of the travel PPC valve.
q At this time, the right travel reverse (or forward)
lever is set, PPC pressure is applied through or-
ifice (6) of piston (4) to the left end of piston (8)
to push piston (8) to the right.
q When operated for boom RAISE (or arm IN and
OUT, bucket CURL and DUMP), spool (1) moves
to the left.
q Maximum stroke of the spool is limited to (st1) for
the amount of movement (st2) of piston (8) to the
right.

HB205-1, HB215LC-1 10-93

 94
Hydraulic system
Functions and operation by valve

Boom hydraulic drift prevention valve

When raising boom

Function
q This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) and the
boom from lowering under its weight while the
boom lever is not operated.

Operation
q When the boom is raised, pressurized oil from
the control valve works on the ring-shaped area
(S) caused by the difference between outside di-
ameter (d1) of poppet (5) and seat diameter (d2)
to move it to the left.
q Contracts spring (4) and poppet (5) moves to the
left.
q As a result, pressurized oil from the control valve
passes through the opening of poppet (5) and
flows to the bottom end of the boom cylinder.

10-94 HB205-1, HB215LC-1

 95
Hydraulic system
Functions and operation by valve

When the boom is in neutral

Operation
q Moves the lever to neutral with the boom raised.
q Pressurized oil flown inside poppet (5) from ori-
fice (a) of poppet (5) is closed by pilot piston (2).
q Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom
are shut off.
q The holding pressure of boom cylinder bottom
works on the ring-shaped area (S) caused by the
difference between outside diameter (d1) of pop-
pet (5) and seat diameter (d2) to move it to the
right.
q The sum of this force and the force of spring (4)
closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom
are shut off.

HB205-1, HB215LC-1 10-95

 96
Hydraulic system
Functions and operation by valve

When lowering boom

Operation
q When the boom is lowered, pilot pressure from
the PPC valve presses pilot piston (2).
q Pressurized oil in chamber (b) inside the poppet
is drained through orifice (c).
q Pressurized oil of the boom bottom flows to ori-
fice (a) o chamber (b) o orifice (c) o drain (T),
and the pressurized oil in chamber (b) lowers.
q As the pressure of chamber (b) lowers under the
pressure of port (B), poppet (5) opens.
q Pressurized oil from port (B) is led to port (A) and
then flows to the control valve.

10-96 HB205-1, HB215LC-1

 97
Hydraulic system
Functions and operation by valve

Arm hydraulic drift prevention valve (if equipped)

When arm OUT

Function
q This valve prevents the oil in the arm head from
leaking through spool (1) and the boom from
lowering under its weight while the arm lever is
not operated.

Operation
q When the arm OUT is operated, pressurized oil
from the control valve works on the ring-shaped
area (S) caused by the difference between the
outside diameter (d1) of poppet (5) and the seat
diameter (d2) to move it to the left.
q Contracts spring (4) and poppet (5) moves to the
left.
q As a result, pressurized oil from the control valve
passes through the opening of poppet (5) and
flows to the arm cylinder head.

HB205-1, HB215LC-1 10-97

 98
Hydraulic system
Functions and operation by valve

When the arm is in neutral

Operation
q Moves the lever to neutral with the arm OUT.
q Pressurized oil flown inside poppet (5) from ori-
fice (a) of poppet (5) is closed by pilot piston (2).
q Pressurized oil from the control valve and the
holding pressure of the arm cylinder head are
shut off.
q The holding pressure of arm cylinder head works
on ring-shaped area (S) caused by the differ-
ence between outside diameter (d1) of poppet
(5) and seat diameter (d2) to move it to the right.
q The sum of this force and the force of spring (4)
closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure of the arm cylinder head are
shut off.

10-98 HB205-1, HB215LC-1

 99
Hydraulic system
Functions and operation by valve

When arm IN

Operation
q When the arm IN is operated, pilot piston (2) is
pushed under the pilot pressure from the PPC
valve.
q Pressurized oil in chamber (b) inside the poppet
is drained through orifice (c).
q Pressurized oil of the arm head flows to orifice
(a) o chamber (b) o orifice (c) o drain (T), and
the pressurized oil in chamber (b) lowers.
q As the pressure of chamber (b) lowers under the
pressure of port (B), poppet (5) opens.
q Pressurized oil from port (B) is led to port (A) and
then flows to the control valve.

HB205-1, HB215LC-1 10-99

 100
Hydraulic system
Functions and operation by valve

When abnormally high pressure is generated

q If abnormally high pressure is generated in the

boom cylinder bottom circuit, the pressurized oil
in port (B) pushes check valve (6) open, then
safety valve (3) operates.
q If arm drift prevention valve (if equipped) is in-
stalled to the arm cylinder head circuit, the boom
cylinder bottom circuit pressure force or arm cyl-
inder head circuit pressure force, whichever hav-
ing higher pressurized oil, pushes check valve
(6) or (6A) open to actuate safety valve (3).

10-100 HB205-1, HB215LC-1

 101
Hydraulic system
Functions and operation by valve

Quick return valve

When arm OUT

Function Operation
q When arm OUT, large volume of oil returns from q When the arm OUT is operated, pilot spool (1) is
the cylinder bottom. pushed under the pilot pressure from the PPC
q Reduces this pressure loss. valve.
q Pressurized oil in chamber (b) inside the valve is
drained through orifice (c).
q Pressurized oil of the arm bottom side flows to
orifice (a) o chamber (b) o orifice (c) o drain
(T), and the pressure in chamber (b) lowers.
q If the pressure of chamber (b) drops lower than
that of port (A), pressure receiving force of the
pressure receiving portion [fd2 area (S2) (seat
diameter area)] on the side of port (A) increases
by the sum of the pressure receiving force of
pressure receiving portion [fd1 area (S1)] on the
chamber (b) side of valve (2) and the spring
force.
q Or (fd2 pressure receiving force > fd1 pressure
receiving force + spring force)
q Valve (2) is pressed to the right and pressurized
oil is led from port (A) to (B).
q From port (B), pressurized oil is drained directly
to the tank.

HB205-1, HB215LC-1 10-101

 102
Hydraulic system
Functions and operation by valve

When the arm is in neutral

Operation
q Returning the lever to neutral reduces the pilot
pressure from the PPC valve to 0 MPa {0 kg/cm2}.
q The pressurized oil that has flowed and been
drained through orifice (a) in valve (2) is closed
by pilot piston (1).
q The holding pressure on the arm bottom side
works on the difference between areas (S2) and
(S1) of valve (2) to the left.
q Valve (2) is closed by the total of this force and
the force of spring (3), so ports (A) and (B) are
shut off.

10-102 HB205-1, HB215LC-1

 103
Lift check valve
Function
q This valve applies back pressure to the drain cir-
cuit to prevent generation of negative pressure
on each actuator (motors, cylinders, etc.).
Operation
While engine is stopped
q Pressurized oil is not fed to the self-pressure re-
ducing valve from the pump, and valve (1) is
pressed to the right by the force of spring (2).
q Drain circuit (a) of the control valve is connected
with port (T) through orifice (b) of valve (1).
HB205-1, HB215LC-1
Hydraulic system
Functions and operation by valve
While engine is running
q Output pressure (PR) of the self-pressure reduc-
ing valve is applied through the control valve to
spring chamber (c) of lift check valve (3).
q Output pressure (PR) applied to spring chamber
(c) is applied to the left end of valve (1) (area of
fd) to push valve (1) to the right.
q At this time, pressure (PA) of drain circuit (a) of
the control valve is applied to the right end of
valve (1) (area of fd1) to push valve (1) to the
left.
q Valve (1) strikes balance to make the back pres-
sure equal to (PA) in the equation below.
(Area of fd) x PR + force of spring (2)
PA=
Area of fd1
10-103
 104
Hydraulic system
Functions and operation by valve

Main relief valve

1. Spring
2. Poppet

Function
q Set pressure of the relief valve is in two stages.
q When power is needed, pilot pressure (P) is
turned ON and the set pressure becomes high-
er.

Operation
q The set pressure of relief valve is determined by
spring (1) installed load. (1st stage)
q Respective setting is not required for both the 1st
and 2nd stages. Setting the 1st stage completes
the setting of the 2nd stage.

If pilot pressure (P) is OFF: Low-pressure setting

Set pressure is determined by spring (1) installed
load.

If pilot pressure (P) is ON: High-pressure setting

Spring (1) installed load is added with pilot pressure
(P) applied to the area of poppet diameter (d1), rais-
ing the set pressure to higher level.

10-104 HB205-1, HB215LC-1

 105
Hydraulic system
Functions and operation by valve

2-stage safety-suction valve

[Installed to port (B) of the service valve]

1. Spring
2. Piston
3. Spring
4. Holder

Function If pilot pressure is OFF (high-pressure setting)

q Enables to provide the safety valve set pressure
in two stages, and make the low-pressure set-
ting smaller.
q Enables to relieve a load without lever operation
if high load is applied to the cylinder.
q Improves work efficiency and reduces machine
body vibration.
q Since pilot pressure (P) is OFF, piston (2) is
pressed to the left by spring (3). [Spring (1) in-
stalled load < spring (3) installed load]
q Spring (1) installed load becomes maximum and
the set pressure rises.
q Passage (B) is interconnected to the drain circuit
through passage (C) and chamber (D).

Operation
q The safety valve set pressure is determined by
spring (1) installed load.

HB205-1, HB215LC-1 10-105

 106
Hydraulic system
Functions and operation by valve

If pilot pressure is ON (low-pressure setting)

q If the pilot pressure (P) is ON, the pilot pressure
is led to section (A) through passage (B).
q Piston (2) works on the pressure-receiving bore
portion [(d2) (d1)] of section (A).
q This pilot pressure contracts spring (3), and pis-
ton (2) moves to the right until making contact
with holder (4).
q Spring (1) stretches, installed load is reduced,
and the set pressure lowers.
q Pressurized oil proportionate to the piston stroke
is drained through passage (C) and chamber
(D).

10-106 HB205-1, HB215LC-1

 107
Hydraulic system
Travel motor

Travel motor 107

Type: HMV110ADT-2

B : Brake release pressure port Specifications

MA: MA pressure pickup port Models
MB: MB pressure pickup port HB205-1, HB215LC-1
Item
P : From travel speed solenoid valve Type HMV110ADT-2
PA: From control valve Theoretical Min. 78.6 cm3/rev
PB: From control valve displacement Max. 106.2 cm3/rev
T : To tank Rated pressure 37.3 MPa {380 kg/cm2}
Capacity min. 2,805 rpm
Rated speed
Capacity max. 1,842 rpm
Brake release pressure 1.18 MPa {12 kg/cm2}
Travel speed Differential
0.78 MPa {8 kg/cm2}
selector pressure pressure

HB205-1, HB215LC-1 10-107

 108
Hydraulic system
Travel motor

10-108 HB205-1, HB215LC-1

 109
Hydraulic system
Travel motor

1. Regulator piston
2. Spring
3. Regulator valve
4. Motor case
5. Suction-safety valve spring
6. Check valve
7. Output shaft
8. Rocker cam
9. Retainer guide
10. Pin
11. Retainer
12. Piston
13. Cylinder block
14. Valve plate
15. Counterbalance valve
16. Ring
17. Brake piston
18. Plate
19. Disc
20. Ball

HB205-1, HB215LC-1 10-109

 110
Hydraulic system
Travel motor
Operation of motor
At slow speed (motor swash plate angle at maximum)
q As the solenoid valve is de-energized, the pilot
pressurized oil from the self-pressure reducing
valve does not flow to port (P).
q Regulator valve (9) is pushed to the right by
spring (10).
q Pressurized oil being transmitted from the con-
trol valve to end cover (8) by pressing check
valve (22) is shut off by regulator valve (9).
q Fulcrum (a) of rocker cam (4) is eccentric to the
working point (b) of the combined force of the
propulsion force of cylinder (6).
10-110
q The combined force of the piston propulsion
forces works as the moment to incline rocker
cam (4) toward the maximum swash plate angle.
q The pressurized oil at regulator piston (15) pass-
es through orifice (c) of regulator valve (9) and is
drained in the motor case.
q Rocker cam (4) is inclined in the maximum
swash plate angle direction. The motor capacity
becomes maximum, turning on the low speed
travel.
HB205-1, HB215LC-1
 111
Hydraulic system
Travel motor

At high speed (motor swash plate angle at minimum)

q As the solenoid valve is energized, the pilot pres-

surized oil from the self-pressure reducing valve
flows to port (P).
q Regulator valve (9) is pushed to the left.
q The pressurized oil from the control valve pass-
es through passage (d) in regulator valve (9) and
enters regulator piston (15).
q Regulator piston (15) is pushed to the right.
q Rocker cam (4) is inclined in the minimum swash
plate angle direction. The motor capacity be-
comes minimum, turning on the high speed trav-
el.

HB205-1, HB215LC-1 10-111

 112
Hydraulic system
Travel motor

Operation of parking brake

When machine starts to travel

q As the travel lever is operated, pressurized oil

from the pump acts on counterbalance valve
spool (19), to open the parking brake circuit.
q The pressurized oil is transmitted to chamber (e)
of brake piston (12) and compresses spring (11),
pushing piston (12) toward the left.
q Since the pushing force does not act on plate
(13) and disc (14), plate (13) is separated from
disc (14) and the parking brake is released.

10-112 HB205-1, HB215LC-1

 113
Hydraulic system
Travel motor

When machine stops

q As the travel lever is returned to the neutral po-

sition, counterbalance valve spool (19) returns to
the neutral position and closing the parking
brake circuit.
q The pressurized oil in chamber (e) of brake pis-
ton (12) passes through orifice (f) of brake piston
(12) and is drained in the case.
q Brake piston (12) is pushed to the right by spring
(11).
q Plate (13) and disc (14) are pushed together,
and the parking brake engages.
q As brake piston (12) returns, slow return valve
(22) restricts the return flow of pressurized oil.
q The restriction of the return flow of pressurized
oil delays the application of the parking brake.
The parking brake is applied after the machine
has stopped.

HB205-1, HB215LC-1 10-113

 114
Hydraulic system
Travel motor

Brake valve Operation when pressurized oil is supplied

q The brake valve consists of suction safety valve q When the travel lever is operated, the pressur-
(18A) and counterbalance valve (18). ized oil from the control valve flows to port (PA).
q Functions and operations of respective compo- q The pressurized oil opens suction safety valve
nents are as follows. (18A) and then flows to motor outlet port (MB)
through motor inlet port (MA).
Counterbalance valve and check valve q The motor outlet side is closed by suction safety
valve (18B) and spool (19), so the pressure at
Function the supply side rises.
q When the machine travels down a slope, its trav-
el speed tends to get faster than the motor (en-
gine) speed because of the downward force
generated from its own weight.
q If the machine travels with the engine at low
speed, the motor may run idle, and the machine
runs out of control; it is in a very dangerous situ-
ation.
q These valves are used to prevent above by con-
trolling the machine to travel according to the en-
gine speed (pump delivery).

10-114 HB205-1, HB215LC-1

 115
q The pressurized oil on the supply side flows to
chamber (S1) through orifice (E1) and orifice
(E2) of the spool (19).
q As the pressure in chamber (S1) goes above the
spool selector pressure, spool (19) is pushed to-
ward the right.
q Port (MB) and port (PB) are connected, opening
the motor outlet port side and starting the motor
rotating.
HB205-1, HB215LC-1
Hydraulic system
Travel motor
Operation of brake during travelling downhill
q If the machine runaway is sensed while it travels
down a slope, the motor will be caused to run
idle and the inlet side oil pressure will be de-
creased.
q Pressure in chamber (S1) is released through or-
ifices (E1) and (E2).
q As the pressure in chamber (S1) become lower
than the spool selector pressure, spool (19) is re-
turned to the left by spring (20) and outlet port
(MB) is throttled.
q The pressure at the outlet port side rises, gener-
ating rotation resistance on the motor to prevent
the machine from a runaway.
q The spool moves to a position where the pres-
sure on outlet port (MB) can be balanced against
the machine's own weight and the inlet port pres-
sure.
q Oil flow from the outlet circuit is restricted to en-
sure the travel speed corresponded to the pump
delivery.
10-115
 116
Hydraulic system
Travel motor

Suction-safety valve q At the time of left turn, it makes reverse opera-

tion for right turn.
Function
q As long as the machine travel is stopped (or it
travels down a slope), the counterbalance valve
closes the inlet and outlet circuits of the motor.
q Since the motor is rotated by inertial force, pres-
sure in the motor outlet port side is abnormally
increased, potentially resulting in damages on
the motor and piping.
q The suction-safety valve releases this abnormal
pressure to the inlet port side of the motor in or-
der to prevent damages to the equipment.

Operation
During machine stops (or when travelling down-
When starting travel (or when traveling at a con-
hill) (Right turn)
stant speed)
q Reduction of the pressure at motor inlet (PA) de-
q As the travel lever is operated, the pressurized
creases the pressure in chamber (S1).
oil from the pump moves spool (19) toward the
q When it drops beyond the spool selector pres-
right.
sure, spool (19) is returned to the left by spring
q The passage to the suction-safety valve func-
(20), reducing the pressure at outlet passage
tions as a circuit which passes through notch
(B1).
(B2) of spool (19), producing large differential
q The motor tries to continue rotation with inertial
pressure.
force, thus pressure on the outlet port (MB) is in-
q The pump pressure rises, providing a large trac-
creased.
tional force to the valve.

q When the pressure rises above the set pressure

of the suction-safety valve, poppet (1) opens.
q The pressurized oil passes through notch (A1) of
spool (19) into chamber (MA) of the circuit at the
opposite side.

10-116 HB205-1, HB215LC-1

 117
Hydraulic system
PPC valve

PPC valve 17

Work equipment and swing PPC valve

P: From self-pressure reducing valve

P1: L.H. PPC valve: Arm OUT port / R.H. PPC valve: Boom LOWER port
P2: L.H. PPC valve: Arm IN port / R.H. PPC valve: Boom RAISE port
P3: L.H. PPC valve: Swing LEFT port / R.H. PPC valve: Bucket CURL port
P4: L.H. PPC valve: Swing RIGHT port / R.H. PPC valve: Bucket DUMP port
T: To tank

HB205-1, HB215LC-1 10-117

 118
Hydraulic system
PPC valve

10-118 HB205-1, HB215LC-1

 119
Hydraulic system
PPC valve

1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter

HB205-1, HB215LC-1 10-119

 120
Hydraulic system
PPC valve

Operation
When in neutral
q Ports (A) and (B) of the control valve and ports
(P1) and (P2) of the PPC valve are connected to
drain chamber (D) through fine control hole (f) in
spool (1).
q The relationship of the position of spool (1) and
body (10) [fine control hole (f) is in the middle be-
tween drain chamber (D) and pump pressure
chamber (PP)] does not change until retainer (9)
contacts spool (1).
q Metering spring (2) compresses in proportion to
the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force of
the return spring of the control valve spool are
balanced.

During fine control

(Neutral o fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, and metering spring (2) moves
spool (1) downward.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil from the self-pressure re-
ducing valve is led to port (A) from port (P1) Note: The description of the control valve spool is
through fine control hole (f). not applied to the control for the swing electric mo-
q When the pressure at port (P1) becomes higher, tor.
spool (1) is pushed back and fine control hole (f)
is shut off from pump pressure chamber (PP). At
almost the same time, it is connected to drain
chamber (D) to release the pressure at port (P1).
q As a result, spool (1) moves upward and down-
ward until the force of metering spool (2) is bal-
anced with the pressure at port (P1).

10-120 HB205-1, HB215LC-1

 121
Hydraulic system
PPC valve

During fine control At full stroke

(When control lever is returned) q Disc (5) pushes down piston (4), and retainer (9)
q When disc (5) starts to be returned, spool (1) is moves spool (1) downward.
pushed up by the force of centering spring (3) q Fine control hole (f) is shut off from drain cham-
and the pressure at port (P1). ber (D), and is interconnected to pump pressure
q Because of this, fine control hole (f) is connected chamber (PP).
to drain chamber (D), and the pressurized oil at q Therefore, the pilot pressure oil from the
port (P1) is released. self-pressure reducing valve passes through fine
q If the pressure of port (P1) is lowered excessive- control hole (f) and flows to chamber (A) from
ly, spool (1) is pushed down by metering spring port (P1) to push the control valve spool.
(2). q The oil returning from chamber (B) passes from
q Fine control hole (f) is shut off from drain cham- port (P2) through fine control hole (f') and flows
ber (D), and it is almost simultaneously intercon- to drain chamber (D).
nected to pump pressure chamber (PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
control lever position.
q When the spool of the control valve returns, the
oil in drain chamber (D) flows in from fine control
hole (f') in the valve on the side that is not work-
ing. The oil passes through port (P2) and enters
chamber (B) to replenish the chamber with pres-
surized oil.

Note: The description of the control valve spool is

not applied to the control for the swing electric mo-
tor.

HB205-1, HB215LC-1 10-121

 122
Hydraulic system
PPC valve

Travel PPC valve

P: From self-pressure reducing valve

P1: L.H. travel REVERSE port
P2: L.H. travel FORWARD port
P3: R.H. travel REVERSE port
P4: R.H. travel FORWARD port
P5: Travel signal port
P6: Steering signal port
T: To tank

10-122 HB205-1, HB215LC-1

 123
Hydraulic system
PPC valve

1. Plate 5. Valve
2. Body 6. Damper
3. Piston 7. Steering signal spool
4. Collar

HB205-1, HB215LC-1 10-123

 124
Hydraulic system
PPC valve

Pressure reducing valve function
Operation
When in neutral
q Ports (A) and (B) of the control valve and ports
(P1) and (P2) of the PPC valve are connected to
drain chamber (D) through fine control hole (f) in
spool (1).
q The relationship of the position of spool (1) and
body (10) [the position of fine control hole (f) is in
the middle between drain chamber (D) and
pump pressure chamber (PP)] does not change
until retainer (9) contacts spool (1).
q Metering spring (2) compresses in proportion to
the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force of
the return spring of the control valve spool are
balanced.

During fine control

(Neutral o fine control)
q When piston (4) is pushed by lever (5), retainer
(9) is pushed, metering spring (2) moves spool
(1) downward.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil from the pressure reducing
valve is led to port (A) from port (P1) through fine
control hole (f).
q When the pressure at port (P1) becomes higher,
spool (1) is pushed back and fine control hole (f)
is shut off from pump pressure chamber (PP). At
almost the same time, it is connected to drain
chamber (D) to release the pressure at port (P1).
q As a result, spool (1) moves upward and down-
ward until the force of metering spool (2) is bal-
anced with the pressure at port (P1).

10-124 HB205-1, HB215LC-1

 125
During fine control
(When control lever is returned)
q When lever (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and pressure at port (P1).
q Because of this, fine control hole (f) is connected
to drain chamber (D), and the pressurized oil at
port (P1) is released.
q If the pressure of port (P1) is lowered excessive-
ly, spool (1) is pushed down by metering spring
(2).
q Fine control hole (f) is shut off from drain cham-
ber (D), and it is almost simultaneously intercon-
nected to pump pressure chamber (PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
control lever position.
q When the spool of the control valve returns, the
oil in drain chamber (D) flows in from fine control
hole (f') in the valve on the side that is not work-
ing. The oil passes through port (P2) and enters
chamber (B) to replenish the chamber with pres-
surized oil.
At full stroke
q Lever (5) pushes down piston (4), and retainer
(9) moves spool (1) downward.
q Fine control hole (f) is shut off from drain cham-
ber (D), and is interconnected to pump pressure
chamber (PP).
HB205-1, HB215LC-1
Hydraulic system
PPC valve
q Therefore, the pilot pressure oil from the
self-pressure reducing valve passes through fine
control hole (f) and flows to chamber (A) from
port (P1) to push the control valve spool.
q The oil returning from chamber (B) passes from
port (P2) through fine control hole (f') and flows
to drain chamber (D).
Travel signal/Steering function
Travel signal
q If either of the L.H. or R.H. travel levers is oper-
ated, the higher PPC valve output pressure of
both sides is output as the travel signal.
q Accordingly, whether the machine is traveling is
judged by the signal of port (P5).
Steering signal
q If the operation quantities of both levers are dif-
ferent from each other as in the steering opera-
tion, the higher one of the PPC valve output
pressures of both sides is output as the steering
signal.
q Any signal is not output from port (P6) while the
machine is travelling straight (forward or re-
verse) or in the neutral position.
q Accordingly, whether the machine is being
steered is judged by the signal of port (P6).
10-125
 126
Hydraulic system
PPC valve

Operation
At the neutral position

q Any signal is not output from respective output

ports [from port (P1) to (P4)], travel signal [port
(P5)] and steering signal [port (P6)].

10-126 HB205-1, HB215LC-1

 127
Hydraulic system
PPC valve

During straight travel

a The Illustration shows the circuit for travelling straight forward.

q When operating L.H. motor forward [port (P2)
output] and R.H. motor forward [port (P4) out-
put], pressure of both L.H. spring chamber (k)
and R.H. spring chamber (l) rises high.
q Steering signal spool (j) remains at neutral posi-
tion and does not output a steering signal to port
(P6).

HB205-1, HB215LC-1 10-127

 128
Hydraulic system
PPC valve

At turn or pivot turn

a The Illustration shows the circuit for travelling left forward (slow) and right forward (fast) operation.

q If the operation quantities of both levers are dif- q Port (P4) pressure of the L.H. or R.H. PPC
ferent from each other as in the steering opera- valves, whichever having a higher output pres-
tion (if the difference of the pilot pressure sure, is output to port (P6) as the steering signal.
between both sides is higher than a certain lev-
el), the pilot pressure is output as the steering
signal.
q The pressure in left spring chamber (k) of steer-
ing signal spool (j) is (P2).
q The pressure in right spring chamber (l) is (P4).
q When the pressure reaches [(P4 P2) x (Spool
cross-sectional area) > Spring set load], the
spool shifts to the direction of the arrow.

10-128 HB205-1, HB215LC-1

 129
Hydraulic system
PPC valve

At counter rotate turn

a The illustration shows the circuit for travelling left reverse and right forward.

q When operating L.H. motor reverse [port (P1)

output] and R.H. motor forward [port (P4) out-
put], pressure of the R.H. spring chamber (l) only
rises high.
q Steering signal spool (j) shifts to the left to output
the steering signal to port (P6).

HB205-1, HB215LC-1 10-129

 130
Hydraulic system
PPC valve

Service PPC valve (with EPC valve)

a For the details of operation, see the paragraph of Work equipment and swing PPC valve.

10-130 HB205-1, HB215LC-1

 131
Hydraulic system
PPC valve

P: From self-pressure reducing valve

P1: To service valve
P2: To service valve
T: To tank

1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve

HB205-1, HB215LC-1 10-131

 132
Hydraulic system
PPC valve

EPC valve

C: To control valve 1. Body

P: From self-pressure reducing valve 2. Plug
T: To hydraulic tank 3. Spool
4. Push pin
5. Coil
6. Plunger
7. Connector

10-132 HB205-1, HB215LC-1

 133
Function
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion.
q When it receives signal current (i) from the pump
controller, it generates the EPC output pressure
in proportion to the size of the signal, and out-
puts it to the control valve.
HB205-1, HB215LC-1
Hydraulic system
PPC valve
Operation
When signal current is 0
(coil is de-energized)
q When there is no signal current flowing from the
controller to coil (14), coil (14) is de-energized.
q Spool (11) is pushed to the right by spring (12).
q Port (P) closes and the pressurized oil from the
front pump does not flow to the control valve.
q The pressurized oil from the control valve is
drained to the tank through port (C) and port (T).
10-133
 134
Hydraulic system
PPC valve
When signal current is very small
(coil is energized)
q When a very small signal current flows to coil (5),
coil (5) is energized, and a propulsion force is
generated on the left side of plunger (6).
q Push pin (4) pushes spool (2) to the left, and
pressurized oil flows from port (P) to port (C).
q Pressures on port (C) increases and the force to
act on surface (a) of spool (2) and the spring load
on spring (3) become larger than the propulsion
force of plunger (6).
q Spool (2) is pushed to the right, port (P) is shut
off from port (C) and ports (C) and (T) are con-
nected.
q Spool (2) moves up and down so that the propul-
sion force of plunger (6) may be balance with
pressure of port (C) + spring load of spring (3).
q The circuit pressure between the EPC valve and
the control valve is controlled in proportion to the
size of the signal current.
10-134
When signal current is maximum
(coil is energized)
q As the signal current flows to coil (5), coil (5) is
energized.
q When this happens, the signal current is at its
maximum, so the propulsion force of plunger (6)
is also at its maximum.
q Spool (2) is pushed to the left by push pin (4).
q The maximum volume of pressurized oil is con-
ducted from port (P) to port (C), increasing the
circuit pressure across EPC valve and the con-
trol valve to the maximum level.
q Since port (T) is closed, pressurized oil does not
flow to the hydraulic tank.
HB205-1, HB215LC-1
 135
Hydraulic system
PPC valve

Service PPC valve

a For the details of operation, see the paragraph of Work equipment and swing PPC valve.

P: From self-pressure reducing valve 1. Spool

P1: To service valve 2. Piston
P2: To service valve 3. Lever
T: To tank 4. Plate
5. Retainer
6. Body

HB205-1, HB215LC-1 10-135

 136
Hydraulic system
Solenoid valve

Solenoid valve 136

For PPC lock, travel junction, travel speed, swing brake, and 2-stage relief solenoid valves

10-136 HB205-1, HB215LC-1

 137
Hydraulic system
Solenoid valve

1. PPC lock solenoid valve When solenoid is energized

2. 2-stage relief solenoid valve q As the signal current flows from the controller to
3. Swing brake solenoid valve solenoid (8), solenoid (8) is energized.
4. Travel speed solenoid valve Accordingly, spool (9) is pushed to the right.
5. Travel junction solenoid valve This operation allows the flow of the pressurized
6. Connector oil from the main pump, through port (P), via
7. Moving core inside spool (9), to port (A), and eventually to the
8. Coil actuator.
9. Spool At the same time, port (T) closes, the oil does not
10. Block flow to the tank.
11. Spring

T: To tank
A1: To PPC valve
A2: To main valve (2-stage relief valve)
A3: To swing motor
A4: To L.H. and R.H. travel motors
A5: To main valve (Travel junction valve)
P1: From main pump
ACC: To accumulator

Operation
When solenoid is de-energized
q Since the signal current does not flow from the
controller, solenoid (8) is de-energized.
For this reason, spool (9) is pushed to the left by
spring (11).
Since the pass from port (P) to port (A) is closed,
pressurized oil from the main pump does not
flow to the actuator.
At this time, the oil from the actuator is drained
through ports (A) and (T) into the tank.

HB205-1, HB215LC-1 10-137

 138
Hydraulic system
Attachment circuit selector valve

Attachment circuit selector valve 138

ACC: To accumulator
ATT: To attachment
P1: From attachment selector solenoid valve
T: To hydraulic tank
TS: To hydraulic tank
V: To control valve

1. Spool
2. Spring

10-138 HB205-1, HB215LC-1

 139
Function
q When a breaker is installed, the return oil from
the breaker does not pass through the main
valve, but returns directly to the hydraulic tank.
q When other attachments (crusher, etc.) are in-
stalled, the attachment and the main valve are
interconnected.
Operation
When attachment other than breaker is installed
q Spool (1) is pressed to the left by the force of
spring (2).
q Ports (ATT) and (V) are interconnected and
ports (ATT) and (T) are shut off. Attachment is
thus interconnected to the control valve.
HB205-1, HB215LC-1
Hydraulic system
Attachment circuit selector valve
When breaker is installed
q Pilot pressure from the attachment circuit selec-
tor solenoid valve contracts spring (2), and spool
(1) moves to the right to the stroke end.
q Ports (ATT) and (V) are shut off and ports (ATT)
and (T) are interconnected.
q Pressurized oil returning from the breaker re-
turns directly to the hydraulic tank through port
(T) without passing through the control valve.
10-139
 140
Hydraulic system
Return oil filter

Return oil filter 140

For breaker

1. Drain plug Specifications

2. Filter Rated pressure: 6.9 MPa {70 kg/cm2}
3. Case Flow rate: 200 l/min
4. Head cover Relief valve cracking pressure:
5. Relief valve 0.34 0.05 MPa {3.5 0.5 kg/cm2}
Filter mesh size: 6 mm
Filtering area: 4,570 cm2

10-140 HB205-1, HB215LC-1

 141
Hydraulic system
Return oil filter

HB205-1, HB215LC-1 10-141

 142
Hydraulic system
Center swivel joint

Center swivel joint 142

1. Cover 4. O-ring
2. Slipper seal 5. Shaft
3. Body

A1: To L.H. travel motor port (PB)

A2: From control valve port (A2)
B1: To L.H. travel motor port (PA)
B2: From control valve port (B2)
C1: To R.H. travel motor port (PA)
C2: From control valve port (A5)
D1: To R.H. travel motor port (PB)
D2: From control valve port (B5)
E: To L.H. and R.H. travel motors port (P)
T1: From L.H. and R.H. travel motors port (T)
T2: To tank

10-142 HB205-1, HB215LC-1

 143
Hydraulic system
Accumulator

Accumulator 143

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port

Specifications
Gas capacity: 300 cc (for PPC)

HB205-1, HB215LC-1 10-143

 144
Electrical system
Electrical control system

Electrical system 14

Electrical control system 14

Machine control system diagram

10-144 HB205-1, HB215LC-1

 145
Electrical system
Electrical control system

HB205-1, HB215LC-1 10-145

 146
Electrical system
Electrical control system

Engine control function

Starting engine
q When the starting switch is turned to the START
position, the starting signal flows to the starting
motor. Then, the starting motor turns to start the
engine.
Stopping engine
q When detecting that the starting switch is set to
the STOP position, the engine controller stops
the signal of the supply pump drive solenoid to
stop the engine.

At this time, the engine controller receives the

signal voltage from the fuel control dial and sets
the engine speed to the set speed.

Engine speed control

q The fuel control dial sends a signal voltage cor-
responding its position to the engine controller.

The engine controller sends a driving signal to

the supply pump depending on the signal
voltage to control the fuel injection pump, and
eventually controls the engine speed.

10-146 HB205-1, HB215LC-1

 147
Electrical system
Electrical control system

Engine and pump combined control function

HB205-1, HB215LC-1 10-147

 148
Electrical system
Electrical control system

Function
q This function allows the machine to select engine torque (T) and pump absorption torque depending on
the type of work. Five modes of P, E, L, B, and ATT (three modes of P, E, and L for machines with "No
ATT" specified) are set as working modes.
q Select working mode with the working mode switch of the machine monitor. The inverter controls the en-
gine speed and pump absorption torque according to the lever operation quantity and operation pattern.
q The inverter controls the pump so that the pump will absorb all the torque at each engine output point ac-
cording to the pump absorption torque set for each mode, speed set with the fuel control dial and actual
engine speed.
Control method in each mode
P mode, E mode and ATT mode
q Matching point:

Working mode Max. matching point

104 kW/1,810 rpm
P
(139 HP/1,810 rpm)
78 kW/1,770 rpm
E
(105 HP/1,770 rpm)

q In the P and E modes, the engine speed is kept

near the matching point in each mode indicated
by the inverter.
q If the pump load increases and the pressure in-
creases consequently, the engine speed (N) de-
creases. At this time, the pump controller
decreases pump delivery (Q) to increase the en-
gine speed to near the matching point. If the load
decreases reversely and the pressure decreas-
es consequently, the pump controller increases
the pump delivery until the engine speed reach-
es near the matching point.
q The inverter calculates the command value from
the lever operation quantity, operation pattern,
load, pump absorption torque set for each mode,
speed set with the fuel control dial and actual en-
gine speed. The maximum command value is at
the maximum matching point.
q Since the matching point calculated by the in-
verter varies with the load, less fuel is consumed
than in the control where the maximum matching
point is commanded constantly.

10-148 HB205-1, HB215LC-1

 149
Electrical system
Electrical control system

B mode and L mode

Mode B L
Partial output point 75% 70%

Working mode Matching point

80.9 kW/1,790 rpm
B
{108 HP/1,790 rpm}
73.5 kW/1,800 rpm
L
{99 HP/1,800 rpm}
q In B or L mode, engine output is controlled to a
constant level.
q The controller controls the pump absorption
torque to decrease the engine speed while keep-
ing the engine torque at a constant level along
the equal engine horsepower curve.
q The controller controls pump delivery (Q) so that
the engine torque can be kept at a constant level
along the equal engine horsepower curve.

HB205-1, HB215LC-1 10-149

 150
Electrical system
Electrical control system

Pump control function during travel

q During travel in Lo, the inverter gives a command of the matching point in accordance with the load to the
pump controller as in the control method in each mode described above.
q During travel in Mid or Hi, the engine speed (N) increases to the fuel control dial setting, regardless of the
load.
q The engine speed and pump absorption torque in the P mode are different from those in the E mode.

10-150 HB205-1, HB215LC-1

 151
Electrical system
Electrical control system

Control function when emergency pump drive

switch is turned ON
q Even if the controller or a sensor has a trouble,
the operator can operate the machine with ab-
sorption torque almost equivalent to in the E
mode by turning emergency pump drive switch
(1) ON.
In this case, since a constant current flows from
the battery to the EPC valve for the PC, oil pres-
sure is sensed by only the sensor of the EPC
valve for the PC.
The engine speed is kept at a constant value set
with the fuel control dial, regardless of the load
and lever operation.

HB205-1, HB215LC-1 10-151

 152
Electrical system
Electrical control system

Pump and valve control function

Function
q The machine is matched to various types of work
properly with the 2-stage relief function to in-
crease the digging force, etc.

10-152 HB205-1, HB215LC-1

 153
Electrical system
Electrical control system

LS control function 2-stage relief function

q Depending on the operation condition of the ac- q The relief pressure in the normal work is 34.8
tuator, this function changes the pressure output MPa {355 kg/cm2}. If the 2-stage relief function is
from the LS-EPC valve to LS valve to change the turned on, however, the relief pressure rises to
change point (LS set differential pressure (DLS)) about 37.2 MPa {380 kg/cm2}. By this operation,
of the pump discharge in the LS valve. the hydraulic force is increased further.
q By this operation, the start-up time of the pump
Operating condition for turning on
discharge is optimized and the combined opera- Relief pressure
2-stage relief function
tion and fine control performance is improved. q During travel
q When swing lock switch is turned to 34.8 MPa
the ON position {355 kg/cm2}
q When boom is lowered O
q When one-touch power maximizing 37.2 MPa
function is turned on {380 kg/cm2}
q When L mode is operated

Cut-off function
q This function increases PC-EPC current (J) to
reduce the flow rate in the relief state, improving
fuel consumption.
Operating condition for turning on cut-off function
When the average value of the front and rear pressure
sensors is 27.9 MPa {285 kg/cm2} or more with the
one-touch power maximizing function off.
The cut-off function does not work, however, while the
machine is travelling in P mode, swing lock switch is in
the ON position.

HB205-1, HB215LC-1 10-153

 154
Electrical system
Electrical control system

One-touch power maximizing function

Function
q The one-touch power maximizing function al-
lows the operator to increases power for a cer-
tain time by operating the left knob switch.
q This function is used to increase digging force for
a certain period of time (e.g., when digging up a
large rock).
q Pressing the L.H. knob switch in P, E or ATT
mode increases a hydraulic force by approxi-
mately 7% and horsepower by approximately
3%, increasing a digging force.
At this time, each function is automatically set as
shown below.
q These settings are automatically reset after 8.5
seconds when the switch is pressed.
Function Setting
Matching at rated
Engine and pump control
output point
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Software cut-off function Cancel

10-154 HB205-1, HB215LC-1

 155
Electrical system
Electrical control system

Auto-deceleration function

Function
q The auto-deceleration function automatically re- When any control lever is operated
duces the engine speed to its medium speed q If any control lever is operated while the engine
range when the all control levers are set in the speed is kept at the deceleration speed, the en-
NEUTRAL position while waiting for a dump gine speed increases immediately in accor-
truck or work to reduce the fuel consumption and dance with the lever operation quantity.
noise.
q If the control lever is operated, the engine speed
increases immediately in accordance with the le-
ver operation quantity. At this time, the engine
speed upper limit is set with the fuel control dial.

Operation
When control levers are set in the neutral posi-
tion
q If the all control levers are set in the neutral po-
sition while the machine is working/traveling with
the auto-deceleration function is ON, the engine
speed decreases to the waiting speed
(1,250 rpm) temporarily. If the machine is kept Engine speed when auto-deceleration is ON
under this condition for 4 seconds, the engine Working mode Engine speed
speed decreases further to the deceleration P 1st stage 2nd stage
speed (about 700 rpm) and keeps at that speed E 1,250 rpm o 700 rpm
until any lever is operated. Without deceleration
q If the capacitor voltage decreases during decel- L
function
eration, the engine speed increases to B 1,400 rpm
1,150 rpm to charge the capacitor. After the ca- 1st stage 2nd stage
pacitor is charged, the engine speed decreases ATT
1,250 rpm o 700 rpm
to about 700 rpm.

HB205-1, HB215LC-1 10-155

(03)
 156
Electrical system
Electrical control system

Auto-warm-up function

Function
q After the engine is started, if the engine coolant temperature is low, the engine speed is raised automati-
cally to warm up the engine
Operating condition (All of following conditions) Operation
Coolant temperature: Below 30C
Engine speed: 1,200 rpm
Engine speed: Max. 1,200 rpm

Resetting condition (Any one of following conditions) Free

Coolant temperature: Above 30C
Auto
Auto-warm-up operation time: Min. 10 minutes
Fuel control dial: Engine speed: Any level
Manual Kept at 70% of full level or more for 3 sec. or
longer

10-156 HB205-1, HB215LC-1

 157
Electrical system
Electrical control system

Overheat prevention function

Overheat prevention function for engine and hydraulic components
q If the engine coolant temperature rises too high during work, the pump load and engine speed are reduced
to protect the engine from overheating.
q This function starts when coolant temperature reaches 100C or hydraulic oil temperature reaches 95C.

Operating condition Operation/Remedy Resetting condition

Hydraulic oil temperature: Below 95C
Working mode: Travel
Hydraulic oil tempera- q Under above condition, controller is set to
Engine speed: Keep as is.
ture: Min. 95C condition before operation of function.
Lower travel speed.
(Automatic reset)

Operating condition Operation/Remedy Resetting condition

Coolant temperature: Hydraulic oil or coolant temperature: Below
Min. 100C Working mode: P or E mode 100C
or Engine speed: Keep as is. q Under above condition, controller is set to
Hydraulic oil tempera- Reduce pump delivery. condition before operation of function.
ture: Min. 100C (Automatic reset)

Operating condition Operation/Remedy Resetting condition

Coolant temperature: Hydraulic oil or coolant temperature: Below
Working mode: P or E mode
Min. 102C 102C
Engine speed: Keep as is.
or q Under above condition, controller is set to
Monitor alarm lamp: Lights up.
Hydraulic oil tempera- condition before operation of function.
Reduce pump delivery.
ture: Min. 102C (Automatic reset)

Operating condition Operation/Remedy Resetting condition

Hydraulic oil temperature: Below 105C
Coolant temperature:
Working mode: Any mode Fuel control dial: Return to low idle position
Min. 105C
Engine speed: low idle once.
or
Monitor alarm lamp: Lights up. q Under above condition, controller is set to
Hydraulic oil tempera-
Alarm buzzer: Sounds condition before operation of function.
ture: Min. 105C
(Manual reset)

Overheat prevention function for hybrid components

q This function decreases the hybrid system load to protect the hybrid components from an overheat when
their temperature increases high.
q When this function operates, the alarm buzzer sounds and the hybrid temperature monitor lights up.
q If an overheat cannot be prevented with this function, the alarm buzzer sounds and the monitor displays
an error to indicate the component overheat, and the hybrid system stops.

HB205-1, HB215LC-1 10-157

 158
Electrical system
Electrical control system

Swing control function

Function
The swing lock and swing brake function are provid-
ed as a swing control function.

10-158 HB205-1, HB215LC-1

 159
Electrical system
Electrical control system

Swing lock and swing holding brake function Quick hydraulic oil warm-up function when
q The swing lock function (manual) is used to lock swing lock switch is in the ON position
machine from swinging at any position. The q If swing lock switch (2) is in the ON position, the
swing holding brake function (automatic) is used pump cut-off function is cancelled and the relief
to prevent hydraulic drift after the machine stops pressure rises from 34.8 MPa {355 kg/cm2} to
swinging. 37.2 MPa {380 kg/cm2}.
q Operation of swing lock switch and swing lock/ If the work equipment circuit is relieved under
swing holding brake this condition, the hydraulic oil temperature rises
Swing quickly and the warm-up time can be shortened.
Swing
lock Function Operation
lock lamp
switch
If swing lever is moved to
the neutral position,
Swing swing brake operates in
OFF OFF holding about 5 sec.
brake If swing lever is operated,
brake is released and
machine can swing freely
Swing lock operates and
machine is locked from
swinging.
Swing
ON ON Even if swing lever is
lock
operated, swing lock is
not reset and machine
does not swing.

Swing holding brake cancel function

q If the controller, etc. has a problem, the swing
holding brake is not released normally, and the
machine cannot swing, the swing lock can be re-
leased with the swing brake cancel switch
Release Normal
Swing brake
(When controller (When the controller
cancel switch
has trouble) is normal)
Swing lock
ON OFF ON OFF
switch
Swing
Swing Swing Swing
holding
Swing brake lock lock is lock
brake
works. canceled. works.
works.

q Even if the swing brake cancel switch is turned

to "RELEASE", while the swing lock switch stays
in the ON position, the swing holding brake is not
released.
q If the swing lock is released, note that, the upper
structure may swing by its gravity on a slope.

k If the swing lock is released while the hy-

brid system is in an abnormal state, the
stop function is lost.
Accordingly, if this operation is performed
on a slope, the upper structure swings
down, and this is dangerous. Never
perform this operation since it can cause
a serious accident.

HB205-1, HB215LC-1 10-159

 160
Electrical system
Electrical control system

Travel control function

Function
q The machine is provided with a function that en-
sures travel performance best fit to the type of
work and jobsite by controlling pumps during
travel or allowing operator to change travel
speed automatically or manually.

10-160 HB205-1, HB215LC-1

 161
Electrical system
Electrical control system

Pump control function during travel

q For details, see "Engine and pump combined
control function".
Travel speed change function
Manual change with travel speed switch
Switching the travel speed selector switch from
Lo to Mi and Hi causes the pump controller to
control the pump capacity and motor capacity at
each gear speed as shown below, switching the
travel speed.
Mi
Travel speed Lo (Low Hi (High
(Medium
selector switch speed) speed)
speed)
Pump capacity (%) 80 90 100
Motor capacity Max. Max. Min.
Travel speed (km/h) 3.0 4.1 5.5

Automatic selection corresponding to

engine speed
If you adjust the engine speed to 1,500 rpm or
less with the fuel control dial,
q The travel speed does not switch to Hi when
the machine is traveling in Mi.
q The travel speed automatically switches to
Mi when the machine is travelling in Hi.
Automatic selection corresponding to pump
discharge pressure
If the travel hydraulic pressure is kept to 24.5
MPa {250 kg/cm2} or more at least 0.5 sec. due
to increased load during traveling in Hi on an
uphill, the travel motor capacity automatically
switches to the medium speed (Mi) (the travel
speed switch stays at Hi).
If the machine starts traveling on level ground or
downhill during operation of the above
mentioned function and the travel hydraulic
pressure goes 14.7 MPa {150 kg/cm2} or less
and continues such the condition at least 0.5
sec., the travel motor capacity will automatically
change, switching the travel speed switch back
to Hi.

HB205-1, HB215LC-1 10-161

 162
Electrical system
Electrical control system

Attachment flow control circuit selector function (if equipped)

Function
q This function is available only with attachment
specification.
q The function acts as follows according to the flow
command and working mode from the monitor.
1) It throttles the attachment PPC pressure and
controls the flow when the pedal is
depressed fully.
2) Attachment operation switches depending on
the working mode as shown below.
Working mode Attachment operation
ATT Double-acting
B Single-acting

10-162 HB205-1, HB215LC-1

 163
Electrical system
Electrical control system

System component parts

Engine controller

Input and output signals

q Meanings of signal category in the terminal table
CN-CE01
are as follows.
Signal
A: Power supply Pin No. Signal name category
B: Input 11 NC (*)
C: Ground/Shield/Return 12 NC (*)
D: Output 13 NC (*)
E: Communication 14 WIF sensor B
CN-CE01 15 Coolant temperature sensor B
Signal 16 5 V electric power supply for sensor A
Pin No. Signal name category 17 Oil pressure switch B
1 NC (*) 18 NC (*)
2 Electric power supply for IMA D 19 NC (*)
3 Ambient pressure sensor B 20 NC (*)
4 NC (*) 21 NC (*)
5 NC (*) 22 NC (*)
6 CAN () E 23 Boost temperature sensor B
7 NC (*) 24 NC (*)
8 CAN(+) E 25 Common rail pressure sensor B
9 NC (*) 26 Buckup sensor (+) B
10 NC (*) 27 NE sensor (+) B
*: Never connect to NC, or malfunctions or failures will *: Never connect to NC, or malfunctions or failures will
occur. occur.

HB205-1, HB215LC-1 10-163

 164
Electrical system
Electrical control system

CN-CE01 CN-CE02
Signal Signal
Pin No. Signal name Pin No. Signal name
category category
28 NC (*) 13 NC (*)
29 NC (*) 14 NC (*)
30 NC (*) 15 NC (*)
31 NC (*) 16 NC (*)
32 IMA return C 17 NC (*)
33 5 V electric power supply for sensor A 18 NC (*)
34 NC (*) 19 NC (*)
35 NC (*) 20 NC (*)
36 NC (*) 21 NC (*)
37 5 V electric power supply for sensor A 22 Fuel control dial (+5 V) A
38 (GND) C 23 Fuel control dial () C
39 NC (*) 24 NC (*)
40 NC (*) 25 NC (*)
41 NC (*) 26 NC (*)
42 NC (*) 27 NC (*)
43 NC (*) 28 NC (*)
44 Boost pressure sensor B 29 NC (*)
45 Injector #1 (+) D 30 NC (*)
46 Injector #3 (+) D 31 NC (*)
47 Bkup sensor () C 32 NC (*)
48 Ne sensor () C 33 GND C
49 NC (*) 34 NC (*)
50 NC (*) 35 NC (*)
51 NC (*) 36 NC (*)
52 Injector #4 () C 37 NC (*)
53 Injector #1 () C 38 NC (*)
54 NC (*) 39 Key switch (ACC) B
55 Injector #4 (+) D 40 Electrical intake air heater relay drive D
56 NC (*) 41 NC (*)
57 Injector #2 (+) D 42 Electrical intake air heater relay return C
58 NC (*) 43 NC (*)
59 Injector #2 () C 44 NC (*)
60 Injector #3 () C 45 NC (*)
46 CAN(+) E
*: Never connect to NC, or malfunctions or failures will
occur. 47 CAN () E
48 NC (*)
49 PWM OUTPUT D
CN-CE02 50 NC (*)
Signal
Pin No. Signal name *: Never connect to NC, or malfunctions or failures will
category
1 NC (*) occur.
2 NC (*)
3 NC (*) CN-CE03
4 NC (*) Signal
Pin No. Signal name
5 NC (*) category
6 NC (*) 1 GND C
7 NC (*) 2 NC (*)
8 NC (*) 3 Electric power supply (+24 V constantly) A
9 Fuel control dial (+) B 4 NC (*)
10 NC (*)
*: Never connect to NC, or malfunctions or failures will
11 NC (*) occur.
12 NC (*)

*: Never connect to NC, or malfunctions or failures will

occur.

10-164 HB205-1, HB215LC-1

 165
Electrical system
Electrical control system

Pump controller

HB205-1, HB215LC-1 10-165

(03)
 166
Electrical system
Electrical control system

Input and output signals

CN-C01 CN-C01
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 Constant power supply Input 50 NC (*)
2 Constant power supply GND Input 51 NC (*)
3 Window washer Output 52 Service switch Input
4 Constant power supply Input 53 Boom RAISE pressure sensor Input
5 Constant power supply GND Input 54 NC (*)
6 NC (*) 55 Travel pressure switch Input
7 NC (*) 56 Wiper limit switch Input
8 Potentiometer power supply (5 V) Output 57 Window limit switch Input
9 Potentiometer power supply (5 V) Output 58 Model Select 4 Input
10 NC (*) 59 NC (*)
11 NC (*) 60 Key SW (C) Input
12 NC (*) 61 NC (*)
13 NC (*) 62 External drive signal Input
14 Boom LOWER pressure SW Input 63 NC (*)
15 Arm OUT pressure SW Input 64 CAN_L Input/Output
16 Swing (L) pressure sensor Input 65 NC (*)
17 Arm IN pressure sensor Input 66 NC (*)
18 Analog GND Input 67 NC (*)
19 Swing lock Input 68 R pump pressure sensor Input
20 NC (*) 69 NC (*)
21 Model Select 2 Input 70 Analog GND Input
22 NC (*) 71 NC (*)
23 NC (*) 72 Swing (R) pressure sensor Input
24 Key Switch (ACC) Input 73 Bucket CURL pressure sensor Input
25 NC (*) 74 NC (*)
26 NC (*) 75 Wiper (P) Input
27 NC (*) 76 NC (*)
28 NC (*) 77 Model Select 3 Input
29 Hydr. Oil Temperature Input 78 NC (*)
30 NC (*) 79 Key Switch (ACC) Input
31 NC (*) 80 NC (*)
32 NC (*) 81 NC (*)
33 NC (*)
*: Never connect to NC, or malfunctions or failures will
34 Bucket DUMP pressure sensor Input occur.
35 NC (*)
36 Travel steering pressure SW Input
37 NC (*)
38 Swing brake cancel switch Input
39 Model Select 5 Input
40 Model Select 1 Input
41 Knob SW Input
42 NC (*)
43 Key Switch (ACC) Input
44 NC (*)
45 CAN_H Input/Output
46 Analog GND Input
47 NC (*)
48 NC (*)
49 F pump pressure sensor Input

*: Never connect to NC, or malfunctions or failures will

occur.

10-166 HB205-1, HB215LC-1

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Electrical system
Electrical control system

CN-C02
Pin No. Signal name Input/output
82 NC (*)
83 NC (*)
84 NC (*)
85 NC (*)
86 ATT circuit selector solenoid Output
87 Travel speed solenoid Output
88 LS-EPC Output
89 Merge-devider (LS) EPC Output
90 NC (*)
91 NC (*)
92 NC (*)
93 NC (*)
94 NC (*)
95 NC (*)
96 PC-EPC (F) Output
97 Service flow adjustment EPC Output
98 NC (*)
99 NC (*)
100 NC (*)
101 Swing holding brake solenoid Output
102 NC (*)
103 NC (*)
104 PC-EPC (R) Output
105 NC (*)
106 NC (*)
107 NC (*)
108 Battery relay Output
109 2-stage relief solenoid Output
110 Travel junction SOL Output
111 NC (*)
112 Merge-divider (main) EPC Output
113 NC (*)
114 Wiper motor () Output
115 Solenoid GND Input
116 Solenoid power Input
117 Solenoid GND Input
118 Solenoid power Input
119 Wiper motor(+) Output
120 Solenoid GND Input
121 Solenoid power supply Input

*: Never connect to NC, or malfunctions or failures will

occur.

HB205-1, HB215LC-1 10-167

 168
Electrical system
Electrical control system

Fuel control dial

1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector

10-168 HB205-1, HB215LC-1

 169
Electrical system
Electrical control system

Function
q The fuel control dial is installed on the machine
monitor side.
q Turning knob (1) rotates the shaft of potentiome-
ter (5).
q The rotation of the shaft changes the resistance
of the variable resistor in potentiometer (5),
sending any throttle signal to the engine control-
ler.
q The hatched area in the graph below is the ab-
normality detection area. If the throttle voltage is
within the area, a fuel control dial error is detect-
ed and the engine speed cannot be controlled
with the dial.

HB205-1, HB215LC-1 10-169

 170
Electrical system
Electrical control system

Engine oil pressure switch

1. Connector
2. Sensor
3. O-ring

Specifications 10-190

Contact type: Normally closed

Function 10-190

q This oil pressure switch is installed in the cylin-

der block. It detects engine oil pressure, and
turns the switch on when the pressure goes be-
low the specified value.

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 171
Electrical system
Electrical control system

PPC oil pressure switch

1. Plug
2. Switch
3. Connector

Specifications 10-191

Type of contacts: Normally open

Operating pressure to make contact point ON:
0.5 0.1 MPa {5.0 1.0 kg/cm2}
Operating pressure to break contact point OFF:
0.3 0.05 MPa {3.0 0.5 kg/cm2}

Function 10-191

q Two of these sensors are installed to the relay

block in the pilot circuit between the PPC valve
and control valve. They detect the PPC oil pres-
sure when each actuator is operated, and turn
the switch on when the pressure exceeds the
specified value.

HB205-1, HB215LC-1 10-171

 172
Electrical system
Electrical control system

Inverter

10-172 HB205-1, HB215LC-1

 173
Electrical system
Electrical control system

Input and output signals

CN-HC01 (DRC) CN-HC02 (DRC)
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 Terminal M+24 V Input 1 CAN line Input/Output
2 NC (*) 2 Main monitor Input/Output
3 Capacitor contactor (+) Output 3 Emergency stop Switch Input
4 NC (*) 4 SRM position sensor Input
5 Contactor +24 V Input 5 Resolver R1 OUT Output
6 ACC Input 6 Resolver S1 IN Input
7 Terminal M+24 V Input 7 Sensor power supply Output
8 Swing lock Output 8 Coolant Th (spare) Input
9 Capacitor contactor () 9 Swing lever Input
10 NC (*) 10 Arm lever Input
11 Contactor +24 V Input 11 CAN line Input/Output
12 ACC Input 12 Main monitor Input/Output
13 Terminal M GND 13 NC (*)
14 NC (*) 14 Interlock input Input
15 PPC lock lever Input 15 Resolver R2 OUT Output
16 NC (*) 16 Resolver S3 IN Input
17 GND 17 GND
18 Service connector Input 18 PM motor temperature Input
19 Terminal M GND 19 Swing lever Input
20 Terminal M GND 20 Bucket lever Input
21 Pump controller output Input 21 NC (*)
22 NC (*) 22 NC (*)
23 GND 23 NC (*)
24 NC (*) 24 Interlock output Output
25 NC (*)
*: Never wire NC since this can cause a malfunction and
a trouble. 26 Resolver S2 IN Input
27 Capacitor Th1 Input
28 SR motor temperature Input
29 Boom lever Input
30 NC (*)
31 NC (*)
32 NC (*)
32 GND
33 GND
34 NC (*)
35 Resolver S4 IN Input
36 Capacitor Th2 Input
37 GND
98 GND
39 NC (*)

*: Never wire NC since this can cause a malfunction and

a trouble.

HB205-1, HB215LC-1 10-173

 174
Electrical system
Machine monitor system

Machine monitor system 174

1. Machine monitor Outline

2. Battery q The monitor system keeps the operator informed
3. Pump controller of all machine functions, by monitoring the ma-
4. Engine controller chine conditions by using the sensors and
5. Air conditioner controller switches installed in various parts of the machine
6. Inverter and processing them instantly to display on the
7. KOMTRAX terminal machine monitor.
8. Sensors and switches The information displayed on the machine
9. Wiper motor and window washer motor monitor falls into the following types:
1. Alarm when the machine has problem
Input/output signal 2. Machine condition display (coolant tempera-
a. Power supply ture, hydraulic oil temperature, and fuel level)
b. CAN signal q The switches on the machine monitor controls
c. Sensor and switch signals the machine.
d. Drive signal

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 175
Machine monitor
Outline 10-193
q The machine monitor has monitor display func-
tion, mode selection function and switch function
for electrical parts etc. Also it has an alarm buzz-
er.
q The machine monitor has a CPU (Central Pro-
cessing Unit) in it to process, display, and output
the information.
q The machine monitor consists of a display and
switches: the display is of LCD type, and the
switches are of flat sheet switch.
q If an error occurs in the machine monitor itself,
controller or wiring circuit between monitor and
controller, the monitor does not display properly.
HB205-1, HB215LC-1
Electrical system
Machine monitor system
Precautions on the machine monitor display
q The LCD panel may have black points (points
which are not lighted) and bright points (points
which do not go off) for the reason of its charac-
teristics. If the number of the bright points and
black points does not exceed 10, it does not in-
dicate a failure or a defect.
q When the engine is started, the battery voltage
may drop suddenly depending on ambient tem-
peratures and battery conditions. In this case,
the machine monitor display may go off for a mo-
ment. However, this phenomenon is not a fail-
ure.
q Continuous operation of the machine monitor
may display blue bright spots on the screen hav-
ing a black background; it is quite normal.
Blue points can never be a problem as the
screen has usually blue or white background.
(White in the LCD is made up of red, green and
blue.)
10-175
 176
Electrical system
Machine monitor system

Input/output signal
070-18P (1) [CN-CM01]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Unswitched power supply (24 V) Input 10 NC (*)
2 Unswitched power supply (24 V) Input 11 Battery charge Input
3 GND (unswitched power supply) 12 GND (machine analog signal)
4 GND (unswitched power supply) 13 Lamp switch Input
5 Wake-up Input/output 14 Starting switch ACC signal Input
Starting motor cut-out relay (for 15 Starting switch C signal Input
6 Output 16 Preheating Input
personal code)
7 NC (*) 17 NC (*)
8 NC (*) 18 NC (*)
9 Fuel level Input
*: Never connect any cable to NC, or malfunctions or failures will occur.

070-12P (1) [CN-CM02]

Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC (*) 7 NC (*)
2 Engine oil level sensor Input 8 CAN terminal
3 Coolant level sensor Input 9 CAN_H Input/output
4 Air cleaner clogging sensor Input 10 CAN_L Input/output
5 Swing lock switch Input 11 NC (*)
6 NC (*) 12 NC (*)

*: Never connect any cable to NC, or malfunctions or failures will occur.

070-18P (2) [CN-CM03]

Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
RS232C CD for communication For communication terminal:
1 Input 10 Input
terminal RS232C CTS
RS232C RXD for communication For communication terminal:
2 Input 11 Input
terminal RS232C RI
RS232C SG for communication GND (communication terminal
3 12
terminal power supply)
GND (communication terminal Communication terminal status
4 13 Input
control signal) signal CH1
Communication terminal selection Communication terminal power
5 Input 14 Output
signal supply control signal
For communication terminal: Communication terminal control
6 Output 15 Output
RS232C RTS signal CH1
For communication terminal: Communication terminal control
7 Output 16 Output
RS232C TXD signal CH2
For communication terminal: Communication terminal status
8 Output 17 Input
RS232C DTR signal CH2
For communication terminal: Communication terminal power
9 Input 18 Output
RS232C DSR supply (12 V)

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Electrical system
Machine monitor system

070-12P (2) [CN-CM04]

Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC (*) 7 NC (*)
2 NC (*) 8 NC (*)
3 NC (*) 9 NC (*)
4 NC (*) 10 NC (*)
5 NC (*) 11 NC (*)
6 NC (*) 12 NC (*)

*: Never connect any cable to NC, or malfunctions or failures will occur.

B60-8P [CN-CM05]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Camera power supply (8 V) Output 5 GND (Camera power supply)
2 Camera NTSC signal 1 Input 6 GND (Camera signal 1)
3 Camera NTSC signal 2 Input 7 GND (Camera signal 2)
4 Camera NTSC signal 3 Input 8 GND (Camera signal 3)

HB205-1, HB215LC-1 10-177

 178
Electrical system
Machine monitor system

Display

A: Standard screen
B: All indicators light-up screen
q If problems indicated by monitors (15) to (20) occur after starting the engine, the corresponding monitors
are displayed from the left top in the order of occurrence of the problems.
q If a problem indicated by monitors (15) to (20) occurs while working, the relevant monitor is displayed in
large size for two seconds and then displayed in small size.
q If the hydraulic oil temperature goes High or Low while a monitor is being displayed at the central portion
of the screen, at whitch the hydraulic oil temperature monitor is to be displayed, the screen displays only
hydraulic oil temperature monitor (2b).
C: Screen with maintenance time reminder
D: Screen with emergency swing stop switch operation

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 179
Electrical system
Machine monitor system

Display
NO. Display item Description Remarks
category
Temperature Background q Indicates corresponding temperature
Range (C) color range.
W1 105 Red q Alarm buzzer sounds when the temper-
W2 102 Red ature exceeds 105C.
1a Gauge (*1) q If the monitor background appears
Engine coolant W3 100 Blue white, warm-up the engine.
temperature W4 85 Blue
W5 60 Blue
W6 30 White
1b Caution See the column "Gauge".
Temperature Background q Indicates corresponding temperature
Range (C) color range.
H1 105 Red q Alarm buzzer sounds when the temper-
H2 102 Red ature exceeds 105C.
2a Gauge (*1) q If the monitor background appears
Hydraulic oil H3 100 Blue white, warm-up the hydraulic compo-
temperature H4 85 Blue nents.
H5 40 Blue
H6 20 White
2b Caution See the column "Gauge".
Temperature Background q Indicates corresponding temperature
Range (%) color range.
E1 102 Red q Alarm buzzer sounds when the temper-
E2 100 Red ature exceeds 102%.
3a Gauge (*1) (*2)
Hybrid E3 95 Blue
temperature E4 50 Blue
E5 20 Blue
E6 0 White
3b Caution See the column "Gauge".
q
Quantity (l) Background
Indicates corresponding fuel level.
Range color
F1 230 Blue
F2 195 Blue
4a Gauge (*1) F3 160 Blue
Fuel level
F4 80 Blue
F5 60 Blue
F6 40 Red
4b Caution See the column "Gauge".
Segment Load level q
Indicates average load per minute on a
Light to scale of 1 to 10.
5 ECO gauge Green 18 medium (Indicates when "Default (ECO display
is set to active)" of the service mode is
Orange 9,10 Heavy "ON".)
q Displays the average fuel consumption
of 1 minute.
(*1) q Right end gauge: Latest value
Top of gauge: 30 l/h
Fuel q Left end gauge: Value 5 minutes
6 Gauge Middle of gauge: 18 l/h
consumption before q Graph is erased each time when starting
monitor q Total 5 gauges (1 minute interval)
switch is turned from OFF position to ON
position.
q Indicates accumulated engine operating
Service meter reading 00000h 99999h hours (the alternator is running).
(F4 switch changes it for clock display.)
7
q Displays time.
q 12-hour display (AM/PM)
Clock q 24-hour display
(F4 switch changes it for service meter
display.)
Background (If KOMTRAX is installed.)
Condition
color q The condition of the message is dis-
8 Message Green There is unread message. played.
Blue There is unsent message. (OFF when no message exists.)
Pilot q Indicates air conditioner and air blower
Air conditioner Light ON: ON
9 Light OFF: OFF operating status.
INT: Intermittent q Indicates front glass wiper operating
10 Wiper ON: Continuous condition.
Light OFF: Stop
*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer goes off.
*2: The hybrid temperature gauge displays in percentage to indicate the temperature load of hybrid equipment.
(See separate page for detail.)

HB205-1, HB215LC-1 10-179

 180
Electrical system
Machine monitor system

Display
NO. Display item Description Remarks
category
Swing lock Swing brake Monitor q Indicates swing lock operating status.
switch cancel switch display
OFF OFF OFF
11 Swing lock ON OFF ON
OFF ON Blink
ON ON Blink
Elapsed time after turning q Indicates preheat operating status.
Monitor
the starting switch to display
"HEAT (preheat)".
12 Preheating 0 30 sec. ON
30 40 sec. Blink
40 sec. or longer OFF
One-touch q Indicates the operating status of
Pilot power max. Monitor display one-touch power maximizing function.
One-touch switch
13 power max. ON (Goes off if pressed
ON for 8.5 seconds)
OFF Off
Light ON: ON q Indicates auto-decelerator operating
14 Auto-decelerator Light OFF: OFF status.
P: Heavy-duty operation q Displays working mode.
E: Low-fuel consumption operation
15 Working mode L: Fine operation
B: Breaker operation
ATT: Double-acting attachment operation
Lo: Low speed q Displays travel speed setting.
16 Travel speed Med: Medium speed
Hi: High speed
(*3) Light ON: Abnormal range (below the q When an error is detected with the en-
17 Radiator coolant specified value) gine stopped, the monitor lights up on
level Light OFF: Normal range the screen.
Light ON: Defective battery charge q When an error is detected with the en-
(*3)
18 (Charge voltage < Battery voltage) gine running, the monitor lights up on
Battery charge Light OFF: Normal range the screen.
(*3) Light ON: Abnormal range (below the q The monitor lights up on the screen and
19 Engine oil specified value) alarm buzzer sounds, when an error is
pressure Light OFF: Normal range detected with the engine running.
Light ON: Abnormal range (above the q When an error is detected with the en-
Hybrid
20 specified value) gine running, the monitor lights up on
temperature Light OFF: Normal range the screen.
Light ON: Abnormal range (below the q When an error is detected with the en-
(*3)
21 specified value) gine stopped, the monitor lights up on
Engine oil level Light OFF: Normal range the screen.
(*3) Light ON: Abnormal range (above the q When an error is detected with the en-
22 Air cleaner specified value) gine running, the monitor lights up on
clogging Light OFF: Normal range the screen.
Caution Light ON: Abnormal range (water level q When an error is detected with the en-
(*3)
23 is above the specified value) gine running, the monitor lights up on
Water separator Light OFF: Normal range the screen.
q When an error is detected with the en-
Light ON: Hybrid system is abnormal
24 Hybrid gine running, the monitor lights up on
Light OFF: Hybrid system is normal
the screen.
Background q The display changes depending on the
Condition
color time to/after the replacement.
There is a maintenance q After the starting switch is turned to ON
Maintenance item which is 30 hours or position, the monitor turns on if the mon-
25 Yellow itor light-up conditions are met, and then
time less left before next
replacement. goes off in 30 seconds.
There is a replacement
Red overdue item.
q The swing emergency stop function is
Swing Lights up: Swing emergency stop switch operated.
26 q If an error occurs while the swing emer-
emergency stop is turned ON
gency stop is operated, the monitor
changes to display the error.
*3: Included in the start-up check. After the staring switch is turned to ON position, the monitor turns on for two seconds,
and changes to the standard screen if no error is found.

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 181
Electrical system
Machine monitor system

Hybrid temperature gauge (detail)

Temperature of hybrid equipment below is converted to percentage and the maximum value is indicated in gauge.

Hybrid equipment Capacitor cell Pressure booster Pressure booster Pressure booster
%
temp. temp. IGBT base temp. IGBT JCT Temp. inductor temp.
A1 102 65 80 130 125
A2 100 63 78 125 120
A3 95 60 75 110 110
A4 50 40 55 90 90
A5 20 0 0 0 0
A6 0 -30 -30 -30 -30

Hybrid equipment Swing motor coil Motor-generator Generator driver Swing inverter JCT
%
temp. temp. temp. temp. temp.
A1 102 140 180 95 134
A2 100 120 170 85 133
A3 95 100 130 60 110
A4 50 80 110 40 90
A5 20 0 0 0 0
A6 0 -30 -30 -30 -30

HB205-1, HB215LC-1 10-181

 182
Electrical system
Machine monitor system

Switches

NO. Model Function Operation

Turns the auto-decelerator function q When the working mode is in "L", the au-
Auto-deceleration switch ON/OFF. to-decelerator does not work.
1
[Numeric keypad: 1] Light ON: ON
Light OFF: OFF OFF io ON
P: Heavy-duty operation
(*1)
E: Low-fuel consumption operation
Working mode Displays the working mode selector
2 L: Fine operation
selector switch screen.
B: Breaker operation
[Numeric keypad: 2]
ATT: Double attachment operation
Changes the travel speed. o Lo o Mi o Hi o
Travel speed (Low speed) (Medium (High speed)
Lo light ON: Low speed
3 selector switch
Mi light ON: Medium speed I speed) O
[Numeric keypad: 3] i i i i i i
Hi light ON: High speed
Buzzer cancel Stops the alarm buzzer. q Stops the alarm buzzer.
4 switch (Some alarm buzzer does not stop even if q The alarm buzzer resumes sounding when
[Numeric keypad: 4] the switch is pressed.) another error is detected.
Operates the front window glass wiper. o INT o ON o OFF o
(*2) (Intermittent) (Continuous) (Stop)
INT: Intermittent
5 Wiper switch
ON: Continuous I O
[Numeric keypad: 5] i i i
Light OFF: Stop
ON: Washer fluid is sprayed and wiper works
continuously.
[When wiper stops]
(*2)
OFF: Wiper works twice and stops after the
Window washer Sprays washer fluid onto the front window
6 switch is released.
switch glass.
[When wiper operates intermittently]
[Numeric keypad: 6]
OFF: Wiper works twice continuously and
returns to intermittent operation after the
switch is released.

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 183
Electrical system
Machine monitor system

NO. Model Function Operation

q The air flow increases immediately after
Fan switch (increase)
7a Controls the flow rate of the air the air conditioner adjustment screen ap-
[Numeric keypad: 7]
conditioner in 6 levels. pears.
(Low, Medium 1, Medium 2, Medium 3, q The air flow decreases immediately after
7b Fan switch (decrease) Medium 4, High) the air conditioner adjustment screen ap-
pears.
Temperature control q The preset temperature increases immedi-
8a switch (UP) ately after the air conditioner adjustment
[Numeric keypad: 8] Controls the temperature inside the cab. screen appears.
(18.0C 32.0C: adjustable at every
Temperature control q The preset temperature decreases imme-
0.5C)
8b switch (DOWN) diately after the air conditioner adjustment
[Numeric keypad: 0] screen appears.
q Automatically controls the air flow, air vent,
(*3) Auto-runs the air conditioner and air fresh/recirculated air change according to
9 Auto switch blower. the temperature setting, immediately after
[Numeric keypad: 9] AUTO light ON: Auto run the air conditioner adjustment screen ap-
pears.
q Switches to the air conditioner adjustment
Turns the air conditioner ON/OFF. screen, and pressing it again switches
(*4)
10 AC ON lights-up: manual operation ON/OFF.
Air conditioner switch
Light OFF:Stop
OFF io ON
q Switches to the air conditioner adjustment
FRESH/RECIRC air screen, and pressing it again switches
11 Changes the FRESH/RECIRC. FRESH/RECIRC.
selector switch
RECIRC io FRESH
q Switches to the air conditioner adjustment
Selects the air vent mode from 6 modes. screen, and pressing it again switches air
1. Front vent mode.
2. Front and rear q Modes 5 and 6 are not available with auto
12 Vent selector switch 3. Front and rear foot mode.
4. Foot o1 o2 o3 o4 o5 o6 o
5. Foot and defroster
6. Defroster I O
i i i i i i
Stops the fan and air conditioner.
13 OFF switch q The fan and air conditioner stop.
Light OFF: OFF
14a Guidance icon
See "Guidance icon and function switch." section.
14b Function switch

*1: When the working mode is changed, the auto-decelerator function turns "ON".
*2: When the front window is open, the windshield wiper and the washer do not operate even if the switch is
pressed.
*3: When the temperature is set to 18.0C or 32.0C, the fan speed is kept at "High". Even if the set temper-
ature is reached, the flow rate remains fixed at "High".
*4: When the fan is set to Stop, the air conditioner does not start even if the switch is pressed.

HB205-1, HB215LC-1 10-183

 184
Electrical system
Machine monitor system

Guidance icon and function switch

q Functions available with the function switch vary depending on the guidance icon displayed above the
switch.
q No function is available if no guidance icon appears above the function switch.
q The following is the list of guidance icons and the functions displayed above the function switches.

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 185
Electrical system
Machine monitor system

Guidance
Function switch Role Function
icon
1 Clear Clears selected/displayed item.

2 Display No. 1 camera screen Selects No. 1 camera screen.

Moves selectable item page down one page.
3 Change selectable items
(To the top page from the bottom page.)
4 Set Performs setting.
F1 Starts function.
5 Start (Used for starting measurement of split fuel
consumption.)
Stops operation.
6 Stop (Used for stopping measurement of split fuel
consumption.)
*1
7 Selects energy monitor screen 7.
Display energy monitor
Sets selected item back to default.
1 Return to default setting
(Used for screen adjustment.)
2 Display No. 2 camera screen Selects No. 2 camera screen.
Moves selectable item page up one page.
3 Change selectable items
F2 (To the bottom page from the top page.)
4 Clear Clears selected/displayed item.
*1
5 Display fuel consumption Switches fuel consumption monitor screen.
record screen
1 Switching to camera screen Switches to camera screen.

2 Display No. 3 camera screen Selects No. 3 camera screen.

F3 Moves selectable item down one item.
3 Select item (To the top item from the bottom item.)
Releases holding of the monitor.
Moves selectable item to the left.
4 Select item
(To the rightmost item from the leftmost item.)
1 Switching clock/service meter Switches clock/service meter display.
Display No. 1 and No. 2 camera Display both images of No.1 and No.2 cameras
2
screens simultaneously.
F4 Moves selectable item up one item.
3 Select item (To the bottom item from the top item.)
Holds the monitor.
Moves selectable item to the right.
4 Select item
(To the leftmost item from the rightmost item.)
Selection of maintenance
1 Switches to the maintenance screen.
screen
F5
2 Return Returns to the previous screen or status.

1 Select user mode screen Switches to the user mode screen.

F6
2 Enter Enters selected/set item.

HB205-1, HB215LC-1 10-185

 186
Electrical system
Machine monitor system

Operator mode function

q The operator can select the information to be displayed on the standard screen and the function to be
used, by operating the switches. Note that some information displays and function selections require the
special operations of the switches.
q Items available in the operator mode are as follows:

Category Display order (*2)

Item
(*1) V W X Y Z
KOMATSU logo screen 1 1 1 1 1
Password input screen 2
Breaker mode check screen 2
Start-up check screen 3 2 3 2 2
A Warning after "start-up check" screen 3
Overdue replacement item screen 3
Working mode and travel speed check screen 4 3 4 4 4
Display of standard screen 5 4 5 5 5
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner
Operation of fuel consumption monitor/energy monitor
Operation to display camera mode (If camera is equipped)
B Switching between clock display and service meter display
Check of maintenance information
Entering user mode
q Breaker/Attachment Settings
q User Messages (including KOMTRAX messages for user)
q Screen Adjustment
q Clock Adjustment
q Language
q Economy Mode Adjustment
q Reset Average Fuel Consumption Logs
q Auto Decel Setting
Display of energy-saving guidance
C Display of caution monitor
Displaying user code and failure code
Function of checking display of LCD (Liquid Crystal Display)
D Function of checking service meter
Function of changing attachment/maintenance password

*1: The items available in the operator mode fall into the following categories.
A: Display from the time starting switch is turned to ON position until the standard screen appears. Display
after the starting switch is turned to OFF position.
B: Display when the switch on the machine monitor is operated.
C: Display when a certain condition is satisfied
D: Display to requires special operation of the switches.
*2: For the category A, the order in which items are displayed varies depending on the settings and conditions
of the machine as follows:
V: When engine start lock is set effective
W: When engine start lock is disabled
X: When working mode at start is set to "Breaker Mode (B)"
Y: When an error is detected during start-up check.
Z: When a replacement time overdue is detected.

a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Special
functions of machine monitor" section in Testing and adjusting.
a For how to set the engine start lock on/off, see "Password setting/cancel manual".

10-186 HB205-1, HB215LC-1

 187
Electrical system
Machine monitor system

Oil flow setting for breaker Oil flow setting for attachment

q Oil flow for the breaker can be changed in the q Oil flow for the 2-way attachment can be
"Breaker/attachment setting" of the user mode. changed in the "Breaker/attachment setting" of
q Oil flow level can be set as follows: the user mode.
Flow level Flow rate (l/min) Remarks q Oil flow level can be set as follows:
1 70 Flow level Flow rate (l/min) Remarks
2 80 1 30
3 90 2 90
4 100 3 115
5 110 4 140
6 120 5 170
7 130 6 250
8 140 7 350
9 150 8 430 Default
10 160
Language setting
11 170
12 180 Default
13 190
14 200
15 210

q The language used in the machine monitor can

be changed in the "Language setting" of the user
mode.
q The available languages are as follows:
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, Turkish,
Indonesian, and Thai.

HB205-1, HB215LC-1 10-187

 188
Electrical system
Machine monitor system

Economy mode adjustment

q Fuel consumption can be improved by adjusting

the engine output power at "Economy Mode Ad-
justment" in user mode.
q The level can be selected from 4 stages,
E0/E1/E2/E3. The larger, the number of stage
becomes, the more the fuel consumption im-
proves, while the production reduces.

10-188 HB205-1, HB215LC-1

 189
Electrical system
Machine monitor system

Service mode function

q The functions in this mode are not displayed on the standard screen. The arrangements for the information
display and various setting can be made only by the technician through the special operation of the switch-
es.
This mode is used for special setting, testing, adjusting, or troubleshooting.
q Items available in the service mode are as follows:

Monitoring
Mechanical Systems
Abnormality Record Electrical Systems
Air-conditioning System
Maintenance Record
Maintenance Mode Change
Phone Number Entry
Key-on Mode
Unit
With/Without Attachment
Default
Attachment/Maintenance Password
Camera
ECO Display
Pump Absorption Torque (F)
Pump Absorption Torque (R)
Adjustment
Low Speed
Attachment Flow Adjustment
Discharge of capacitor
Cylinder Cut-Out
No Injection
Fuel Consumption
Terminal Status
KOMTRAX Settings GPS & Communication Status
Modem S/N
Service Message

a For how to operate the service mode functions, see "Special functions of machine monitor" section in Test-
ing and adjusting.

HB205-1, HB215LC-1 10-189

 190
Electrical system
KOMTRAX system

KOMTRAX system 190

(if equipped)

q The KOMTRAX system consists of the

KOMTRAX terminal, communication antenna,
machine monitor and GPS antenna.
q This system sends various information on the
machine via wireless communication. It allows
operators of the KOMTRAX to obtain the ma-
chine information from the office and to provide
various services with the customers.
q The information available from the KOMTRAX
system are as follows:
1. Operation map
2. Service meter reading
3. Location information
4. Failure history
and others.
a To provide the services, you need to make an ar-
rangement for starting the KOMTRAX service
separately.

10-190 HB205-1, HB215LC-1

 191
Electrical system
KOMTRAX system

KOMTRAX terminal
Model: TH300
q The KOMTRAX system utilizes satellite communications technology.

1. Communication antenna connection Outline

2. Machine harness connection (AMP-14P) q The terminal is a radio communication equip-
3. Machine harness connection (AMP-10P) ment which transmits various machine informa-
tion obtained by the machine monitor through
Input/output signal network signals and input signals, as well as
AMP-14P [CN-CK01] GPS positioning data. The terminal can transmit
data via the communication antenna.
Input/Output
Pin No. Signal name q The status of the terminal can be monitored on
signal
A1 Power supply (4.75 6 V) Input the machine monitor when it is in the service
A2 NC (*) mode "KOMTRAX setting display".
A3 NC (*) q Use of KOMTRAX terminal must be limited for

A4 NC (*) the countries in which such communication is al-

A5 NC (*) lowed.
A6 NC (*)
A7 GND Input a When commencing operation of the KOMTRAX
A8 GND Input system or changing the country in which the sys-
A9 PSW Input tem is used, you must give notice to Komatsu
A10 IN-SERVICE Input Ltd..
A11 SLI-SLP Input a When operating the system in Japan, install a
A12 NC (*) terminal dedicated for use in Japan.
A13 DTE-REST Output
A14 NC (*)
*: Never connect any cable to NC, or malfunctions or
failures will occur.

AMP-10P [CN-CK02]
Input/Output
Pin No. Signal name
signal
B1 RS232C DCD Output
B2 RS232C RXD Output
B3 RS232C TXD Input
B4 RS232C DTR Input
B5 RS232C SGND Input
B6 RS232C DSR Output
B7 RS232C RTS Input
B8 RS232C CTS Output
B9 RS232C RI Output
B10 NC (*)
*: Never connect any cable to NC, or malfunctions or
failures will occur.

HB205-1, HB215LC-1 10-191

 192
Electrical system
Sensors

Sensors 192

Boost pressure/temperature sensor

1. Connector 3. O-ring
2. Sensor

Function
q This sensor is installed in the intake manifold. It detects the boost pressure and intake air temperature,
and outputs signal as a variable voltage for pressure, and a resistance change for temperature.

Coolant temperature sensor

1. Connector 3. O-ring
2. Sensor

Function
q This sensor, installed on the cylinder head, converts the temperature variation into the change in resis-
tance, and outputs the corresponding signals.

10-192 HB205-1, HB215LC-1

 193
Electrical system
Sensors

Crankshaft speed sensor

Camshaft speed sensor

1. Connector 3. O-ring
2. Sensor

Function
q Crankshaft speed sensor and camshaft speed sensor are installed to the adjacency of the gear and the
ring on the cooling fan side of crankshaft and camshaft, respectively, and output pulse voltages due to
gear rotations.

Water-in-fuel sensor

1. Connector 3. Sensor
2. Tube 4. O-ring

Function
q This sensor is installed to the cup of fuel prefilter, and outputs a signal when detecting water exists in the
fuel.

HB205-1, HB215LC-1 10-193

 194
Electrical system
Sensors

Engine oil level sensor

1. Connector 3. Float
2. Bracket 4. Switch

Function
q This sensor is installed on the side face of the oil pan, and turns "OFF" by the lowered float, if the oil level
becomes lower than specified.

10-194 HB205-1, HB215LC-1

 195
Electrical system
Sensors

PPC oil pressure sensor

1. Sensor q The relationship between the pressure applied

2. Connector to sensors (P) and output voltage (E) is shown in
the following figure.
Function
q Eleven PPC oil pressure sensors are installed to
the junction block.
q This sensor detects the operating condition of
each actuator by the PPC pressure and trans-
mits it to the pump controller and inverter.

Operation
q The oil pressure is applied to the diaphragm of
the oil pressure sensor from the pressure intake
part, the diaphragm is deformed.
q The deformation in the diaphragm causes the re-
sistance of the gauge to change. This causes a
change in the output voltage, which is transmit-
q The amplifier increases output voltage (E) and
ted to the amplifier (voltage amplifier).
transmits it to the pump controller.

HB205-1, HB215LC-1 10-195

 196
Electrical system
Sensors

Front pump oil pressure sensor

Rear pump oil pressure sensor

1. O-ring Output characteristics

2. Sensor
3. Connector

Function
q Front pump oil pressure sensor and rear pump
oil pressure sensor are installed to the control
valves, detect the discharge pressures of
pumps, and output the corresponding variable
voltages.

Hydraulic oil level sensor

1. Connector 3. Float
2. Bracket 4. Switch

Function
q This sensor is installed on the side face of the hydraulic tank, and turns "OFF" by the lowered float, if the
oil level becomes lower than specified.

10-196 HB205-1, HB215LC-1

 197
Electrical system
Sensors

Fuel level sensor

1. Float 3. Cover
2. Connector 4. Variable resistor

Function
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The movement of the float rotates the shaft of the variable resistor through the arm. As a result, the source
voltage is changed according to the resistance change due to the arm angle change and is output as a
signal.

HB205-1, HB215LC-1 10-197

 198
Electrical system
Sensors

Air cleaner clogging sensor

1. Boss 4. Wire
2. Switch 5. Connector
3. Conduit

Function
q The sensor is installed on the air cleaner outlet side. It turns "ON", if the air cleaner is clogged and the
pressure level drops to the specified level (negative pressure).

Coolant level sensor

1. Reserve tank 3. Sensor

2. Float 4. Connector

Function
q This sensor is integrated with reservoir tank, and turns "OFF" by the lowered float, if the coolant level be-
comes lower than specified.

10-198 HB205-1, HB215LC-1

 0 -1
HB205-1, HB215LC-1

HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1

Machine model Serial number

HB205-1 1001 and up
HB215LC-1 1001 and up

20 Standard value table 30-1

HB205-1, HB215LC-1 20-1

(01)
 2
Contents

Contents 10-2

20 Standard value table

Standard value table for engine .............................................................................................. 20- 3 3
Standard value table for engine ........................................................................................... 20- 3 3
Standard value table for machine ........................................................................................ 20- 4 4

20-2 HB205-1, HB215LC-1

(01)
 3
Standard value table
Standard value table for engine

Standard value table 3

Standard value table for engine 3

Applicable model HB205-1, HB215LC-1

Engine SAA4D107E-1
Cate- Standard value for Judgement
Item Measurement condition Unit
gory new machine criteria
2,060 70 2,060 70
(*)High idle rpm
1,250 70 1,250 70
q Coolant temperature:
Engine speed
within operating range
Low idle rpm 700 50 700 50

Rated speed rpm 2,000 2,000

Intake pressure q Coolant temperature: operating range kPa Min. 133 107
(boost pressure) q Arm IN relief + Power Max. {mmHg} {Min. 1,000} {800}
At sudden
% Max. 25 35
q Coolant temperature: acceleration
Exhaust gas color
within operating range
At full speed %

Intake valve mm 0.25 0.152 0.381

Valve clearance q Normal temperature
Exhaust
mm 0.51 0.381 0.762
valve
Engine

Compression MPa Min. 2.41 1.69

Compression pressure {kg/cm2} {Min. 24.6} {17.2}
q Oil temperature: 40 60C
pressure Engine
rpm 250 280 250 280
speed
q Coolant temperature: operating range kPa Max. 0.98 1.96
Blow-by pressure
q Arm IN relief + power max. {mmH2O} {Max. 100} {200}
q SAE0W30EOS,
SAE5W40EOS, MPa Min. 0.29 0.25
Full speed
SAE10W30DH, {kg/cm2} {Min. 3.0} {2.5}
Oil pressure SAE15W40DH,
SAE30DH engine oil MPa Min. 0.10 0.07
q Coolant temperature: Low idle
{kg/cm2} {Min. 1.0} {0.7}
within operating range
Oil temperature q Whole speed range (inside oil pan) C 80 110 120
q Between fan pulley and alternator pulley
Fan belt tension q Deflection when pressed with finger mm Auto-tensioner Auto-tensioner
force of approx. 98 N {10 kg}
q Between fan pulley and compressor pul-
Air conditioner
ley
compressor belt mm 6.3 8.7 6.3 8.7
q Deflection when pressed with finger
tension
force of approx. 60 N {6.2 kg}

(*) The high idle speed:

1) When auto-decelerator is OFF: 1,250 rpm
2) When the travel lever is operated a little to a degree that the travel motor does not move (When the
travel switch of monitoring code "01900" is ON): 2,060 rpm

HB205-1, HB215LC-1 20-3

(01)
 4
Standard value table
Standard value table for machine

Standard value table for machine 4

Applicable model HB205, HB215LC-1

Cate- Standard value Judgement
Item Measurement condition Unit
gory for new machine criteria
q Engine coolant temperature: Within oper-
ating range
q Hydraulic oil temperature: Within operating
2 pumps at relief(*) range rpm 1,800 100 1,800 100
q Engine at full speed
q Working mode (P)
Engine speed

q Arm IN relief + swing lock switch ON

q Engine coolant temperature: Within oper-
ating range
q Hydraulic oil temperature: Within operating
At 2-pump relief +
range rpm 1,950 100 1,950 100
power max.(*)
q Engine at full speed
q Working mode: P mode
q Arm IN relief + Left knob switch ON
Speed when auto- q Fuel control dial high idle (Max.) position
deceleration is q Auto-deceleration switch in ON position rpm 700 50 700 50
operated q All control levers in NEUTRAL position
RAISE mm 11.5 0.5 11.5 0.5
Boom control valve
LOWER mm 9.5 0.5 9.5 0.5
IN mm 11.5 0.5 11.5 0.5
Spool stroke

Arm control valve

q Engine stopped OUT mm 9.5 0.5 9.5 0.5
Bucket control q For measuring point, see CURL, mm 9.5 0.5 9.5 0.5
valve Control valve. DUMP
LH, RH
Swing control valve swing mm 9.5 0.5 9.5 0.5
Forward,
Travel control valve Reverse mm 9.5 0.5 9.5 0.5
Boom control lever mm 85 10 85 10
Travel of control levers

Arm control lever mm 85 10 85 10

q Engine stopped
Bucket control lever mm 85 10 85 10
q Control lever grip at center
Swing control lever q Max. value reading up to stroke end mm 85 10 85 10
Travel control lever (except lever play in NEUTRAL position) mm 115 12 115 12
Work mm Max. 15 Max. 20
equipment
Play of control lever
Travel mm Max. 20 Max. 25
N 15.7 3.9 Max. 24.5
Boom control lever
{kg} {1.6 0.4} {Max. 2.5}
control levers and pedal

N 15.7 3.9 Max. 24.5

Arm control lever
Operating effort of

q Hydraulic oil temperature: Within operating {kg} {1.6 0.4} {Max. 2.5}
range N 12.7 2.9 Max. 21.6
Bucket control lever
q Engine at full speed {kg} {1.3 0.3} {Max. 2.2}
q Control lever grip at center N 12.7 2.9 Max. 21.6
Swing control lever q Pedal at tip {kg} {1.3 0.3} {Max. 2.2}
q Max. value reading up to stroke end N 24.5 5.9 Max. 39.2
Travel control lever
{kg} {2.5 0.6} {Max. 4.0}
N 74.5 18.6 Max. 107.6
Travel control pedal
{kg} {7.6 1.9} {Max. 11}

(*) The high idle speed:

1) When auto-decelerator is OFF: 1,250 rpm
2) When the travel lever is operated a little to a degree that the travel motor does not move (When the travel switch
of monitoring code "01900" is ON): 2,060 rpm

20-4 HB205-1, HB215LC-1

(01)
 5
Standard value table
Standard value table for machine

Applicable model HB205, HB215LC-1

Cate- Standard value Judgement
Item Measurement condition Unit
gory for new machine criteria
q Hydraulic oil temperature: Within operating
range
q Engine at full speed MPa 3.5 1.0 3.5 1.0
Unload pressure
q Working mode: P mode {kg/cm2} {36 10} {36 10}
q Hydraulic pump output pressure with all
control levers in NEUTRAL position
Normal MPa 33.8 36.3 33.3 36.8
Boom relief pres- relief {kg/cm2} {345 370} {340 375}
sure Power MPa 36.3 38.7 36.3 39.2
q Hydraulic oil temperature: max. {kg/cm2} {370 395} {370 400}
Within operating range Normal MPa 33.8 36.3 33.3 36.8
q Engine at full speed relief {kg/cm2} {345 370} {340 375}
Arm relief pressure q Working mode: P mode
q Hydraulic pump output pres- Power MPa 36.3 38.7 36.3 39.2
sure with all measurement cir- max. {kg/cm2} {370 395} {370 400}
cuits relieved Normal MPa 33.8 36.3 33.3 36.8
Bucket relief pres- relief {kg/cm2} {345 370} {340 375}
Hydraulic pressure

sure Power MPa 36.3 38.7 36.3 39.2

max. {kg/cm2} {370 395} {370 400}
q Hydraulic oil temperature: Within operation
range
Travel relief pres- q Engine at full speed MPa 38.7(+1.0/-2.0) 36.8 40.2
sure q Working mode: P mode {kg/cm2} {395(+10/-20)} {375 410}
q Hydraulic pump output pressure with all
measurement circuits relieved
q Hydraulic oil temperature: Within operating
range
Control circuit q Engine running at full speed MPa 3.23(+0.2/-0.3) 2.75 3.43
source pressure q Self pressure reducing valve output pres- {kg/cm2} {33(+2/-3)} {28 35}
sure with all control levers in NEUTRAL
position
q Hydraulic oil temperature: When all
Within operating range control MPa 3.5 1.0 3.5 1.0
q Engine at full speed levers in
NEUTRAL {kg/cm2} {36 10} {36 10}
q Working mode: P mode
LS differential pres- position
q Traveling speed: Hi
sure When
q Run either track idle
q LS differential pressure = travel MPa 1.8 0.1 1.8 0.1
Hydraulic oil pump pressure levers at {kg/cm2} {18 1} {18 1}
LS pressure half stroke

HB205-1, HB215LC-1 20-5

(01)
 6
Standard value table
Standard value table for machine

Applicable model HB205, HB215LC-1

Cate- Standard value Judgement
Item Measurement condition Unit
gory for new machine criteria
q Hydraulic oil temperature: Within operating
range
q Engine running at full speed
Overrun when deg. Max. 100 Max. 130
q Working mode: P mode
stopping swing (mm) () ()
q Swing circle misalignment amount when
stopping after one turn
q For measuring posture, see Swing 1.
q Hydraulic oil temperature:
Within operating range
q Engine running at full speed 90 sec. 3.1 0.3 Max. 3.7
q Working mode: P mode
Time taken to start
q Time required for passing
swing
points 90 and 180 from
starting point 180 sec. 4.4 0.4 Max. 5.5
q For measuring posture, see
Swing

Swing 1.
q Hydraulic oil temperature: Within operating
range
q Engine running at full speed
Time taken to swing q Working mode: P mode sec. 24.2 2.5 Max. 30
q Time required for 5 more turns after mak-
ing initial one turn
q For measuring posture, see Swing 1.
q Hydraulic oil temperature: Within operating
range
q Engine stopped
q Keeping upper structure transverse on
Drift of upper struc-
slope of 15, and make a mating mark on mm 0 0
ture
inner and outer races of swing circle
q Mating mark misalignment amount during
5 minutes
q For measuring posture, see Swing 2.

20-6 HB205-1, HB215LC-1

(01)
 7
Standard value table
Standard value table for machine

Applicable model HB205, HB215LC-1

Cate- Standard value Judgement
Item Measurement condition Unit
gory for new machine criteria
q Hydraulic oil temperature:
Within operating range Lo sec. 51.3 5.1 46.2 60.4
q Engine running at full speed
q Working mode: P mode
Travel speed
q Time required for track shoes Mi sec. 37.5 3.8 33.7 45.3
(Run the track idle)
to make 5 turns after making
one initial idle turn
q For measuring posture, see Hi sec. 26.5 1.3 25.2 29.8
Travel 1.
q Hydraulic oil temperature:
Within operating range Lo sec. 24 2.5 21.5 27.5
q Engine running at full speed
Travel speed q Working mode: P mode Mi sec. 17 2.5 14.5 20.5
(actual running) q Time required for traveling 20
m after 10 m trial run
q For measuring posture, see Hi sec. 13 1.0 12.0 15.0
Travel 2.
q Hydraulic oil temperature: Within operating
range
Travel

q Engine at full speed

q Working mode: P mode
Travel deviation q Travel speed: Lo mm Max. 150 Max. 250
q Deviation (X) while traveling 20 m after ini-
tial 10 m trial run on solid and level ground
q For measuring posture, see Travel 2 and
3.
q Hydraulic oil temperature: Within operating
range
q Engine stopped
Hydraulic drift of
q Parking machine on slope of 12 with mm 0 0
travel
sprocket facing upslope
q Sliding distance for 5 minutes
q For measuring posture, see Travel 4.
q Hydraulic oil temperature: Within operating
range
Leakage of travel q Engine at full speed
l/min 13.6 27.2
motor q Traveling with sprocket locked by using pin
q Oil leakage amount for one minute with
traveling in relief condition

HB205-1, HB215LC-1 20-7

(01)
 8
Standard value table
Standard value table for machine

Applicable model HB205, HB215LC-1

Cate- Standard value Judgement
Item Measurement condition Unit
gory for new machine criteria
q Hydraulic oil temperature: Within operating
range
Whole work q Flat and level ground mm Max. 600 Max. 900
equipment q Fill bucket with dirt or rated load (0.8 m3:
14.1 kN {1,440 kg})
Hydraulic drift of work equipment

q Boom horizontal, arm cylinder fully retract-

ed, bucket cylinder fully extended
q Engine stopped
Boom cylinder q Work equipment control lever in NEUTRAL mm Max. 18 Max. 27
position
q Fall amount for 15 minutes as measured
every 5 minutes starting immediately after
initial setting
q Whole work equipment: Lowering distance
Arm cylinder of tooth tip mm Max. 160 Max. 240
q Boom cylinder: Retraction distance of cyl-
inder
q Arm cylinder: Extension distance of cylin-
der
q Bucket cylinder: Retraction distance of cyl-
Bucket cylinder inder mm Max. 40 Max. 58
q For measuring posture, see Work equip-
Work equipment

ment 1.
q Hydraulic oil temperature:
Within operating range
q Engine running at full speed RAISE sec. 3.5 0.4 Max. 4.7
q Working mode: P mode
Boom q Time required from RAISE
stroke end till bucket touches
ground LOWER sec. 2.5 0.3 Max. 3.7
q For measuring posture, see
Word equipment 2.
Work equipment speed

q Hydraulic oil temperature:

Within operating range
IN sec. 3.7 0.4 Max. 4.5
q Engine running at full speed
q Working mode: P mode
Arm
q Time required from OUT
stroke end to IN stroke end
q For measuring posture, see OUT sec. 2.7 0.3 Max. 3.5
Work equipment 3.
q Hydraulic oil temperature:
Within operating range
q Engine running at full speed CURL sec. 2.6 0.3 Max. 3.3
q Working mode: P mode
Bucket q Time required from DUMP
stroke end to CURL stroke
end. DUMP sec. 2.0 0.2 Max. 2.7
q For measuring posture, see
Work equipment 4.

20-8 HB205-1, HB215LC-1

(01)
 9
Standard value table
Standard value table for machine

Applicable model HB205, HB215LC-1

Cate- Standard value Judgement
Item Measurement condition Unit
gory for new machine criteria
q Hydraulic oil temperature: Within operating
range
q Engine running at low idle
q Working mode: P mode
Boom q Time required from RAISE stroke end till sec. Max. 1.0 Max.1.2
bucket touches ground and pushes up ma-
chine front
q For measuring posture, see Work equip-
ment 5.
q Hydraulic oil temperature: Within operating
range
q Engine running at low idle
q Working mode: P mode
Time lag

q Time required from OUT stroke end till arm

Arm sec. Max.2.0 Max.2.8
stops momentarily after control lever is
Work equipment

moved to IN position and starts to move

again
q For measuring posture, see Work equip-
ment 6.
q Hydraulic oil temperature: Within operating
range
q Engine running at low idle
q Working mode: P mode
q Time required from DUMP stroke end till
Bucket sec. Max. 1.0 Max. 3.6
bucket stops momentarily after control le-
ver is moved to CURL position and starts
to move again
q For measuring posture, see Work equip-
ment 7.
Internal leakage

q Hydraulic oil temperature: Within operating

Cylinders range cc/min 4.5 20
q Engine running at full speed
q Leakage amount for one minute with cylin-
Center swivel der or travel to be measured in relief condi- cc/min 10 50
joint tion
Performance in combined operation

q Hydraulic oil temperature: Within operating

range
Deviation in q Engine at full speed
combined q Working mode: P mode
operation of work q Travel speed: Lo mm Max. 200 Max. 220
equipment and q Deviation (X) while traveling 20 m after ini-
travel tial 10 m trial run on solid and level ground
q For measuring posture, see Travel 2 and
3.

HB205-1, HB215LC-1 20-9

(01)
 10
Standard value table
Standard value table for machine

Applicable model HB205, HB215LC-1

Cate- Standard value Judgement
Item Measurement condition Unit
gory for new machine criteria
Characteristics of PC flow control valve

q Hydraulic oil temperature: Within operating

range
q Engine at full speed
q Working mode: P mode
Time required for q Rated load applied to bucket (0.8m3: 14.1
swinging from 0 to kN {1,440 kg}) 4.3 0.4
sec.
90 with boom q On solid and level ground, set arm verti- (Reference value)
RAISE cally and lower back of bucket to ground
q Time required for swinging from 0 to 90
with boom RAISE
q For measuring posture, see Work equip-
ment 8.

Hydraulic pump
See "Performance of hydraulic pump" (next page).
delivery

20-10 HB205-1, HB215LC-1

(01)
 11
Standard value table
Standard value table for machine

Applicable model HB205, HB215LC-1

Standard lower
Item Measurement condition Unit Standard value
limit of delivery
q Pump speed (rpm): 2,000 rpm
Hydraulic pump

q PC-EPC current value (mA): 440 mA

q Discharge pressure of test pump (MPa
Performance of {kg/cm2}): P1 Q Q
l/min
hydraulic pump q Discharge pressure of another pump (See graph) (See graph)
(MPa {kg/cm2}): P2
q Average discharge pressure (MPa
{kg/cm2}): Pp=(P1+P2)/2

a As far as possible, measure pump discharge pressure P1 and P2 as close as possible to the average pres-
sure.
Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump delivery and the engine speed at the time of
measurement, and use them as a base for calculating the pump delivery at the specified speed.

HB205-1, HB215LC-1 20-11

(01)
 12
Standard value table
Standard value table for machine

For all models (Posture of machine for measur- Travel 1: Travel speed (run the track idle)
ing performance and measurement procedure)

Control valve: spool stroke

Travel 2: Travel speed (actual running), travel devi-

ation

Swing 1: Overrun when stopping swing, time taken

to start swing, time taken to swing

Travel 3: Travel deviation

Swing 2: Drift of upper structure

20-12 HB205-1, HB215LC-1

(01)
 13
Standard value table
Standard value table for machine

Travel 4: Hydraulic drift of travel Work equipment 3: Arm speed

Work equipment 1: Hydraulic drift of work equipment Work equipment 4: Bucket speed

Work equipment 2: Boom speed Work equipment 5: Boom time lag

HB205-1, HB215LC-1 20-13

(01)
 14
Standard value table
Standard value table for machine

Work equipment 6: Arm time lag

Work equipment 7: Bucket time lag

Work equipment 8: Characteristics of PC flow con-

trol valve

20-14 HB205-1, HB215LC-1

(01)
 0 -1
HB205-1, HB215LC-1

HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1

Machine model Serial number

HB205-1 1001 and up
HB215LC-1 1001 and up

30 Testing and adjusting 30-1

HB205-1, HB215LC-1 30-1

(01)
 2
Contents

Contents 10-2

30 Testing and adjusting

Tools for testing, adjusting and troubleshooting ..................................................................... 30- 4 4

Tools for testing, adjusting and troubleshooting .................................................................. 30- 4 4

Engine and cooling system ..................................................................................................... 30- 9 9

Testing engine speed........................................................................................................... 30- 9 9

Testing boost pressure ........................................................................................................ 30- 11 11

Checking exhaust gas color................................................................................................. 30- 12 12

Adjusting valve clearance .................................................................................................... 30- 13 13

Testing compression pressure............................................................................................. 30- 15 15

Testing blowby pressure ...................................................................................................... 30- 18 18

Testing engine oil pressure.................................................................................................. 30- 19 19

Handling fuel system parts................................................................................................... 30- 20 20

Releasing remaining pressure from fuel system.................................................................. 30- 20 20

Testing fuel system pressure ............................................................................................... 30- 21 21

Cylinder cut-out test mode operation ................................................................................... 30- 23 23

No injection cranking operation............................................................................................ 30- 23 23

Testing fuel delivery, return rate and leakage...................................................................... 30- 24 24

Bleeding air from fuel circuit................................................................................................. 30- 28 28

Testing fuel circuit for leakage ............................................................................................. 30- 29 29

Handling of controller high-voltage circuit ............................................................................ 30- 30 30

Testing and adjusting air conditioner compressor belt tension ............................................ 30- 31 31

Replacement of fan belt ....................................................................................................... 30- 32 32

Undercarriage and frame ........................................................................................................ 30- 33 33

Testing swing circle bearing clearance ................................................................................ 30- 33 33

Testing and adjusting track tension ..................................................................................... 30- 34 34

Hydraulic system..................................................................................................................... 30- 37 37

Testing and adjusting hydraulic oil pressure in work equipment and travel circuits............. 30- 37 37

Testing source pressure of control circuit ............................................................................ 30- 40 40

Testing and adjusting oil pressure in pump PC control circuit ............................................. 30- 41 41

Testing and adjusting oil pressure in pump LS control circuit.............................................. 30- 44 44

Testing solenoid valve output pressure ............................................................................... 30- 48 48

Testing PPC valve output pressure ..................................................................................... 30- 51 51

Adjusting play of work equipment and swing PPC valves ................................................... 30- 53 53

Checking parts which cause hydraulic drift of work equipment ........................................... 30- 54 54

Releasing remaining pressure from hydraulic circuit ........................................................... 30- 56 56

Testing oil leakage ............................................................................................................... 30- 57 57

Bleeding air from each part.................................................................................................. 30- 59 59

Cab and its attachments ......................................................................................................... 30- 61 61

Checking cab tipping stopper............................................................................................... 30- 61 61

Adjusting mirrors .................................................................................................................. 30- 62 62

Angle adjustment of rear view camera................................................................................. 30- 65 65

Hybrid relation......................................................................................................................... 30- 66 66

Testing swing holding brake ................................................................................................ 30- 66 66

Cleaning and replacement of oil filter of swing electric motor.............................................. 30- 67 67

Operation check of swing emergency stop switch ............................................................... 30- 68 68

Electrical system ..................................................................................................................... 30- 70 70

Special functions of machine monitor .................................................................................. 30- 70 70

Handling voltage circuit of engine controller ........................................................................ 30-132 132

Precautions related to hybrid machines............................................................................... 30-133 133

Preparation work for troubleshooting of electrical system ................................................... 30-134 134

Procedure for testing diodes ................................................................................................ 30-140 140

30-2 HB205-1, HB215LC-1

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 3
Contents

Pm Clinic................................................................................................................................. 30-141 141

Pm Clinic service ................................................................................................................. 30-141 141

HB205-1, HB215LC-1 30-3

(01)
 4
Tools for testing, adjusting and troubleshooting
Tools for testing, adjusting and troubleshooting

Tools for testing, adjusting and troubleshooting 4

Tools for testing, adjusting and troubleshooting 4

Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
Testing boost pressure A 799-201-2202 Boost gauge kit 1 -101 200 kPa {-760 1,500 mmHg}
1 799-201-9001 Handy smoke checker 1
Testing exhaust gas color B Commercially Bosch index: 0 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve clearance C Commercially
2 Feeler gauge 1 Intake: 0.25 mm, Exhaust: 0.51 mm
available
1 795-502-1590 Compression gauge 1 0 7 MPa {0 70 kg/cm2}
2 795-799-6700 Puller 1 107E-1 engine
Testing compression pres-
D 795-790-4411 Adapter 1 107E-1 engine
sure 3
6754-11-3130 Gasket 1 107E-1 engine
4 795-799-8150 Remover 1
1 799- 201-1504 Blow-by checker 1 0 5 kPa {0 500 mmH2O}
Testing blow-by pressure E
2 795-790-3300 Blow-by tool 1 107E-1 engine
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing engine oil pressure F Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
795-790-4430 Adapter 1
2 101.0 mm o R1/8
Testing fuel system pres- 6215-81-9710 O-ring 1
G
sure Fuel pressure gauge
3 795-790-5200 1
adapter kit
Pressure gauge: 0 254 kPa
4 795-790-1470 Pressure gauge 1
{0 75 inHg}
5
799-201-2202 Boost gauge kit 1
6
795-790-5110 Screw 1
1
795-790-4700 Tester kit 1
2
795-790-6700 Adapter 1
6754-71-5340 Connector 1
Testing fuel return rate and 3
H 6754-71-5350 Washer 1
leakage Commercially
4 Measuring cylinder 1
available
Commercially
5 Stopwatch 1
available
Testing swing circle bear- Commercially
J Dial gauge 1
ing clearance available
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
Testing and adjusting {25, 60, 400, 600 kg/cm2}
1
hydraulic oil pressure in Pressure gauge: 60 MPa
K 790-261-1204 Digital hydraulic tester 1
work equipment and travel {600 kg/cm2}
circuits 799-101-5220 Nipple 3
2 Size: 101.25 mm
07002-11023 O-ring 3
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing source pressure of Pressure gauge: 60 MPa
L 790-261-1204 Digital hydraulic tester 1
control circuit {600 kg/cm2}
799-101-5220 Nipple 1
2 Size: 101.25 mm
07002-11023 O-ring 1

30-4 HB205-1, HB215LC-1

(01)
 5
Tools for testing, adjusting and troubleshooting
Tools for testing, adjusting and troubleshooting

Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Testing and adjusting oil 1
Pressure gauge: 60 MPa
pressure in pump PC con- M 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
trol circuit
799-101-5220 Nipple 6
2 Size: 101.25 mm
07002-11023 O-ring 6
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
Testing and adjusting oil 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
pressure in pump LS con- N Differential pressure
trol circuit 2 799-401-2701 1 50 MPa {500 kg/cm2}
gauge
799-101-5220 Nipple 6
3 Size: 101.25 mm
07002-11023 O-ring 6
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Testing solenoid valve out- 1
P Pressure gauge: 60 MPa {600
put pressure 790-261-1204 Digital hydraulic tester 1
kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing PPC valve output Pressure gauge: 60 MPa
Q 790-261-1204 Digital hydraulic tester 1
pressure {600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
3 799-401-3200 Adapter 1 Size: 03
799-601-4101
or T-adapter assembly 1
799-601-4201
799-601-4130 T-adapter 1 Ne Sensor
799-601-4150 T-adapter 1 For oil pressure sensor
Troubleshooting for engine For DRC60, ECONO (Not included in
controller/sensors/actua- R 799-601-4350 Measurement box 1
799-601-4201)
tors 799-601-4211 q T-adapter 1 Engine controller
799-601-4220 q T-adapter 1 Engine controller
799-601-4250 q T-adapter 1 For boost pressure sensor
799-601-4260 q T-adapter 1 Engine controller
799-601-9040 q T-adapter 1 For injector

HB205-1, HB215LC-1 30-5

(01)
 6
Tools for testing, adjusting and troubleshooting
Tools for testing, adjusting and troubleshooting

Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter assembly 1 799-601-2900 is no more available
or
799-601-7100
or
799-601-7400
or
799-601-8000
For ECONO (Not included in
799-601-2600 q T-adapter box 1
799-601-2700)
799-601-4101
or
799-601-4201
or T-adapter assembly 1
799-601-9000
or
799-601-9200
For DRC60, ECONO and DT6P
799-601-4350 q Measurement box 1 (Not included in 799-601-4201,
799-601-9000 and 799-601-9200)
For DT and HD (Not included in
799-601-9320 q Measurement box 1
799-601-4101 and 799-601-4201)
Troubleshooting for chas- 799-601-9020 q Adapter for DT 1 For DT2P
sis sensors/wiring har- S For DT3P (Not included in
nesses 799-601-9030 q Adapter for DT 1
799-601-4010 and 799-601-4201)
For DTP4 (Not included in
799-601-4260 q Adapter for DT 1
799-601-9000 and 799-601-9200)
For DT12P (Not included in
799-601-9110 q Adapter for DT (GR) 1
799-601-4101 and 799-601-4201)
For AMP3P (Not included in
799-601-9420 q Adapter for AMP 1
799-601-9000 and 799-601-9200)
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
For X1P (Not included in
799-601-7010 q Adapter for X 1
799-601-7000 and 799-601-7100)
799-601-7020 q Adapter for X 1 For X2P
For SW6P (Not included in
799-601-7050 q Adapter for SWP 1
799-601-8000)
For SW8P (Not included in
799-601-7060 q Adapter for SWP 1
799-601-8000)
799-601-7090 q Adapter for M For M2P
799-601-7110 q Adapter for M For M3P
799-601-7120 q Adapter for M For M4P
799-601-7130 q Adapter for M For M6P
799-601-7140 q Adapter for S For S8P

30-6 HB205-1, HB215LC-1

(01)
 7
Tools for testing, adjusting and troubleshooting
Tools for testing, adjusting and troubleshooting

Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
799-601-7500 T-adapter assembly
799-601-7520 q Adapter for 070 For 070-12P
799-601-7540 q Adapter for 070 For 070-18P
799-601-8980 Adapter for multiple For DT-2, 3, 4/DTM-2P
Troubleshooting for chas-
799-601-4280 Measurement box AMP121P (for pump controller)
sis sensors/wiring har- S
nesses 799-601-7310 Adapter for SWP For SW12P
799-601-7360 Adapter for relay For REL-5P
799-601-7370 Adapter for relay For REL-6P
Socket for CRI-T2
799-601-9410 For YAMAZAKI 2P
engine
Commercially
Testing oil leakage T Measuring cylinder 1
available
566-35-43561 Nipple 1
1
07002-11822 O-ring 1
Diagnosis of cooling cir-
U 2 799-101-5160 Joint 1
cuit for hybrid system
3 799-101-5150 Hose 1
4 799-401-2311 Pressure gauge 1
Testing coolant tempera-
799-101-1502 Digital thermometer 1 -99.9 1,299C
ture and oil temperature
Testing operating effort 79A-264-0021 Push-pull scale 1 0 294 N {0 30 kg}

and depressing effort 79A-264-0091 Push-pull scale 1 0 490 N {0 50 kg}
Testing stroke and hydrau- Commercially
Scale 1
lic drift available
Testing work equipment Commercially
Stopwatch 1
speed available
Testing voltage and resis- Commercially
Circuit tester 1
tance available
Removal and installation of
Commercially 3.26 mm Torx wrench
boost pressure and tem- Hexlobe (TORX) wrench 1
available (KTC Q4T15 or equivalent)
perature sensors
Removal and installation of 27 mm hexagonal deep socket
795-799-6210 Deep socket 1
engine oil pressure sensor (inner diameter: 24.5 mm)
Removal and installation of
19 mm deep socket
engine coolant tempera- 795T-981-1010 Deep socket 1
(MITOLOY 4ML-19 or equivalent)
ture sensor

Socket

HB205-1, HB215LC-1 30-7

(03)
 8
Tools for testing, adjusting and troubleshooting
Tools for testing, adjusting and troubleshooting

30-8 HB205-1, HB215LC-1

(01)
 9
Engine and cooling system
Testing engine speed

Engine and cooling system 9

Testing engine speed 9

3. Testing full speed
1) Start the engine and set the fuel control dial
to the full speed (MAX) position.
2) Keep the bucket lowered to the ground.
a Test the engine speed with the monitoring func-
3) Set the working mode in the power mode (P)
tion of the machine monitor.
and select the auto-deceleration OFF.
a Test the engine speed under the following condi-
4) Fine control the travel lever (fine control
tion.
within the dead band of the travel PPC valve)
q Engine coolant temperature: Within operat-
to increase the engine speed and check it
ing range
after it has stabilized.
q Hydraulic oil temperature: Within operating
a Test without supplying oil to the travel
range
motor or moving the travel mechanism.
k If the travel lever is tilted too much (ex-
1. Preparation work
ceeds the dead band), the machine
Operate the machine monitor so that the engine
starts moving in the travel lever opera-
speed can be monitored.
tion direction. Accordingly, carry out
a For the operating method of the machine
this check in a safe place so that no ac-
monitor, see "Special functions of machine
cidents occur even if the machine
monitor".
moves.
a Monitoring code: 01002 Engine speed
4. Testing the engine speed when 2-pumps are
relieved
1) Arm IN relief condition
1] Start the engine and operate the arm
cylinder to the IN stroke end.
2] Set the fuel control dial to the full speed
(MAX) position and set the working mode
to the power mode (P).
3] Operate the left work equipment control
lever to relieve the arm circuit at the IN
stroke end and test the engine speed.
2) Travel circuit relief condition
1] Start the engine and lock the travel mech-
anism. For the method of locking the
2. Testing low idle speed travel mechanism, see Testing and
1) Start the engine and set the fuel control dial adjusting hydraulic oil pressure in work
to the low idle (MIN) position. equipment and travel circuits, "5. Testing
a Confirm the two conditions of auto-decel- travel relief pressure".
eration switch ON/OFF. 2] Set the working mode to power mode (P),
2) Set all the control levers and pedals for work travel speed to Mi (medium) or Hi (high),
equipment, swing, and travel to the neutral and fuel control dial to the full speed
position and test the engine speed. (MAX).
k Before operating the travel lever
and pedal, check the lock pin posi-
tion and locking direction (forward
or reverse travel) again.
3] Operate the travel lever to relieve the
travel circuit oil pressure and check the
engine speed at this time.

HB205-1, HB215LC-1 30-9

(01)
 10
Engine and cooling system
Testing engine speed

5. Testing 2-pump relief and power maximizing 6. Testing the speed when auto-deceleration is
speed (near rated speed) in operation
1) Arm IN relief condition 1) Start the engine, set the fuel control dial to
1] Start the engine and operate the arm the full speed position (MAX), and turn the
cylinder to the IN stroke end. auto-deceleration ON.
2] Set the fuel control dial to the full speed 2) Set all the control levers and pedals for work
(MAX) position and set the working mode equipment, swing, and travel to the neutral
to the power mode (P). and measure the engine speed when the
3] While operating the left work equipment auto-deceleration operates.
control lever to relieve the arm circuit at a If all the control levers and pedals are set to
the IN stroke end and pressing the neutral, the engine speed decreases to the
one-touch power maximizing switch, test waiting speed (1,250 rpm). If the machine is
the engine speed. kept under this condition for 4 seconds or
2) Travel circuit relief condition more, the engine speed decreases further to
1] Start the engine and lock the travel mech- the deceleration speed (approximately 700
anism. For the method of locking the rpm). Check the engine speed at this time.
travel mechanism, see Testing and (Reference: See 10 Structure and function,
adjusting hydraulic oil pressure in work Electrical system, "Auto-deceleration func-
equipment and travel circuits, "5. Testing tion".
travel relief pressure".
2] Set the working mode to power mode (P),
travel speed to Mi (medium) or Hi (high),
and fuel control dial to the full speed
(MAX) position.
k Before operating the travel lever
and pedal, check the lock pin posi-
tion and locking direction (forward
or reverse travel) again.
3] While operating the travel lever to relieve
the travel circuit oil pressure and holding
down the one-touch power maximizing
switch, test the engine speed.
a The one-touch power maximizing function is
reset automatically in approximately 8.5 sec-
onds even if the switch is kept pressed. Ac-
cordingly, test the engine speed in that
period.
a You may check with the swing lock switch
ON (In this case, you do not need to operate
the one-touch power maximizing switch).

30-10 HB205-1, HB215LC-1

(01)
 11
Engine and cooling system
Testing boost pressure

Testing boost pressure 1

3. Run the engine at middle or higher speed and
bleed oil from the hose.
a Testing tools for boost pressure a Insert the connector into the gauge halfway
Symbol Part No. Part name in order to open the self-seal on the hose side
A 799-201-2202 Boost gauge kit repeatedly, and the oil will be drained.
a If Pm kit (A) is available, use the air bleeding
k Stop the machine on level ground and lower coupling (790-261-1130) in that kit.
the work equipment to the ground. a If oil is left in the hose, the gauge does not
a Test the boost pressure under the following con- work. Accordingly, be sure to drain the oil.
dition.
q Engine coolant temperature: Within operat-
4. Set the working mode to the power mode (P) and
ing range turn the swing lock switch ON.
q Hydraulic oil temperature: Within operating
a If the swing lock switch is turned ON, the
range main relief valve is set for high-pressure re-
lief.
1. Open the engine hood and remove boost pres-
sure pickup port plug (1) (R1/8) from the intake 5. While running the engine at full speed, relieve
air connector. the arm circuit at the IN and measure the boost
pressure.

2. Install nipple [2] of boost gauge kit A and

connect it to gauge [1]. 6. After finishing test, remove the testing tools and
return the removed parts.

HB205-1, HB215LC-1 30-11

(01)
 12
Engine and cooling system
Checking exhaust gas color

Checking exhaust gas color 12

2. Testing by using smoke meter B2
1) Insert probe of smoke meter B2 in the outlet
a Testing tools for exhaust gas color of the exhaust pipe (1) and fix it to the
Symbol Part No. Part name exhaust pipe with a clip.
1 799-201-9001 Handy smoke checker
B Commercially
2 Smoke meter
available
k Stop the machine on level ground and lower
the work equipment to the ground.
k Be careful not to touch any hot part when re-
moving or installing the testing tools.
a Test the exhaust gas color under the following
condition.
q Engine coolant temperature: Within operat-
ing range
a If an air source and an electric power source are
not available in the field, use handy smoke
checker B1. When recording official data, use 2) Connect the probe hose, plug of the acceler-
smoke meter B2. ator switch, and air hose to smoke meter B2.
a Limit the supplied air pressure to 1.5 MPa
1. Testing by using handy smoke checker B1 {15 kg/cm2}.
1) Place a sheet of filter paper to smoke 3) Connect the power cable to the AC100V
checker B1. receptacle.
2) Insert the exhaust gas intake pipe in exhaust a Check that the smoke meter power switch
pipe (1). is in the OFF position, before connecting
3) Start the engine and accelerate it suddenly or the power cable to the receptacle.
run it at full speed and operate the handle of 4) Loosen the cap nut of the suction pump and
smoke checker B1 so that the filter paper will place the filter paper.
absorb the exhaust gas. a Place the filter paper securely so that the
a Absorbing time: 1.4 0.2 sec exhaust gas will not leak.
5) Turn on the power switch of smoke meter B2.

4) Remove the filter paper and compare it with

the attached scale for judgement.
5) After finishing testing, remove the testing
tools and return the removed parts.
6) Start the engine and accelerate it suddenly or
run it at full speed and depress the acceler-
ator pedal of smoke meter B2 and collect the
exhaust gas into the filter paper.
7) Put the polluted filter paper on non-polluted
filter paper (more than 10 sheets) in the filter
paper holder, and read the indicated value.
8) After finishing testing, remove the testing
tools and return the removed parts.

30-12 HB205-1, HB215LC-1

(01)
 13
Engine and cooling system
Adjusting valve clearance

Adjusting valve clearance 13

3. Rotate the crankshaft in the normal direction by
using gear C1 and align wide slit (b) in the speed
a Valve clearance adjustment tools sensor ring with projection top (a) of the front
Symbol Part No. Part name cover.
1 795-799-1131 Gear a Projection top (a) must be within the range of
C Commercially wide slit (b) when it is seen from the air con-
2 Feeler gauge
available ditioner compressor side.
k Stop the machine on level ground and lower a If top (a) of the projection and yellow paint of
the work equipment to the ground. wide slit (b) can be checked, you may match
a Adjust the valve clearance under the following them.
k Note that this aligning method does not
condition.
q Engine coolant temperature: Normal temper-
bring No.1 or No.4 cylinder to TDC posi-
ature tion.

1. Open the engine hood and remove cylinder

head cover (1).
a Since the breather connector on the rear side
of the cylinder head cover is connected to the
flywheel housing by using the O-ring, pull it
together with the cylinder head cover.

4. Check the movement of the rocker arm of the

No. 1 cylinder to determine the valve to be
adjusted.
a If you can move the rocker arms of exhaust
valves (EX) by hand by the valve clearance
amount, adjust the valves marked with q in
the valve arrangement drawing.
a If you cannot move the rocker arm of exhaust
2. Remove plug (2) above the starting motor and
valve (EX) by hand, adjust the valves marked
install gear C1.
with Q in the valve arrangement drawing.
a Valve arrangement drawing

HB205-1, HB215LC-1 30-13

(01)
 14
Engine and cooling system
Adjusting valve clearance

5. Adjust the valve clearance according to the

following procedure.
1) While adjustment screw (3) is being held
from turning, loosen locknut (4).
2) Place feeler gauge C2 in the clearance
between rocker arm (5) and crosshead (6)
and adjust the valve clearance with adjust-
ment screw (3).
a With the feeler gauge placed, turn the ad-
justment screw until a slight drag is felt on
the feeler gauge.
3) While adjustment screw (3) is being held
from turning, tighten locknut (4).
3 Locknut:
24 4 Nm {2.45 0.41 kgm}
a After tightening the locknut, check the
valve clearance again.

6. Rotate the crankshaft in the normal direction by

1 turn and align wide slit (b) with projection top
(a) according to step 3.

7. Adjust the other valve clearances according to

steps 4 and 5.
a If the valves marked with Q in the valve ar-
rangement drawing were adjusted in steps 4
and 5, adjust the valves marked with q.
a If the valves marked with q in the valve ar-
rangement drawing were adjusted in steps 4
and 5, adjust the valves marked with Q.

8. After finishing adjustment, remove the testing

tools and return the removed parts.
k Be sure to remove gear C1.
3 Cylinder head cover mounting bolt:
24 4 Nm {2.45 0.41 kgm}

30-14 HB205-1, HB215LC-1

(01)
 15
Engine and cooling system
Testing compression pressure

Testing compression pressure 15

7. Remove retaining nut (6) and remove inlet
connector (7).
a Testing tools for compression pressure a When removing the inlet connector, remove
Symbol Part No. Part name the dust from around the inlet connector so
1 795-502-1590 Gauge assembly that no dust will enter the holes of the cylinder
2 795-799-6700 Puller head or the inlet connector.
D 795-790-4411 Adapter a Use remover D4 to remove the inlet connec-
3 tor.
6754-11-3130 Gasket
4 795-799-8150 Remover
k When testing the compression pressure,
take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rota-
tion part.

a Test the compression pressure when the engine

is warm.
(Engine oil temperature: 40 60C)

1. Remove cylinder head cover (1).

a For the following procedure, see Disassem-
bly and assembly, "Removal and installation
of fuel injector assembly".

8. Using tool D2, remove injector (5).

2. Loosen injector terminal nuts (4) and remove the
harness terminals from the injector.

3. Set the cylinder to be tested to the compression

top dead center.
a See "Adjusting valve clearance" for the bar-
ring method.

4. Remove the mounting bolts of rocker arm

assembly (2) on the exhaust side and remove
rocker arm assembly (2) on the exhaust side.
a When removing the injector, the rocker arm
assembly on the exhaust side does not need
to be removed.

5. Disconnect injector wiring harness (3a).

6. Disconnect fuel high-pressure pipe (3).

a When disconnecting fuel high-pressure pipe
No. 1 or No. 3, disconnect wiring harness
connector (3b) from the rocker arm housing.

HB205-1, HB215LC-1 30-15

(01)
 16
Engine and cooling system
Testing compression pressure
9. Install adapter D3 to the injector mounting hole
by using the injector holder, and connect
compression gauge D1.
a Be sure to install the gasket to the adapter
tip.
a Tighten the holder mounting bolts alternately.
3 Injector holder mounting bolt:
8 0.8 Nm {0.8 0.08 kgm}
a If a little quantity of engine oil is applied to the
joint of the adapter and gauge, air does not
leak easily.
10. Install rocker arm assembly (2) on the exhaust
side and adjust the valve clearance.
3 Rocker arm assembly mounting bolt:
36 5 Nm {3.67 0.5 kgm}
a See "Adjusting valve clearance".
11. Select the no-injection cranking operation from
the machine monitor.
a See the section of "Special functions of ma-
chine monitor".
k Be sure to select the no-injection crank-
ing operation. Otherwise, the engine can
be started during the inspection, poten-
tially inducing risks to the inspecting per-
sonnel.
12. Rotate the crankshaft by the starting motor and
test the compression pressure.
a Read the pressure gauge pointer when it is
stabilized.
30-16
13. After finishing testing, remove the testing tools
and return the removed parts.
a Install the injector and high-pressure fuel
tube according to the following procedure.
1) Mate protrusion (a) of the injector with notch
(b) of the injector holder, and set the injector
to the cylinder head.
a Set the injector with the above mating po-
sition toward the fuel inlet connector
pass-through.
2) Tighten injector holder mounting bolts (10)
three to four threads.
3) Set fuel inlet connector (7) to the injector.
a Press it in until you feel the O-ring clicks
in.
4) Tighten partially retainer (6) for connector
(7).
3 Retainer: 15 5 Nm {1.5 0.5 kgm}
a Tighten retainer to the specification in
step 6).
5) Alternately tighten injector holder mounting
bolts (10).
3 Injector holder mounting bolt:
8 0.8 Nm {0.8 0.08 kgm}
6) Tighten retainer (6) of the fuel inlet
connector.
3 Inlet connector retainer:
50 5 Nm {5.1 0.5 kgm}
HB205-1, HB215LC-1
(01)
 17
Engine and cooling system
Testing compression pressure

14. After installing the rocker arm assembly, adjust

the valve clearance. For details, see "Adjusting
valve clearance".
3 Rocker arm assembly mounting bolt:
36 5 Nm {3.67 0.51 kgm}
a Install injector wiring harness terminals (4)
taking care that they will not interfere with
rocker arm (2) when the rocker arm moves
up and down.

15. Tighten the injector terminal nuts with the

following torque.
3 Terminal nut:
1.5 0.25 Nm {0.15 0.025 kgm}
a Check that the injector wiring harness does
not interfere with the rocker arm.

16. Tighten the head cover mounting nuts to the

following torque.
3 Head cover mounting nut:
24 4 Nm {2.45 0.41 kgm}

HB205-1, HB215LC-1 30-17

(01)
 18
Engine and cooling system
Testing blowby pressure

Testing blowby pressure 18

a Testing tools for blowby pressure

Symbol Part No. Part name
1 799-201-1504 Blowby checker
E
2 795-790-3300 Blowby tool
k Stop the machine on level ground and lower
the work equipment to the ground.
a Test the blowby pressure under the following
condition.
q Engine coolant temperature: Within operat-
ing range
q Hydraulic oil temperature: Within operating
range
5. After finishing test, remove the testing tools and
1. Remove the undercover of the hydraulic pump. return the removed parts.

2. Install tool E2 and gauge [1] of blowby checker

E1 to breather hose.

3. Start the engine, set the working mode to the

power mode (P), and turn the swing lock switch
to the ON position.
a If the swing lock switch is turned to the ON
position, the main relief valve is set for
high-pressure relief.

4. While running the engine at full speed, relieve

the arm circuit at the IN and measure the blowby
pressure.
a Read the blow-by pressure value, when the
needle of the gauge is stabilized.

30-18 HB205-1, HB215LC-1

(01)
 19
Engine and cooling system
Testing engine oil pressure

Testing engine oil pressure 19

3. Start the engine and turn the auto-deceleration
OFF.
a Testing tools for engine oil pressure
Symbol Part No. Part name 4. Test the oil pressure during the engine low idle
799-101-5002 Hydraulic tester and high idle.
1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

k Stop the machine on level ground and lower

the work equipment to the ground.
a Test the engine oil pressure under the following
condition.
q Engine coolant temperature: Within operat-
ing range

1. Open the side cover of the pump room and

remove oil pressure pickup port plug (1) from the
engine oil filter head.

5. After finishing test, remove the testing tools and

return the removed parts.

2. Install nipple [1] of hydraulic tester F1 and connect

hydraulic tester F2.

HB205-1, HB215LC-1 30-19

(01)
 20
Engine and cooling system
Handling fuel system parts
Handling fuel system parts 20
a Precautions for testing and maintaining fuel sys-
tem
The common rail fuel injection system (CRI)
consists of more precise parts than the conven-
tional fuel injection pump and nozzles. If contam-
inant enters this system, it can cause a trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc. sticks
to any part, wash that part thoroughly with clean
fuel.
a Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzles, it
employs a high-efficiency special filter to prevent
contaminant from entering it. If a filter other than
the genuine one is used, the fuel system may
have a trouble. Accordingly, never use such a
filter.
30-20
Releasing remaining pressure
from fuel system
20
a Pressure is generated in the low-pressure circuit
and high-pressure circuit of the fuel system while
the engine is running.
Low-pressure circuit:
Feed pump Fuel main filter Supply pump
High pressure circuit:
Fuel supply pump Common rail Fuel
injector
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level au-
tomatically after 30 seconds when the engine
stops.
a Before the fuel circuit is tested and its parts are
removed, the remaining pressure in the fuel cir-
cuit must be released completely. Accordingly,
observe the following.
k Before testing the fuel system or removing
its parts, wait at least 30 seconds after stop-
ping the engine until the remaining pressure
in the fuel circuit is released. (Do not start the
work just after stopping the engine since
there is residual pressure.)
HB205-1, HB215LC-1
(01)
 21
Engine and cooling system
Testing fuel system pressure

Testing fuel system pressure 21

2) Install adapter G2 and nipple [1] of hydraulic
tester G1 and connect them to oil pressure
a Testing tools for fuel pressure gauge [2].
Symbol Part number Part name a Use the oil pressure gauge of 2.5 MPa
799-101-5002 Hydraulic tester {25 kg/cm2}.
1
790-261-1204 Digital hydraulic tester
Adapter
795-790-4430
2 (10 1.0 mm o R1/8)
6215-81-9710 O-ring
G
Fuel pressure gauge adapter
3 795-790-5200
kit
4 795-790-1470 Pressure gauge
5 799-201-2202 Boost gauge kit
6 795-790-5110 Screw
k Park the machine on level ground and lower
the work equipment to the ground.
a Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel main
filter to the supply pump and the return circuit
3) Start the engine and test the pressure in the
from the supply pump/common rail/injector to
fuel low-pressure circuit with the auto-decel-
fuel tank.
k Since the pressure in the high-pressure cir-
eration OFF and the engine at low idle.
a If the pressure in the fuel low-pressure cir-
cuit from the supply pump through the com-
cuit is in the following range, it is normal.
mon rail to the injector is very high, it cannot
be tested. 0.5 1.3 MPa
At low idle
{5.1 13.3 kg/cm2}
0.3 1.1 MPa
1. Testing pressure in fuel low-pressure circuit During cranking
{3.1 11.3 kg/cm2}
k
1) Open the side cover of the pump room and
remove fuel pressure pickup port plug (on the If the engine cannot be started, you
fuel inlet side) (1) from the fuel main filter may test the fuel return rate while ro-
head. tating the engine with the starting mo-
tor. Do not run the starting motor for
more than 20 seconds continuously,
however, for protection of the starting
motor.

4) After finishing test, remove the testing tools

and return the removed parts.
3 Fuel pressure pickup port plug:
10 2 Nm {1 0.2 kgm}

HB205-1, HB215LC-1 30-21

(01)
 22
Engine and cooling system
Testing fuel system pressure

2. Testing pressure in fuel return circuit 3. Measuring fuel negative-pressure circuit

1) Disconnect fuel return hose (2). pressure
1) Open the engine hood and remove joint bolt
(2) of fuel hose (1) between the prefilter and
supply pump (3).

2) Install fuel pressure gauge adapter kit G3

and connect it to pressure gauge G4.

2) Connect fuel hose (1) to supply pump (3) by

installing tool G6 instead of joint bolt (2).
a When installing tool G6, place the gas-
kets to both sides of banjor connector on
the fuel hose.
3 Tool G6:
19.6 29.4 Nm {2.0 3.0 kgm}
3) Connect tool G5 to tool G6.

3) Run the engine at low idle and test the pres-

sure in the fuel return circuit.
a If the pressure in the fuel return circuit is
in the following range, it is normal.
At low idle 18.63 kPa or less
During cranking {0.19 kg/cm2 or less}
q Pressure gauge G4 has an "inHg"
scale.
q Conversion: 5.5 inHg o 18.63 kPa
k If the engine cannot be started, you
4) Run the engine and test the circuit negative
pressure at high idle.
may test the fuel return rate while ro-
Circuit standard negative pressure: 50.7
tating the engine with the starting mo-
kPa {380 mmHg} or less.
tor. Do not run the starting motor for
5) If the negative pressure is higher than the
more than 20 seconds continuously,
criteria, the fuel prefilter may be clogged. In
however, for protection of the starting
this case, replace the fuel prefilter and test
motor.
again.
4) After finishing test, remove the testing tools
6) After finishing test, remove the testing instru-
and return the removed parts.
ments and return the removed parts.
3 Joint bolt (2):
19.6 29.4 Nm {2.0 3.0 kgm}

30-22 HB205-1, HB215LC-1

(01)
 23
Engine and cooling system
Cylinder cut-out test mode operation

Cylinder cut-out test mode No injection cranking operation 23

operation
a No-injection cranking means to rotate the engine
23

a Cylinder cut-out test mode operation means to
run the engine with the fuel injector of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purpose and ef-
fect of this operation are as follows.
1. This operation is used to find out a cylinder
which does not output power properly (i.e.
combustion in it is abnormal).
2. When fuel to a cylinder is shut off, if the engine
speed and output do not change from those
before cylinder cut-out (all-cylinder operation),
that cylinder has one or more problems.
The possible problems are as follows.
Gas leakage through the cylinder head
gasket
Defective injection from the injector
Defective piston or piston ring
Defective valve mechanism
Defect in electrical system
by the starting motor while the fuel injection into
all the cylinders are stopped electrically. The
purpose and effect of this operation are as fol-
lows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.
a See the section of "Special functions of machine
monitor" when performing the no-injection crank-
ing operation.
a Use the no-injection cranking operation for only
the purpose of troubleshooting.

3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the technician can perform the cylinder
cut-out test easily by operating the switches to
find out a defective cylinder comparing with the
mechanical fuel injection system.
a See the section of "Special functions of ma-
chine monitor" when performing the cylinder
cut-out operation.
a Use the cylinder cut-out test mode for only
the purpose of troubleshooting.

HB205-1, HB215LC-1 30-23

(01)
 24
Engine and cooling system
Testing fuel delivery, return rate and leakage

Testing fuel delivery, return rate 3) Install test hose H1 to the nipple on the
and leakage discharge side of the supply pump.
a Tie the hose with a wire etc.
24

a Testing tools for fuel delivery, return rate and a Put the end as the testing hose in the con-
leakage tainer so that it will not sag.
Symbol Part number Part name
1 795-790-4700 Tester kit
2 795-790-6700 Adapter
6754-71-5340 Connector
3
H 6754-71-5350 Washer
Commercially
4 Measuring cylinder
available
Commercially
5 Stopwatch
available
a Since some fuel flows out during test, prepare a
container of approximately 20 l.
k Stop the machine on level ground and lower
the work equipment to the ground.
4) Crank the engine for 20 seconds and
1. Testing supply pump delivery measure the delivery by using measuring
1) Open the engine hood and remove counter- cylinder H4.
weight upper cover (1). a Do not crank the engine for more than 20
seconds to protect the starting motor in
any case other than this test.
a If the supply pump delivery is in the fol-
lowing standard range, it is normal.
(30-second conversion)
At cranking speed (125
75 cc or more
rpm)
At cranking speed (150
90 cc or more
rpm)
q Delivery [Q]:
Q = Engine speed x 0.6

2) Remove discharge tube (2) and clamp of the

supply pump.

5) After finishing measurement, remove the

measuring tools and return the removed
parts.
3 Tube sleeve nut:
35 3.5 Nm {3.6 0.4 kgm}
3 Clamp mounting bolt:
24 4 Nm {2.45 0.41 kgm}

30-24 HB205-1, HB215LC-1

(01)
 25
2. Testing supply pump return rate
1) Disconnect quick coupler (2) of the supply
pump return hose from connector (3) on the
pump.
2) Install connector H3 and cap nut [1] of tester
kit H1 to quick coupler (2) side of the return
hose to stop the fuel from flowing out.
a Install the seal washer between connec-
tor H3 and cap nut [1].
3) Connect test hose [2] of tester kit H1 to the
supply pump.
a Put the end of the test hose in the contain-
er so that it will not sag.
HB205-1, HB215LC-1
(01)
Engine and cooling system
Testing fuel delivery, return rate and leakage
4) Run the engine at low idle and measure the
return rate in 25 sec by using measuring
cylinder H4.
a If the return rate from the supply pump is
in the following range, it is normal.
At low idle (750 rpm) 400 cc/min or less
5) After finishing test, remove the testing tools
and return the removed parts.
a When testing the leakage from the pres-
sure limiter or finishing the test: Return
the removed parts to their original posi-
tions.
a When testing the return rate from the in-
jector: Leave the removed parts as they
are and keep the test hose end in the con-
tainer.
30-25
 26
Engine and cooling system
Testing fuel delivery, return rate and leakage
3. Testing leakage from pressure limiter
1) Disconnect quick coupler (4) of the return
hose of the pressure limiter from connector
(5) on the pump.
2) Install connector H3 and cap nut [1] of tester
kit H1 to the return hose side to stop the fuel
from flowing out.
3) Connect test hose [2] of tester kit H1 to the
common rail.
a Put the end of the testing hose in the con-
tainer so that it will not sag.
4. Testing return rate from injector
30-26
4) Run the engine at low idle and test the return
rate in 1 minute by using measuring cylinder
H4.
a If the leakage from the pressure limiter is
in the following range, it is normal.
0 cc/min.
At low idle
(No leakage)
5) After finishing test, remove the testing tools
and return the removed parts.
a The fuel return rate from the injector is tested
while the return hose of the pressure limiter is
connected. Accordingly, before testing the
return rate from the injector, check that the
leakage from the pressure limiter is normal.
1) Referring to "Testing supply pump return
rate", set the supply pump for test.
a The fuel returning from the supply pump
flows out during measurement of the re-
turn rate from the injector. Accordingly,
keep the test hose end in the container.
2) Disconnect return hose (6) of the mainfold.
a Keep the seal washer installed to the re-
turn hose.
HB205-1, HB215LC-1
(01)
 27
Engine and cooling system
Testing fuel delivery, return rate and leakage

3) Install removed joint bolt (7) and cap nut [1]

of tester kit H1 to the return hose side to stop
the fuel from flowing out.
4) Install connector H3 to the manifold side and
connect test hose [3] of tester kit H1.
a Put the end of the testing hose in the con-
tainer so that it will not sag.

5) Run the engine at low idle and measure the

return rate in 1 minute by using measuring
cylinder H4.
a If the return rate from the injector is in the
following range, it is normal.
At low idle 120 cc or less
During cranking 90 cc or less
a The fuel returning from the supply pump
flows out during measurement of the re-
turn rate from the injector. Accordingly,
keep the test hose end in the container.
k If the engine cannot be started, you
may measure the fuel return rate while
rotating the engine with the starting
motor. Do not run the starting motor
for more than 20 seconds continuous-
ly, however, for protection of the start-
ing motor.

6) After finishing test, remove the testing tools

and return the removed parts.
3 Joint bolt:
19.6 29.4 Nm {2.0 3.0 kgm}

HB205-1, HB215LC-1 30-27

(01)
 28
Engine and cooling system
Bleeding air from fuel circuit

Bleeding air from fuel circuit 28

a If fuel is used up or if a fuel circuit part is removed

and installed, bleed air from the fuel circuit ac-
cording to the following procedure.
k Stop the machine on level ground and lower
the work equipment to the ground.

1. Fill the fuel tank with fuel to the brim.

a Supply fuel until float in the sight gauge
reaches to the maximum rising position.

2. Open the side cover of the pump room.

3. Loosen knob (1) of the feed pump and pull it out,

then pump it.
a Operate the knob until it becomes heavy.
a The plug at the top of the fuel main filter head
does not need to be removed.

There may be a case where air remains in the

water separator even after air bleeding opera-
tion. In this case, engine can be started if the
feed pump knob is operated until it becomes
heavy. Operate the engine, then stop it and
leave it as it is. Air will disappear by itself.
This phenomenon occurs when the fuel in the
prefilter is removed excessively, and does not
mean the failure in the fuel system.

4. After bleeding air, push in and tighten knob (1).

30-28 HB205-1, HB215LC-1

(01)
 29
Engine and cooling system
Testing fuel circuit for leakage

Testing fuel circuit for leakage 29

9. Check the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the a Check the high-pressure fuel circuit parts
high-pressure circuit of the fuel system. If coated with the color checker and their pe-
fuel leaks while the engine is running, it is ripheries for fuel leakage.
dangerous since it can catch fire. a If any fuel leakage is detected, repair it and
After testing the fuel system or removing its perform inspection again from step 2.
parts, test it for fuel leakage according to the a If no fuel leakage is detected, check is com-
following procedure. pleted.
k Stop the machine on level ground and lower
the work equipment to the ground.
a Clean and degrease the engine and the parts
around it in advance so that you can find easily
fuel leakage.

1. Spray color checker (developer) over the supply

pump, common rail, fuel injectors, and joints of
the high-pressure fuel piping.

2. Run the engine at a speed below 1,000 rpm and

stop it after its speed is stabilized.

3. Check the fuel piping and devices for fuel

leakage.
a Check the high-pressure fuel circuit parts
coated with the color checker and their pe-
ripheries for fuel leakage.
a If any fuel leakage is detected, repair it and
perform inspection again from step 2.

4. Start the engine and keep it running at low idle.

5. Stop the engine and check the fuel piping and

devices for fuel leakage.
a Check the high-pressure fuel circuit parts
coated with the color checker and their pe-
ripheries for fuel leakage.
a If any fuel leakage is detected, repair it and
perform inspection again from step 2.

6. Start the engine and keep it running at high idle.

7. Stop the engine and check the fuel piping and

devices for fuel leakage.
a Check the high-pressure fuel circuit parts
coated with the color checker and their pe-
ripheries for fuel leakage.
a If any fuel leakage is detected, repair it and
perform inspection again from step 2.

8. Start the engine and keep it running at high

speed under the load.
a Relieve the arm circuit at the IN stroke end.

HB205-1, HB215LC-1 30-29

(01)
 30
Engine and cooling system
Handling of controller high-voltage circuit

Handling of controller
high-voltage circuit 30

1. When disconnecting or connecting the connector

between the engine controller and the engine, be
sure to turn the starting switch to the OFF posi-
tion.

2. Do not start the engine while a T-adapter is

inserted into or connected to the connector
between the engine controller and the engine for
troubleshooting purposes.
a Set the starting switch to the OFF or ON po-
sition and do not set it to the START position.

30-30 HB205-1, HB215LC-1

(01)

Testing and adjusting air
conditioner compressor belt
tension
k Stop the machine on level ground and lower
the work equipment to the ground.
Checking
1. Open the engine hood and remove the belt
guard (1) from the top of the air conditioner
compressor.
2. Press the intermediate point of the belt between
fan pulley and compressor pulley with a thumb
and measure deflection (a) of the belt.
a: 6.3 8.7 mm
q Belt pressing force: 60 N {6.2 kg}
HB205-1, HB215LC-1
(01)
31
Engine and cooling system
Testing and adjusting air conditioner compressor belt tension
Adjusting
a If the belt deflection is abnormal, adjust it accord-
ing to the following procedure.
31
1. Loosen bolts (1) and (2).
2. Move compressor (3) and bracket (4) together to
adjust the belt tension.
3. After positioning compressor (3), tighten bolts
(1) and (2).
a Check each pulley for breakage, wear of the
V-groove, and contact of the V-belt and
V-groove.
a If the V-belt is so elongated that no adjust-
ment allowance remains or it has a cut or a
crack, replace it with a new one.
a If the belt is replaced, adjust the tension
again after operating the machine for 1 hour.
a After tightening the bolts, check the belt ten-
sion again according to the above procedure.
4. After finishing checking and adjusting, return the
removed parts.
30-31

Engine and cooling system
Replacement of fan belt
Replacement of fan belt
a The auto-tensioner is provided for the fan belt.
Thus, testing and adjustment of the belt is usual-
ly not necessary.
a Disconnect air conditioner compressor belt be-
fore replacing the fan belt.
k Stop the machine on level ground and lower
the work equipment to the ground.
1. Open the engine hood and remove hose clamps
(1) (3 places).
2. Remove turbocharger cooling hose (2).
3. Remove compressor belt guard (3) and fan belt
guards (4) and (5).
30-32
32
32
4. Insert a wrench to the portion (A) (width across
flats: 12.7 mm) of the tensioner assembly (3),
and move it in the direction of decreasing the fan
belt (2) tension.
k Make sure that the wrench is applied se-
curely to the portion (A) of the tensioner
assembly (3) before rotating it. (The
spring in the tensioner assembly (3) is
strong. If the wrench is loosely applied,
the wrench may accidentally come off
while being moved and it is extremely
dangerous.)
k After removing the fan belt (2), return the
tensioner assembly (3) slowly with care.
k Be careful not to get your fingers caught
between the pulley and fan belt (2) during
work.
5. Replace the fan belt (2).
q Check each pulley for breakage and crack.
HB205-1, HB215LC-1
(01)
 33
Undercarriage and frame
Testing swing circle bearing clearance

Undercarriage and frame 3

Testing swing circle bearing 4. Set the arm almost perpendicular to the ground
clearance 3
and lower the boom until the front part of the
track floats.
a Testing tools for swing circle bearing clearance a At this time the front of the upper structure
Symbol Part No. Part name rises and the rear lowers.
Commercially
J Dial gauge 5. Under this condition, read dial gauge J.
available
a The value indicated by dial gauge J is the
a When testing the swing circle bearing clearance
clearance of the bearing.
on the complete machine, perform the following
a For the standard value, see Maintenance
procedure.
k Stop the machine on level ground and lower
standard, "Swing circle".
the work equipment to the ground.
k Do not put your hands or feet under the un-
dercarriage during testing.

1. Fix dial gauge J to the track frame and apply the

probe to the lower surface of the outer race.

6. Return the machine to the condition of step 2

and check that dial gauge J indicates zero.
a If the dial gauge does not indicate zero, re-
peat steps 2 through 5.

2. Set the work equipment to the maximum reach

posture and set the bucket tip to the height of the
under side of the revolving frame.
a At this time the front of the upper structure
lowers and the rear rises.

3. Set dial gauge J to the zero point.

HB205-1, HB215LC-1 30-33

(01)
 34
Undercarriage and frame
Testing and adjusting track tension

Testing and adjusting track Adjusting

tension
Testing
1. Run the engine at low idle and drive the machine
forward by the length of track on ground, and
then stop slowly.
2. Place steel bar [1] on the track between the idler
and the 1st carrier roller.
a As the steel bar [1], use an angle steel, etc.
which will not deflect.
3. Measure maximum clearance (a) between steel
bar [1] and track shoe.
q Standard maximum clearance (a):
10 30 mm
34
a If the track tension is abnormal, adjust it accord-
ing to the following procedure.
1. Increasing tension
1) Add grease through grease fitting (1) with a
grease gun.
2) To check that the tension is normal, run the
engine at low idle and move the machine
forward by the length of track on ground, then
stop slowly.
3) After adjusting, check the track tension again
according to the above procedure.

a You may add grease until dimension (b)

between the idler guide and track frame
end becomes 0 mm. If the tension is still
low, the pins and bushings are worn ex-
cessively. In this case, reverse or replace
the pins and bushings.

30-34 HB205-1, HB215LC-1

(01)
 35
Undercarriage and frame
Testing and adjusting track tension

2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten valve (2).
k Do not loosen the valve more than one
turn. If it is loosened more, it may
jump out because of the internal
high-pressure grease.
2) To check that the tension is normal, run the
engine at low idle and move the machine
forward by the length of track on ground, then
stop slowly.
3) After adjusting, check the track tension again
according to the above procedure.

HB205-1, HB215LC-1 30-35

(01)
 36
Undercarriage and frame
Testing and adjusting track tension

30-36 HB205-1, HB215LC-1

(01)
 37
Hydraulic system
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits

Hydraulic system 37

Testing and adjusting hydraulic 2) Install nipples K2 and connect oil pressure
oil pressure in work equipment gauges [1] of hydraulic tester K1.
a Use the oil pressure gauges of 60 MPa
and travel circuits 37

{600 kg/cm2}.
a Testing and adjusting tools for oil pressure in
work equipment and travel circuits.
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
K
799-101-5220 Nipple (10 1.25 mm)
2
07002-11023 O-ring
k Stop the machine on level ground and lower
the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".

Testing
a The oil pressure in the work equipment and trav-
el circuits (pump discharge pressure) can be
checked by using the monitoring function of the
machine monitor, too (For details, see "Special
functions of machine monitor").
q Monitoring code: 01100 F pump pressure
q Monitoring code: 01101 R pump pressure
a Test the oil pressure in the work equipment and
travel circuits under the following condition.
q Hydraulic oil temperature: Within operating
range
1. Preparatory for work
1) Open the side cover of the pump room and
remove oil pressure pickup port plugs (1) and
2. Combination of pump, actuator, and valve
a When the oil from the pumps is divided, the
front pump and rear pump act independently
on each actuator. Note that the relieved valve
varies depending on the actuator.
a When the work equipment circuit is relieved
singly, the oils of the pumps are merged.
When the travel circuit is relieved singly, the
oils of the pumps are divided.
a The actuators in the table are arranged in the
order when the control valve is seen from the
front of the machine (and the service valve is
used for an attachment).
Actuator Valve relieved
(R unload valve) (R main relief valve)
Rear pump

(2). Service Safety-suction valve

q (1): Front pump discharge pressure pick-
Bucket R main relief valve
up port plug Left travel R main relief valve
RAISE: R main relief valve
q (2): Rear pump discharge pressure pick- Boom
Lower: Safety-suction valve
up port plug
(Pump merge-divider valve) (Travel junction valve)
(Self pressure reducing valve)
Front pump

Right
F main relief valve
travel
Arm F main relief valve
(F unload valve) (F main relief valve)
(Centralized safety valve) (Back pressure valve)

HB205-1, HB215LC-1 30-37

(01)
 38
Hydraulic system
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits

3. Testing unload pressure 5. Testing travel relief pressure

1) Start the engine, set the working mode to the 1) Run the engine and lock the travel mecha-
power mode (P), and turn the auto-decelera- nism.
tion OFF. k Put pin [2] between the sprocket and
2) Run the engine at full speed, set all the levers track frame to lock the travel mecha-
and pedals for work equipment control and nism securely.
travel control to the neutral position, and
measure the oil pressure.
a The pressure measured when the unload
valve of the control valve functioned is in-
dicated.

2) Set the working mode to the power mode (P).

3) Run the engine at full speed, operate the
travel lever and pedal to relieve the travel
motor, and measure the oil pressure.
k Before operating the travel lever and
pedal, check the lock pin position and
4. Testing work equipment relief pressure locking direction (forward travel or re-
1) Start the engine and move the cylinder to be verse travel) again.
measured to the stroke end. a The pressure measured when the main
2) Set the working mode to the power mode (P). relief valve of the control valve is relieved
3) Run the engine at full speed, operate the is indicated. The travel circuit is always
right and left work equipment control levers relieved at high pressure.
to relieve the cylinder, and measure the oil
pressure. 6. Work after finishing test
a The pressure measured when the main After finishing test, remove the testing tools and
relief valve is relieved is indicated (If the return the removed parts.
boom is lowered singly, the safety-suction 3 Oil pressure pickup port plug:
valve of the control valve for lowering the 20 27 Nm {2.0 2.8 kgm}
boom is relieved).
a If the one-touch power maximizing switch
is released, the main relief valve is re-
lieved at low pressure. If the former is
pressed, the latter is relieved at high pres-
sure.
a If the swing lock switch is turned ON, the
2-stage relief solenoid valve is kept
turned ON and the relief valve is relieved
at high pressure. Accordingly, keep the
swing lock switch turned OFF.

30-38 HB205-1, HB215LC-1

(01)
 39
Hydraulic system
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits

Adjusting 1) Disconnect pilot hose (5).

a The unload valve and safety-suction valve for 2) While fixing holder (6), loosen locknut (7).
lowering the boom cannot be adjusted. 3) Turn holder (6) to adjust the set pressure.
a If the holder is
1. Adjusting work equipment and travel relief q turned to the right, the set pressure is
pressure increased.
a If the relief pressure of the work equipment q turned to the left, the set pressure is
circuit and travel circuit is abnormal, adjust decreased.
main relief valves (3) and (4) according to the a Amount of adjustment per turn of holder:
following procedure. Approx. 20.5 MPa {Approx. 209 kg/cm2}
q (3): Front (F) main relief valve 4) While fixing holder (6), tighten locknut (7).
q (4): Rear (R) main relief valve 3 Locknut: 49 58.8 Nm {5 6 kgm}
a When adjusting the main relief valves, re-
move the top cover of the control valve.
a Adjust only the low relief pressure of the main
relief valve. If the low relief pressure is adjust-
ed, the high relief pressure is set automati-
cally.
a The low relief pressure is the pressure under
the following condition: the 2-stage relief so-
lenoid valve is turned OFF and the pilot pres-
sure is not applied to the selector port.

5) Connect pilot hose (5).

6) After finishing adjustment, check again that
the oil pressure is normal according to the
above described testing procedure.

HB205-1, HB215LC-1 30-39

(01)
 40
Hydraulic system
Testing source pressure of control circuit

Testing source pressure of 3. Start the engine, set the working mode to the
control circuit 40
power mode (P), and turn the auto-deceleration
OFF.
a Testing tools for source pressure of control cir-
cuit 4. Run the engine at high idle, set all the levers and
Symbol Part No. Part name pedals for work equipment control and travel
799-101-5002 Hydraulic tester control to the neutral position, and measure the
1 oil pressure.
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 1.25 mm)
2
07002-11023 O-ring
k Stop the machine on level ground and lower
the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".
a Test the source pressure of control circuit under
the following condition.
q Hydraulic oil temperature: Within operating
range

1. Remove the control valve top cover and oil pres-

sure pickup port plug (1).
5. After finishing test, remove the testing tools and
return the removed parts.
a The source pressure of control circuit may be
tested by using oil pressure pickup port plug
(2) on the hydraulic pump side.

2. Install nipple L2 and connect oil pressure gauge

[1] of hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
a Do not adjust the relief valve for control circuit
source pressure.

30-40 HB205-1, HB215LC-1

(01)
 41
Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit

Testing and adjusting oil pressure 2) Install nipples M2 and nipples of hydraulic
in pump PC control circuit 41
tester M1 and connect them to oil pressure
gauges [2].
a Testing and adjusting tools for oil pressure in a Connect the pressure gauge to the mea-
pump PC control circuit suring part of plug (3) by using joint
Symbol Part No. Part name (790-301-1271) and elbow (790-301-
799-101-5002 Hydraulic tester 1530) of hydraulic tester M1 and nipple so
1 that it will not interfere with the drain pip-
790-261-1204 Digital hydraulic tester
M ing.
799-101-5220 Nipple (10 1.25 mm)
2 a Use the oil pressure gauges of 60 MPa
07002-11023 O-ring
k
{600 kg/cm2}.
Stop the machine on level ground and lower
the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".

Testing
a Before testing the oil pressure in the PC control
circuit, check that the oil pressure in the work
equipment and travel circuits and the source
pressure of the control circuit are normal.
a Test the oil pressure in the pump PC control cir-
cuit under the following condition.
q Hydraulic oil temperature: Within operating
range 3) Start the engine and operate the arm cylinder
to the IN stroke end.
1. Testing PC valve output pressure (servo 4) Set the working mode to the power mode (P)
piston inlet pressure) and turn the swing lock switch ON.
a Test the PC valve output pressure (servo pis- a If the swing lock switch is turned ON, the
ton inlet pressure) and pump discharge pres- main relief valve is set for high-pressure
sure simultaneously and compare them. relief.
1) Open the side cover of the pump room and 5) Run the engine at full speed, operate the left
remove oil pressure pickup port plugs (1), (2), work equipment control lever to relieve the
(3), and (4). arm circuit at the IN stroke end, and measure
q (1): Front pump discharge pressure pick- the oil pressure.
up port plug
q (2): Rear pump discharge pressure pick-
up port plug
q (3): Front PC valve output pressure pick-
up port plug
q (4): Rear PC valve output pressure pick-
up port plug

HB205-1, HB215LC-1 30-41

(01)
 42
Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit

a Testing condition and method of judg- 2) Install nipples M2 and connect them to oil
ment: If the pressures are in the following pressure gauges [2].
ratio, the PC valve is normal. a Use the oil pressure gauges of 6 MPa
Measured oil Operation of Ratio of oil {60 kg/cm2}.
pressure lever pressures
Pump discharge
1
pressure
Arm IN relief
PC valve output Approx. 0.6
pressure (Approx. 3/5)
a If the PC valve or the servo piston is ab-
normal, the PC valve output pressure
(servo piston inlet pressure) is "the same
as the pump discharge pressure" or "al-
most zero".
6) After finishing test, remove the testing tools
and return the removed parts.

2. Measuring PC-EPC valve output pressure

3) Start the engine and set the working mode to
1) Open the side cover of the pump room and
the power mode (P).
remove oil pressure pickup plugs (5) and (6).
4) Set all the levers and pedals for work equip-
q (5): Front PC-EPC valve output pressure
ment control and travel control to the neutral
pickup port plug
position, run the engine at high idle and low
q (6): Rear PC-EPC valve output pressure
idle, and test the oil pressure at each speed.
pickup port plug

a Testing condition and method of judg-

ment: If the output pressures are in the
following ratio, the PC-EPC valve is nor-
mal.
Operation of
Engine Output pressure
lever
Approx. 2.9 MPa
Low idle All control levers {Approx. 30 kg/cm2}
and pedals in
neutral 0 MPa
High idle
{0 kg/cm2}
5) After finishing test, remove the testing tools
and return the removed parts.

30-42 HB205-1, HB215LC-1

(01)
 43
Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit

Adjusting 1. Loosen locknut (9).

Adjusting pump PC valve
a If either of the following phenomena occurs and
the PC valve seems to be defective, adjust PC
valves (7) and (8) according to the procedure
shown below.
q As the load increases, the engine speed low-
ers considerably.
q The engine speed is normal but the work
equipment speed is low.
q (7): Front pump PC valve
q (8): Rear pump PC valve
a The width across flats of the PC valve locknut is
13 mm and that of the adjustment screw (inside
width) is 4 mm.
Do not turn any other locknuts or adjustment
screws since they affect the hydraulic pump
performance.
a Before loosening the locknut, put matchmark
to the adjustment screw end so that you can
see the position of the locknut before the ad-
justment (and you can return the locknut to its
original position after turning it in reverse).
2. Turn adjustment screw (10) clockwise or coun-
terclockwise for the adjustment.
a Turn the adjustment screw
q clockwise when the work equipment
speed is low (to increase pump absorp-
tion torque) and
q counterclockwise when the engine speed
lowers (to decrease pump absorption
torque).
3. Tighten locknut (9).
3 Locknut: 27 34 Nm {2.8 3.5 kgm}

4. After finishing adjustment, check again that the

PC valve output pressure (servo piston inlet
pressure) is normal according to the above
described measurement procedure.

5. Perform the pump calibration adjustment of the

"Special functions of machine monitor".

HB205-1, HB215LC-1 30-43

(01)

Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit
Testing and adjusting oil pressure
in pump LS control circuit
a Testing and adjusting tools for oil pressure in
pump LS control circuit
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1 the drain piping.
790-261-1204 Digital hydraulic tester
N 2 799-401-2701 Differential pressure gauge
799-101-5220 Nipple (10 1.25 mm)
3
07002-11023 O-ring
k Stop the machine on level ground and lower
the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".
Testing
a Before testing the oil pressure in the PC control
circuit, check that the oil pressure in the work
equipment and travel circuits and the source
pressure of the control circuit are normal.
a Test the oil pressure in the pump LS control cir-
cuit under the following condition.
q Hydraulic oil temperature: Within operating
range
1. Testing LS valve output pressure (servo
piston inlet pressure)
a Test the LS valve output pressure (servo pis-
ton inlet pressure) and pump discharge pres-
sure simultaneously and compare them.
1) Open the side cover of the pump room and
remove oil pressure pickup plugs (1), (2), (3),
and (4).
q (1): Front pump discharge pressure pick-
up port plug
q (2): Rear pump discharge pressure pick-
up port plug
q (3): Front LS valve output pressure pick-
up port plug
q (4): Rear LS valve output pressure pickup
port plug
30-44
44
2) Install nipples N3 and nipples of hydraulic
4
tester N1 and connect them to oil pressure
gauges [2].
a Connect the measuring part of plug (3) by
using joint (790-301-1271) and elbow
(790-301-1530) of hydraulic tester N1
and nipple so that it will not interfere with
a Use the oil pressure gauges of 60 MPa
{600 kg/cm2}.
3) Start the engine and push up the track on the
side to be measured by using the work equip-
ment and prepare for running the track idle.
q When measuring front circuit: Right track
q When measuring rear circuit: Left track
k Since the raised track runs during test-
ing, secure a sufficient working area.
4) Set the working mode to the power mode (P)
and set the travel speed to the High.
5) Run the engine at full speed, set all the levers
and pedals for work equipment control and
travel control to the neutral position, and
measure the oil pressure under this condi-
tion. Then, operate the travel lever to run the
track idle and measure the oil pressure.
k While taking extreme care for safety,
run the raised track.
a Do not operate the travel lever to the
stroke end (stop it halfway).
HB205-1, HB215LC-1
(01)
 45
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit

a Testing condition and method of judg- 2) Install nipples N3 and connect it to differential
ment: If the pressures are in the following pressure gauge N2 or the oil pressure gauge
ratio, the LS valve is normal. of hydraulic tester N1.
Position of levers and pedals a When using differential pressure gauge
Hydraulic pres- Travel lever N2:
sure to be mea- All levers and
moved half- Connect the pump discharge pressure to
sured pedals are at
way (track the high pressure side (back side) and
neutral
idle)
connect the LS pressure to the low pres-
Pump discharge Actual value
pressure is set as 1 sure side (lower side). Since the differen-
Almost same tial pressure gauge needs a 12V power
pressure Approx. 3/5
LS valve output
pressure
of pressure source, connect it to a battery.
above a When using oil pressure gauge (in N1):
6) After finishing test, remove the testing tools Use the oil pressure gauge of 60 MPa
and return the removed parts. {600 kg/cm2} having the unit of 1 MPa
{10 kg/cm2}. Since the differential pres-
2. Testing LS differential pressure sure is about 4 MPa {40 kg/cm2} at
a Test the pump discharge pressure and LS maximum, measure it by installing the
pressure (actuator load pressure) simulta- same gauge to the pickup port plugs
neously and calculate the difference between alternately.
them. q The photo shows the pump discharge

1) Open the side cover of the pump room and pressure side.
remove oil pressure pickup plugs (1), (2), (5),
and (6).
q (1): Front pump discharge pressure pick-
up port plug
q (2): Rear pump discharge pressure pick-
up port plug

q The photo shows the LS pressure side.

q (5): Front LS pressure pickup port plug

q (6): Rear LS pressure pickup port plug

3) Run the engine, push up the track on the side

to be measured by using the work equip-
ment, and prepare for idling the track.
q When measuring front circuit: Right track
q When measuring rear circuit: Left track
k Since the raised track runs during test-
ing, secure a sufficient working area.

HB205-1, HB215LC-1 30-45

(01)
 46
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit

4) Set the working mode to the power mode (P) 3) Start the engine.
and set the travel speed to the High. 4) Run the engine at full speed, operate the
5) Run the engine at full speed, set all the levers travel speed switch and travel lever, and
and pedals for work equipment control and measure the output pressure in each case.
travel control to the neutral position, and a Testing condition and method of judg-
measure the oil pressure under this condi- ment: If the output pressures are in the
tion. Then, operate the travel lever to run the following ratio, the LS-EPC valve is nor-
track idle and measure the oil pressure. mal.
k While taking extreme care for safety, Operation of
Travel speed Output pressure
run the raised track. lever
a Do not operate the travel lever to the Travel lever in
Approx.2.9 MPa
stroke end (stop it halfway). Low {Approx.
neutral
30 kg/cm2}
a Testing condition and method of judg-
Travel lever
ment: If the pressures are in the following 0 MPa
High operated a little
ratio, the LS valve is normal. {0 kg/cm2}
(Note)
LS differential Note: Move the travel lever to a degree that the PPC
Operation of lever
pressure
oil pressure switch is turned ON (before the track
All control levers and pedals Specified LS dif-
are at neutral ferential pres- starts moving).
sure (See
Travel lever moved halfway standard values
(track run idle) table)
6) After finishing test, remove the testing tools
and return the removed parts.

3. Testing LS-EPC valve output pressure

1) Open the side cover of the pump room and
remove oil pressure pickup port plug (7).

5) After finishing test, remove the testing tools

and return the removed parts.

2) Install nipple N3 and connect them to oil pres-

sure gauge [2].
a Use the oil pressure gauges of 6 MPa
{60 kg/cm2}.

30-46 HB205-1, HB215LC-1

(01)
 47
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit

Adjusting
Adjusting LS valve
a If the LS differential pressure is abnormal, adjust
the LS valve according to the following proce-
dure.
q (8): Front pump LS valve
q (9): Rear pump LS valve

1. While fixing adjustment screw (10), loosen

locknut (11).

2. Turn adjustment screw (10) to adjust the differ-

ential pressure.
a If the adjustment screw is
q turned to the right, the differential pres-
sure is increased.
q turned to the left, the differential pressure
is decreased.
a Amount of adjustment (LS differential pres-
sure) per turn of adjustment screw:
Approx. 1.1 MPa {Approx. 10.8 kg/cm2}

3. While fixing adjustment screw (10), tighten

locknut (11).
3 Locknut: 49 68.6 Nm {5 7 kgm}

4. After finishing adjustment, check again that the

LS differential pressure is normal according to
the above described testing procedure.

HB205-1, HB215LC-1 30-47

(01)
 48
Hydraulic system
Testing solenoid valve output pressure

Testing solenoid valve output a When testing at hoses (2) (6), remove the
pressure 48
undercover of the control valve.

a Testing tools for solenoid valve output pressure

Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
P 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (size 02)

k Stop the machine on level ground and lower

the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".
a Before testing the solenoid valve output pres-
sure, check that the source pressure of the con-
trol circuit is normal. 2. Install adapter P2 and connect the disconnected
a Test the solenoid valve output pressure under hose again.
the following condition.
q Hydraulic oil temperature: Within operating 3. Install nipple [1] of hydraulic tester P1 and
range connect it to oil pressure gauge [2].
a Use the oil pressure gauge of 6 MPa
1. Disconnect one of outlet hoses (1) (6) of the {60 kg/cm2}.
solenoid valves to be measured. a The figure shows the testing tools connected
No. Solenoid valve to be measured to outlet hose (1) of the PPC lock solenoid
1 PPC lock solenoid valve valve.
2 2-stage relief solenoid valve
3 Swing brake solenoid valve
4 Travel speed selector solenoid valve
5 Travel junction solenoid valve
ATT return selector solenoid valve
6
(for the machine with attachment)
a When testing at hose (1), remove the under-
cover (rear side) of the operator's cab.

30-48 HB205-1, HB215LC-1

(01)
 49
Hydraulic system
Testing solenoid valve output pressure

4. Start the engine.

5. Run the engine at full speed, operate the control

levers and switches to turn the solenoid valve
ON or OFF, and measure the oil pressure.
a For the conditions for turning the solenoid
valve ON and OFF, see the operation table of
each solenoid valve.
a The operating condition of the solenoid valve
can be checked by using the monitoring func-
tion of the machine monitor (For details, see
"Special functions of machine monitor").
q Monitoring code: 02300 Solenoid 1
q Monitoring code: 02301 Solenoid 2

a If the output pressure is as follows, the sole-

noid valve is normal.
Solenoid valve Output pressure
OFF (De-energized) 0 MPa {0 kg/cm2}
ON (Energized) 2.9 MPa {30 kg/cm2}

6. After finishing test, remove the testing tools and

return the removed parts.

HB205-1, HB215LC-1 30-49

(01)
 50
Hydraulic system
Testing solenoid valve output pressure

Operation table of PPC lock solenoid valve

Opera-
Operating condition
tion
Lock OFF
Lock lever
Free ON

Operation table of 2-stage relief solenoid valve

Opera-
Operating condition
tion
Overheat 1st setting is ON
Overheat 2nd setting is ON OFF
All of work equipment, swing, and travel signals are OFF
Swing lock switch is ON
Travel signal is ON
Boom LOWER signal is ON ON
Signals other than swing single
P/E-mode is signal are ON
Left knob switch is ON
selected
Swing single signal is ON
OFF
Other than above condition

Operation table of swing brake solenoid valve

Opera-
Operating condition
tion
Work equipment, swing, and All are OFF OFF
travel signals Any one is ON ON

Operation table of travel speed switching solenoid valve

Opera-
Operating condition
tion
Overheat 2nd setting is ON
Fuel control dial is at 1,500 rpm or below
Travel speed switch is at Lo/Mi
OFF
Travel signal is OFF
F or R pump pressure is 24.5 MPa {250 kg/cm2}
Travel speed switch is at Hi Travel signal is or higher
ON F or R pump pressure is 15.3 MPa {150 kg/cm2}
or lower ON
Other than above condition

Operation table of travel junction solenoid valve

Opera-
Operating condition
tion
Travel steering signal is ON
Travel lever is F or R pump pressure is 24.5 MPa {250 kg/cm2} or ON
Travel steering signal is OFF operated singly higher
Other than above condition OFF

30-50 HB205-1, HB215LC-1

(01)
 51
Hydraulic system
Testing PPC valve output pressure

Testing PPC valve output pressure 51

Connecting points of PPC piping

a The above figure shows the connecting points of

the PPC piping on the control valve on the ma-
chine with an attachment. The colors in ( ) are
the colors of the bands installed for distinction of
the pipes.
a The figure at right shows the check point of the
steering signal voltage of the travel PPC valve.
When measuring the steering signal voltage, re-
move the undercover of the operator's cab (front
side).

HB205-1, HB215LC-1 30-51

(01)
 52
Hydraulic system
Testing PPC valve output pressure

a Testing tools for PPC valve output pressure

Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Q
2 799-401-3100 Adapter (size 02)
3 799-401-3200 Adapter (size 03)
k Stop the machine on level ground and lower
the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".
a Before testing the PPC valve output pressure,
check that the control circuit source pressure is
normal. a If the output pressure is as follows, the PPC
a Test the solenoid valve output pressure under valve is normal.
the following condition.
Operation of lever Output pressure
q Hydraulic oil temperature: Within operating
Neutral 0 MPa {0 kg/cm2}
range Almost same as control
Stroke end circuit source pressure
1. Disconnect the hose of the PPC circuit to be (See standard values table)
tested.
a For the hose to be disconnected, see "Con- 6. After finishing test, remove the testing tools and
necting points of PPC piping". return the removed parts.

2. Install adapter Q2 and connect the disconnected

hose again.

3. Install nipple [1] of hydraulic tester Q1 and

connect it to oil pressure gauge [2].
a Use the oil pressure gauges of 6 MPa
{60 kg/cm2}.
a The figure shows the testing tools connected
to the hose of the bucket dump PPC circuit.

4. Start the engine and set the working mode to the

power mode (P).

5. Run the engine at full speed and measure the oil

pressure with the control lever in neutral and
moved to the stroke end.

30-52 HB205-1, HB215LC-1

(01)
 53
Hydraulic system
Adjusting play of work equipment and swing PPC valves

Adjusting play of work equipment

and swing PPC valves 53

a If the right and left work equipment levers have

large play, adjust them according to the following
procedure.
a The play of the lever tip must be 0.5 3 mm at a
position of 200 mm from the fulcrum.

1. Remove the work equipment and swing PPC

valve assembly.

2. Remove bellows (1).

3. Loosen locknut (2) and screw down disc (3) until

it touches the heads of 4 pistons (4).
a Do not move the piston while doing this work.

4. Fix disc (3) and tighten locknut (2) to the speci-

fied torque.
3 Locknut: 69 88 Nm {7 9 kgm}

5. Install bellows (1).

6. Install the work equipment and swing PPC valve

assembly.

HB205-1, HB215LC-1 30-53

(01)

Hydraulic system
Checking parts which cause hydraulic drift of work equipment
Checking parts which cause
hydraulic drift of work equipment
a If the work equipment (cylinder) drifts hydrauli-
cally, check to see if the cause is on the cylinder
packing or control valve according to the follow-
ing procedure.
1. Checking boom cylinder and bucket cylinder
1) Set the machine to the posture for testing
hydraulic drift and stop the engine.
a Fill the bucket with a rated load or with dirt
and sand.
2) When checking the boom cylinder, set the
boom control lever to the RAISE position.
When checking the bucket cylinder, set the
bucket control lever to the CURL position.
q If the lowering speed is increased at this
time, the cylinder packing is defective.
q If the lowering speed does not change at
this time, the control valve is defective.
a Operate the control lever while the start-
ing switch is in the ON position.
a If the pressure in the accumulator is lost,
run the engine for approximately 5 sec-
onds to raise the pressure in the accumu-
lator.
30-54
54
2. Checking arm cylinder
54
1) Stop the arm cylinder approximately 100 mm
before the IN stroke end and stop the engine.
2) Operate the arm control lever to the IN posi-
tion.
q If the lowering speed is increased at this
time, the cylinder packing is defective.
q If the lowering speed does not change at
this time, the control valve is defective.
a Operate the control lever while the start-
ing switch is in the ON position.
a If the pressure in the accumulator is lost,
run the engine for approximately 5 sec-
onds to raise the pressure in the accumu-
lator.
[Reference]
Reason why the lowering speed is increased by
the above operation when the cylinder packing is
the cause of the hydraulic drift:
1) If the machine is set to the above posture
(where the holding pressure is applied to the
bottom side), the oil leaks from the bottom
side to the head side. Since the volume on
the head side is less than that on the bottom
side by the volume of the rod, the pressure in
the head side is increased by the oil flowing
in from the bottom side.
2) As the pressure in the head side is increased,
it is balanced at a certain level (which
depends on the leakage), and then the
lowering speed is decreased.
3) If the circuit on the head side is opened to the
drain circuit by the above mentioned lever
operation (the bottom side is closed by the
check valve at this time), the oil on the head
side flows in the drain circuit. As a result, the
pressure balance is lost and the lowering
speed is increased.
HB205-1, HB215LC-1
(01)
 55
Hydraulic system
Checking parts which cause hydraulic drift of work equipment

3. Checking PPC valve

While the pressure in the accumulator is high,
set the lock lever to the LOCK position and
FREE position to measure the lowering
distance.
a Operate the control lever while the starting
switch is in the ON position.
a If the pressure in the accumulator is lost, run
the engine for approximately 5 seconds to in-
crease the pressure in the accumulator.
a If there is a difference in the lowering dis-
tance between the LOCK position and FREE
position, the PPC valve is defective (it has an
internal defect).

HB205-1, HB215LC-1 30-55

(01)
 56
Hydraulic system
Releasing remaining pressure from hydraulic circuit

Releasing remaining pressure 4) Repeat the above steps 2) and 3) two to

from hydraulic circuit
1. Releasing remaining pressure from
hydraulic tank
k Since the hydraulic tank is airtight and
pressurized, release the remaining pres-
sure from it when removing a hose or a
plug connected to it.
1) Lower the work equipment to the ground in a
stable posture and stop the engine.
2) Loosen oil filler cap (1) of the hydraulic tank
gradually to release the air in the tank.
56
three times, and the remaining pressure in
the piping is released completely.
3. Releasing remaining pressure from travel
motor circuit
Since the control valve spool of the travel motor
circuit is open, the pressure in this circuit can be
released by performing "Releasing remaining
pressure from hydraulic tank".

2. Releasing remaining pressure from

hydraulic cylinder circuit
k When disconnecting a piping between the
hydraulic cylinder and the control valve,
release the remaining pressure from the
piping according to the following proce-
dure.
1) Lower the work equipment and release the
remaining pressure from the hydraulic tank.
For details, see "Releasing remaining pres-
sure from hydraulic tank".
a Keep the oil filler cap of the hydraulic tank
removed.
2) Turn the starting switch to ON position and
set the lock lever to the FREE position, and
then operate the right and left work equip-
ment control levers forward, backward, to the
right, and to the left.
a The control valve is operated by the pres-
sure in the accumulator. The pressure in
the accumulator is used up, however, af-
ter the control valve is operated 2 3
times.
3) Run the engine at low speed for 5 seconds to
increase the pressure in the accumulator.
a The engine does not start unless the lock
lever is set to the LOCK position once.

30-56 HB205-1, HB215LC-1

(01)
 57
Hydraulic system
Testing oil leakage

Testing oil leakage 57

2. Testing oil leakage from arm cylinder
1) Move the arm cylinder to the IN stroke end
a Testing tools for oil leakage and stop the engine.
Symbol Part No. Part name k Release the remaining pressure from
Commercially the piping on the arm cylinder head
T Measuring cylinder
available side. For details, see "Releasing re-
a Test the oil leakage under the following condi- maining pressure from hydraulic cir-
tion. cuit" (Operate the lever in the arm IN
q Hydraulic oil temperature: Within operating
direction only, however).
range 2) Disconnect hose (2) from the cylinder head
side and block the hose end with a flange.
k Take care not to disconnect the hose
1. Testing oil leakage from boom cylinder
1) Move the boom cylinder to the RAISE stroke from the cylinder bottom.
end and stop the engine. a Use the following part to block the hose
k Release the remaining pressure from
end.
the piping on the boom cylinder head 07379-00640 (Flange #06)
side. For details, see "Releasing re-
maining pressure from hydraulic cir-
cuit" (Operate the lever in the boom
RAISE direction only, however).
2) Disconnect hoses (1) from the cylinder head
and block the hose end with a flange.
k Take care not to disconnect the hose
from the cylinder bottom.
a Use the following parts to block the hose
end.
07379-00640 (Flange #06)

3) Run the engine at full speed and relieve the

arm circuit by moving the arm IN.
k Take care not to "move the arm OUT".
4) Start measuring the oil leakage 30 seconds
after relieving is started and measure
leakage for 1 minute.
5) After finishing test, return the removed parts.

3) Run the engine at full speed and relieve the

boom circuit by raising the boom.
k Take care not to "lower the boom".
4) Start measuring the oil leakage 30 seconds
after relieving is started and measure
leakage for 1 minute.
5) After finishing test, return the removed parts.

HB205-1, HB215LC-1 30-57

(01)
 58
Hydraulic system
Testing oil leakage

3. Testing oil leakage from bucket cylinder 4. Testing oil leakage from travel motor
1) Move the bucket cylinder to the CURL stroke 1) Remove the travel motor cover.
end and stop the engine. 2) Run the engine, lock the travel mechanism,
k Release the remaining pressure from and stop the engine.
the piping on the bucket cylinder head k Put pin [1] between the sprocket and
side. For details, see "Releasing re- track frame to lock the travel mecha-
maining pressure from hydraulic cir- nism securely.
cuit" (Operate the lever in the bucket
CURL direction only, however).
2) Disconnect hose (3) from the cylinder head
side and block the hose end with a flange.
k Take care not to disconnect the hose
from the cylinder bottom.
a Use the following part to block the hose
end.
07379-00640 (Flange # 06)

3) Disconnect drain hose (5) of the travel motor

and block the hose end with a plug.
a Use the following part to block the hose
end.
07376-70422 (Plug #04)

3) Run the engine at full speed and relieve the

bucket circuit by curling the bucket.
k Take care not to "Dump the bucket".
4) Start measuring the oil leakage 30 seconds
after relieving is started and measure
leakage for 1 minute.
5) After finishing test, return the removed parts.

4) Run the engine at full speed, relieve the

travel circuit, and measure the oil leakage.
k Before operating the travel lever,
check the lock pin position and lock-
ing direction (forward travel or reverse
travel) again.
k Wrong operation of the lever can
cause an accident. Accordingly, make
signals and checks securely.
a Start measuring the oil leakage 30 sec-
onds after relieving is started and mea-
sure leakage for 1 minute.
a Measure several times, moving the motor
a little (changing the position of the valve
plate and cylinder, and that of the cylinder
and piston) each time.
5) After finishing test, return the removed parts.

30-58 HB205-1, HB215LC-1

(01)
 59
Hydraulic system
Bleeding air from each part

Bleeding air from each part 59

Air bleeding items

Air bleeding procedure
1 2 3 4 5
Checking oil
Bleeding air Bleeding air
Starting Bleeding air level and
from hydraulic from travel
engine from cylinder operating
pump motor
machine
q Replacing hydraulic oil q
q q q q
q Cleaning strainer (See note)
q Replacing return oil filter element q o o q
q Replacing and repairing hydraulic
Contents of work

pump q q q o q
q Removing suction piping
q Replacing and repairing control valve
q q o q
q Removing control valve piping
q Replacing and repairing cylinder
q q o q
q Removing cylinder piping
q Replacing and repairing travel motor
q o q q
q Removing travel motor piping
q Replacing and repairing swivel joint
q o o q
q Removing swivel joint piping
Note: Bleed air from the travel motors only when the oil in the motor cases is drained.

1. Bleeding air from hydraulic pump 2. Starting engine

1) Loosen air bleeder (1) and check that oil When running the engine after performing step
oozes out through the air bleeder. 1, let it idle at low speed for 10 minutes.
2) After the oil oozes out, tighten air bleeder (1). a If the engine coolant temperature is low and
3 Air bleeder: the automatic warm-up operation is started,
7.8 9.8 Nm {0.8 1.0 kgm} stop the engine temporarily and cancel the
a Do not use an impact wrench to tighten automatic warm-up operation by using the
the air bleeder. fuel control dial (Set the starting switch to the
ON position and hold the fuel control dial at
the MAX position for 3 seconds. This cancels
the automatic warm-up operation).

3. Bleeding air from cylinder

a In the case of cylinder replacement, bleed air
from the cylinder before connecting it to the
work equipment. In particular, the boom cyl-
inder does not move to the lowering stroke
end, if it is installed to the work equipment.
1) Run the engine at low idle for about 5
minutes.
2) While running the engine at low speed, raise
and lower the boom 4 5 times.
a Stop the piston rod approximately 100
mm before each stroke end. Do not re-
lieve the oil.
3) While running the engine at full speed,
perform step 2).
4) While running the engine at low speed, move
the piston rod to the stroke end and relieve
the oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) 4).

HB205-1, HB215LC-1 30-59

(01)
 60
Hydraulic system
Bleeding air from each part
4. Bleeding air from travel motor
1) Run the engine at low idle.
2) Loosen air bleeder (2) and check that oil
oozes out through the air bleeder.
3) After the oil oozes out, tighten air bleeder (2).
3 Air bleeder:
27.5 35.3 Nm {2.8 3.6 kgm}
5. Checking oil level and operating machine
1) Run the engine, retract the arm cylinder and
bucket cylinder to the stroke end, lower the
work equipment to the ground, and stop the
engine.
30-60
2) Check the oil level by sight gauge on the rear
side of the hydraulic tank.
a If the oil level is below line L, it is insuffi-
cient. Add oil.
a The oil level changes according to the oil
temperature. Add oil when the oil level is
out of the following standard ranges.
q When oil temperature is 10 30C:
Between line H and line L
q When oil temperature is 50 80C:
Near line H
HB205-1, HB215LC-1
(01)
 61
Cab and its attachments
Checking cab tipping stopper

Cab and its attachments 61

Checking cab tipping stopper 61

a Check the cab tipping stopper according to the

following procedure.

q Check the tightening torque of the mounting bolt

(2) of the lock plate (1).
3 Bolt (2): 98 123 Nm {10 12.5 kgm}

[Reference]
q Note that the tightening torque of mounting bolt
(4) of cab tipping stopper (3) is different from that
of a common bolt 30 mm in diameter.
3 Bolt (4): 245 309 Nm {25 31.5 kgm}

HB205-1, HB215LC-1 30-61

(01)
 62
Cab and its attachments
Adjusting mirrors

Adjusting mirrors 62

30-62 HB205-1, HB215LC-1

(01)
 63
Installation and adjustment of mirrors
1. Installation of foldable mirrors
Install foldable mirrors (a1) and (b1) as shown in
the figure.
1) Foldable mirror (a1): Install at 20 mm from
the bottom of the intermediate stay. Install
mirror stay (1) so that the mirror will be fixed
at (A) position out of the 3 stopping positions
where the mirror is extended most and at an
angle of about 86 to the intermediate stay.
3 Mirror bolt (2):
4.0 5.4 Nm {0.41 0.55 kgm}
3 Mirror stay bolt (3): 15 Nm {1.52 kgm}
HB205-1, HB215LC-1
(01)
Cab and its attachments
Adjusting mirrors
2) Fold the mirror to position (C) when trans-
porting the machine.
3) Foldable mirror (b1): Install at 33 mm from
the top of the stay. Install mirror stay (4) so
that the mirror will be fixed at (A) position out
of the 3 stopping positions where the mirror is
extended most and at an angle of about 26
to the side of the machine body.
3 Mirror bolt (5):
4.0 5.4 Nm {0.41 0.55 kgm}
3 Mirror stay bolt (6): 15 Nm {1.52 kgm}
4) Fold the mirror to position (C) when trans-
porting the machine.
30-63
 64
Cab and its attachments
Adjusting mirrors

2. Adjustment of foldable mirrors

With foldable mirrors (a1) and (b1) extended,
loosen mirror bolts (1) and (2) and adjust the
mirrors so that the operator can see the right and
left rear views best which are blind spots from
the operators seat.
a Adjust the mirror so that the operator can see
persons (or things 1 m high and about 30 cm
in diameter) at the right and left rear ends of
the machine.

30-64 HB205-1, HB215LC-1

(01)
 65
Cab and its attachments
Angle adjustment of rear view camera

Angle adjustment of rear view
camera
If the image displayed on the monitor is out of posi-
tion, remove cover (1) and adjust installation angle
(A) of the rear view camera.
Angle (A) can be adjusted in the range of 35 80.
4. Loosen camera mounting bolts (4) and adjust
65
camera installation angle (A) so that the center
of mounting bolts (4) matches with 4th gradua-
tion (B) from the bottom.
a A part of the machine is displayed on the
monitor screen.
5. After adjusting, tighten bolts (4).
3 Camera mounting bolt:
3 5 Nm {0.3 0.5 kgm}

1. When removing cover (1), insert a screwdriver

into the hole in cover (2) to press the inside pawl.

2. Remove 2 bolts (3).

3. Remove cover (1).

HB205-1, HB215LC-1 30-65

(01)
 66
Hybrid relation
Testing swing holding brake

Hybrid relation 6

Testing swing holding brake 6

The swing holding brake disc is a consumable parts.

If the hybrid system has a problem, the swing hold-
ing brake stops the upper structure from swinging.
However, if the swing holding brake has a problem
such as a worn brake disc, it will not be able to stop
the swinging motion.
If the swing emergency stop switch is pressed to
stop the swinging motion, the upper structure
moves downward by its own weight on a slope be-
cause of a swing holding brake problem, or the cus-
tomer complains about swing holding brake
problem, test the swing holding brake according to
the following procedure.
If the swing holding brake disc is found worn as a re-
sult of the test, replace it with a new one.
If any related problems are found, repair them se-
curely.

1. Set the work equipment to the posture for the

travel over flat ground.
(Set the arm vertically and raise the bucket to 40
50 cm above the ground)
4. Operate the left work equipment control lever
slowly in the right and left swing directions.
5. If the upper structure does not swing to either
right or left direction, the swing holding brake is
normal.
If the upper structure swings, the swing lock
solenoid valve does not operate properly or
there are other problems in the electrical or
hydraulic systems, or the swing holding brake
disc is worn or there are other problems in the
mechanical system.
6. Stop the engine.

2. Move the machine to a flat and rigid surface
where there are no obstacles to the swinging
operation.
3. Turn swing lock switch (1) to the ON position
while keeping the machine in the posture
described above.
7. Check the swing lock switch, swing lock solenoid
valve, etc. in the electrical or hydraulic system
for problems.
8. If there are no problems in the electrical and
hydraulic systems, the mechanical system can
be considered to have a problem. Perform a
disassembly inspection, referring to Disas-
sembly and assembly, "Disassembly and
assembly of swing machinery assembly".
9. If the swing holding brake disc is worn, replace it
with a new one.
10. After replacement, check that the swing holding
brake operates normally according to steps 3
5 described above.

30-66 HB205-1, HB215LC-1

(01)
 67
Hybrid relation
Cleaning and replacement of oil filter of swing electric motor

Cleaning and replacement of oil 3. Return the removed filter.

3 Tightening torque of filter:
filter of swing electric motor 67

24.5 34.5 Nm {2.5 3.5 kgm}

Swing electric motor filter (1) is inserted in the lubri-

cation circuit and cooling oil circuit to collect foreign
matter in the oil. Clean or replace the oil filter and re-
place the swing electric motor oil every 2,000 hours.

1. Remove the oil filter.

2. Clean or replace the filter as necessary.

q Part No. of filter: 7875-13-3420
q Part No. of O-ring: 07002-11613
q Part No. of O-ring: 07000-11010

Serial No.: 1001 2634

Serial No.: 2635 and up

HB205-1, HB215LC-1 30-67

(04)
 68
Hybrid relation
Operation check of swing emergency stop switch

Operation check of swing Starting switch

emergency stop switch 68
A: OFF position
B: ON position

Check [1] and [2] shown below.

Perform this check together with "Check of swing
holding brake".

[1] Operation check of swing holding brake

1. Start the engine, retract the arm cylinder and
bucket cylinder to the stroke end, and lower the
work equipment to the ground.
q Turn the swing lock switch to the OFF posi-
tion.
q Set the lock lever to the FREE position.
Swing emergency stop switch
a: ON position
b: OFF position
To set the switch in OFF position (b), pull the
switch head or turn it to the right.
a After turning starting switch key to the OFF
position, system starts up again when turning
starting switch key to the ON position next
time.

2. Turn swing emergency stop switch (1) to the ON

position.
Normally, this switch is in the OFF position.
If this switch is in the ON position, the buzzer
sounds and user code [E09] is displayed in the
machine monitor or the hybrid monitor lights up.

30-68 HB205-1, HB215LC-1

(03)
 69
Hybrid relation
Operation check of swing emergency stop switch

3. Measure the oil pressures of the swing holding 2. Display "09103 Swing motor torque".
brake. Confirm that those pressures are as For details, see "Special functions of machine
follows. monitor".
Output oil
Left work
pressure of swing Monitor screen,
equipment
holding brake etc.
control lever
solenoid valve
Hybrid monitor is
Left swing 0 MPa displayed.
Right swing {0 kg/cm2} Alarm buzzer
sounds.

4. Turn swing emergency stop switch and starting

switch to the OFF position.

5. If there is abnormality, check the swing lock sole-

noid valve and other electrical systems for
abnormality.

[2] Check of swing electric motor torque

1. Start the engine, retract the arm cylinder and
bucket cylinder to the stroke end, and lower the
work equipment to the ground.
Turn the swing lock switch to the OFF position.
Set the lock lever to the FREE position.

3. Turn the swing emergency stop switch to the ON

position. If this switch is turned ON, the alarm
buzzer sounds.

4. Tilt the swing lever and confirm that the swing

electric motor torque displayed on the monitor is
0 kgm and the upper structure does not swing.

5. If a value other than 0 kgm is displayed or the

upper structure swings, check the emergency
stop switch contacts for abnormality, the wiring
for disconnection and short circuit, and the
hybrid controller for failure.

HB205-1, HB215LC-1 30-69

(01)
 70
Electrical system
Special functions of machine monitor

Electrical system 70

Special functions of machine monitor 70

For the machine with air conditioner

30-70 HB205-1, HB215LC-1

(01)
 71
Electrical system
Special functions of machine monitor

Upper section of machine monitor (Display sec-

tion)
(a): Multi-display
a When the engine is cranked, the battery voltage
may lower suddenly, depending on the ambient
temperature and the condition of the battery. In
this case, the machine monitor goes off for a mo-
ment. This phenomenon is not a failure, howev-
er.

Upper section of machine monitor (Switch sec-

tion)
[F1]: F1 Function switch
[F2]: F2 Function switch
[F3]: F3 Function switch
[F4]: F4 Function switch
[F5]: F5 Function switch
[F6]: F6 Function switch
a The function of each function switch is indicated
by a graphic in the multi-display (a) above that
function switch.
a If the graphic of a function switch is not dis-
played, that function switch is not working.

Lower section of machine monitor (Switch sec-

tion)
[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed selector
switch
[4]: Numeral 4 input switch/Alarm buzzer cancel
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer
switch
[7]: Numeral 7 input switch/Air conditioner or heater
switch
[8]: Numeral 8 input switch/Air conditioner or heater
switch
[9]: Numeral 9 input switch/Air conditioner or heater
switch
[0]: Numeral 0 input switch/Air conditioner or heater
switch
Switch having no numerals: Air conditioner or heater
switch
a Each switch has the function indicated by a
graphic and the function of inputting a numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of
multi-display (a).

HB205-1, HB215LC-1 30-71

(01)
 72
Electrical system
Special functions of machine monitor

t Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary functions and special functions, and displays information of various
types on the multi-display.
Some items of the information are displayed automatically according to the internal setting of the machine
monitor and the others are displayed according to the operation of the switches.

1. Ordinary functions: Operator mode

The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by oper-
ating the switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
Operator mode (outline) Service mode
30-73 30-88
A Display of KOMATSU logo 30-73 Monitoring 30-89
A Display of inputting password 30-74 Mechanical Systems 30-95
Abnormality
A Display of check of breaker mode 30-74 Electrical Systems 30-96
Record
A Display of check before starting 30-74 Air-conditioning System 30-98
A Display of warning after check before starting 30-75 Maintenance Record 30-99
A Display of ending of maintenance interval 30-75 Maintenance Mode Change 30-100
Display of check of working mode and travel Phone Number Entry 30-102
A 30-75
speed Key-on Mode 30-103
A Display of ordinary screen 30-75 Unit 30-104
A Display of end screen 30-76 With/Without attachment 30-105
B Selection of auto-deceleration 30-76 Default Attachment/Maintenance Password 30-106
O (Special operation)

B Selection of working mode 30-76 Camera 30-107

B Selection of travel speed 30-77 ECO Display 30-108
B Operation to stop alarm buzzer 30-77 Breaker Detect 30-109
B Operation of windshield wiper 30-78 Pump Absorption Torque (F) 30-110
B Operation of window washer 30-78 Pump Absorption Torque (R) 30-111
B Operation of fuel monitor/energy monitor * 30-78 Low Speed 30-112
B Operation of air conditioner/heater 30-79 Adjustment Attachment Flow Adjustment 30-113
Operation to display camera mode Swing Motor Starting Torque 30-114
B 30-80
(if camera is installed) Hoist Swing Adjustment 30-115
B Operation to display clock and service meter 30-80 Pump Calibration 30-116
B Check of maintenance information 30-81 Discharging capacitor (*) 30-123
Setting and display of user mode Cylinder Cut-Out 30-124
B 30-81
(including KOMTRAX messages for user) No Injection 30-125
C Display of energy-saving guidance 30-82 Fuel Consumption 30-127
C Display of caution monitor 30-82 Terminal Status 30-128
C Display of automatic judgement of breaker 30-83 KOMTRAX
GPS & Communication Status 30-129
Settings
C Display of user code and failure code 30-83 MODEM S/N (TH300) 30-130
O (Special operation) Display of service message 30-131
Function of checking display of LCD (Liquid
D 30-85
Crystal Display)
D Function of checking service meter 30-85
Function of changing attachment/
D 30-86
maintenance password

*: Exclusive mode for hybrid model

a Classification of operator mode

A: Display/Function from time when starting switch is set to ON position to time when screen changes to
ordinary screen and display after starting switch is set to OFF position
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch

30-72 HB205-1, HB215LC-1

(01)
 73
Electrical system
Special functions of machine monitor

t Operator mode (outline) Display of KOMATSU logo

a Only outline of the operator mode is described in When the starting switch is set to ON position, the
this section. KOMATSU logo is displayed for 2 seconds.
For details of contents/operation of each func- a After the KOMATSU logo is displayed for 2 sec-
tion/display, see the "Structure and function" or onds, the screen changes to "Display of inputting
Operation and Maintenance Manual. password", "Display of check of breaker mode (if
a The following are the displays or functions of the B mode is set)", or "Display of check before start-
operator mode explained in this section (includ- ing".
ing some items which need special operations).
Display
pattern
A B C D
Display of KOMATSU logo 1 1 1 1
Display of inputting password 2
Display of check before starting 3 2 2 2
Display of warning after check before
3
starting
Display of ending of maintenance time 3
Display of check of working mode and
4 3 4 4
travel speed
Display of ordinary screen 5 4 5 5
Display of end screen
Selection of auto-deceleration a There may be a case where the following screen
Selection of working mode is displayed instead of the above Display of in-
Selection of travel speed putting password screen.
Operation to stop alarm buzzer a If this screen is displayed, call the person re-
Operation of windshield wiper
sponsible to operation of KOMTRAX in your
Operation of windshield washer
Komatsu distributor and ask for remedy.
Operation of air conditioner
Operation to display camera mode (if camera is installed)
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode
(including KOMTRAX messages for user)
Display of energy-saving guidance
Display of caution monitor
Display of user code and failure code
O (Special operation)
Function of checking display of LCD (Liquid Crystal
Display)
Function of checking service meter
Function of changing maintenance password

a Display pattern of operator mode

The contents of display from the time when
starting switch is set to ON position to time when
screen changes to ordinary screen depends on
the setting and condition of the machine.
A: When engine start lock is set effective
B: When engine start lock is set ineffective
C: When there is abnormal item in check-
before-starting items
D: When there is maintenance item which is not
maintained after specified interval

HB205-1, HB215LC-1 30-73

(01)
 74
Electrical system
Special functions of machine monitor

Display of inputting password

After the KOMATSU logo is displayed, the screen
to input the engine start lock password is displayed.
a This screen is displayed only when the engine
start lock function is set effective.
a If the password is input normally, the screen
changes to "Display of check of breaker mode
(if B mode is set)" or "Display of check before
starting".
a The machine monitor has some password
functions other than the engine start lock.
Those functions are independent from one
another.

Display of check before starting

When the screen changes to the
check-before-starting screen, the check before
starting is carried out for 2 seconds.
a If any abnormality is detected by the check
before starting, the screen changes to "Display
of warning after check before starting" or "Dis-
play of ending of maintenance interval".
a If no abnormality is detected by the check
before starting, the screen changes to "Display
of check of working mode and travel speed".
a The monitors (6 pieces) displayed on the screen
are the items under the check before starting.
Display of check of breaker mode
When the starting switch is turned ON, if the work-
ing mode is set to the breaker mode [B], a message
to inform the operator of starting in the breaker
mode is displayed on the screen.
k If an attachment other than the breaker is
used while the working mode is set to the
breaker mode [B], the machine may move
unexpectedly or may not operate normally
or the hydraulic components may be dam-
aged.
a After operation to check of the breaker mode is
finished, the screen changes to "Display of
check before starting".
If No is selected: Working mode is set to econ-
omy mode [E]
If Yes is selected: Working mode is set to
breaker mode [B]

30-74 HB205-1, HB215LC-1

(01)
 75
Display of warning after check before starting
If any abnormality is detected by the check before
starting, the warning monitor is displayed on the
screen.
a The following figure shows that the engine oil
level monitor (a) is warning of low of engine oil
level.
Display of ending of maintenance interval
When the check before starting is carried out, if a
maintenance item is near or after the end of the set
interval, the maintenance monitor is displayed for
30 seconds to urge the operator to maintenance.
a This screen is displayed only when the mainte-
nance function is effective. The color of the
maintenance monitor (yellow or red) indicates
the length of the time after the maintenance
interval.
a Set or change the maintenance function in the
service mode.
a After display of this screen is finished, the
screen changes to "Display of check of work-
ing mode and travel speed".
HB205-1, HB215LC-1
(01)
Electrical system
Special functions of machine monitor
Display of check of working mode and travel
speed
If the check before starting is finished normally, the
screen to check the working mode and travel speed
is displayed for 2 seconds.
a After display of check of the working mode and
travel speed is finished, the screen changes to
"Display of ordinary screen".
Display of ordinary screen
If the machine monitor starts normally, the ordinary
screen is displayed.
a Service meter (a) or a clock is displayed at the
center upper section of the screen (The ser-
vice meter or clock is selected with [F4]).
a ECO gauge (b) is displayed at the right end of
the screen (It is turned ON and OFF in the ser-
vice mode).
30-75
 76
Electrical system
Special functions of machine monitor

Display of end screen Selection of working mode

When the starting switch is turned OFF, the end
screen is displayed for 5 seconds.
a Another message may be displayed on the
end screen, depending on the message dis-
play function of KOMTRAX.
Select a working mode according to the following
procedure.
1. While the ordinary screen is displayed, press
the working mode selector switch, and the
working mode selection screen is displayed.
a The following figure is the working mode
selection screen displayed when "With
attachment" is set (If "With attachment" is
not set in the service mode, the attach-
ment mode [ATT] is not displayed).

Selection of auto-deceleration
While the ordinary screen is displayed, if the
a u t o- de c e l e r a t i on s w i t c h i s pr e s s e d, l a r g e
auto-deceleration monitor (a) is displayed for 2 sec-
onds and the setting of the auto-deceleration is 2. Operate the function switches or working mode
changed. selector switch to select and confirm the work-
a Each time the auto-deceleration switch is ing mode which you will use.
pressed, the auto-deceleration is turned ON Function switches
and OFF alternately. q [F3]: Move to lower working mode
a If the auto-deceleration is turned ON, large q [F4]: Move to upper working mode
monitor (a) and auto-deceleration monitor (b) q [F5]: Cancel selection and return to ordi-
are displayed simultaneously. nary screen
a If the auto-deceleration is turned OFF, q [F6]: Confirm selection and return to ordi-
auto-deceleration monitor (b) goes off. nary screen
Working mode selector switch
q Press: Move to lower working mode
q Hold down:Confirm selection and return to
ordinary screen
a If you do not touch any of the function
switches and working mode selector
switch for 5 seconds, the selection is con-
firmed and the screen changes to the ordi-
nary screen.

30-76 HB205-1, HB215LC-1

(01)
 77
Electrical system
Special functions of machine monitor

3. When the ordinary screen is displayed again, Selection of travel speed

large working mode monitor (a) is displayed for
2 seconds, and then the setting of the working
mode is changed.
a When large monitor (a) is displayed, the
display of working mode monitor (b) is
changed, too.
While the ordinary screen is displayed, if the travel
speed shifting switch is pressed, large travel speed
monitor (a) is displayed for 2 seconds and the set-
ting of the travel speed is changed.
a Each time the travel speed shifting switch is
pressed, the travel speed is changed to Lo, Mi,
Hi, and Lo again in order.
a When large monitor (a) is displayed, the dis-
play of travel speed monitor (b) is changed,
too.

<Precautions for selecting breaker mode [B]>

q If breaker mode [B] is selected, both of the
control of the hydraulic pump and the setting of
the hydraulic circuit are changed.
q If an attachment other than the breaker is
used, the machine may move unexpectedly or Operation to stop alarm buzzer
may not operate normally or the hydraulic While the alarm buzzer is sounding, if the alarm
components may be damaged. buzzer cancel switch is pressed, the alarm buzzer
q After the breaker mode is selected, the screen stops.
to confirm the selection of the breaker mode is a Even if the alarm buzzer cancel switch is
displayed (The buzzer sounds intermittently pressed, the screen does not change.
while this screen is displayed).
q If the setting is confirmed on this screen, the
screen changes to the ordinary screen.
If No is selected:
Screen returns to screen to select working
mode.
If Yes is selected:
Working mode is set to breaker mode [B]

HB205-1, HB215LC-1 30-77

(01)
 78
Electrical system
Special functions of machine monitor

Operation of windshield wiper

While the ordinary screen is displayed, if the wiper
switch is pressed, large wiper monitor (a) is dis- Operation of fuel monitor/energy monitor
played for 2 seconds and the windshield wiper When operating the fuel monitor, press [F2] to dis-
starts or stops. play the fuel monitor screen while the normal screen
a Each time the wiper switch is pressed, the is displayed.
windshield wiper setting is changed to INT,
ON, OFF, and INT again in order.
a When large monitor (a) is displayed, the dis-
play of wiper monitor (b) is changed or turned
OFF, too.
a If the windshield wiper is turned OFF, large
monitor (a) is not displayed.

a When [F1] is pressed on the fuel monitor screen,

the screen changes to the energy monitor
screen.

Operation of window washer

While the ordinary screen is displayed, if the win-
dow washer switch is pressed, the washing liquid is
splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen does not change.

a If [F2] is pressed while the fuel monitor screen is

displayed, the screen changes to show informa-
tion from the last 60 minutes, last 12 hours, last
week, last month and last 60 minutes in order re-
peatedly.
a When [F5] is pressed on the fuel monitor screen,
the screen returns to the normal screen.

30-78 HB205-1, HB215LC-1

(01)
 79
Electrical system
Special functions of machine monitor

Operation of air conditioner/heater

While the ordinary screen is displayed, press the air
conditioner switch or heater switch, and the air con-
ditioner adjustment screen or heater adjustment
screen is displayed.
a While the air conditioner adjustment screen or
heater adjustment screen is displayed, if you
do not touch any switch for 5 seconds, the
screen changes to the ordinary screen.
a Air conditioner specification

a Heater specification

HB205-1, HB215LC-1 30-79

(01)
 80
Electrical system
Special functions of machine monitor

Operation to display camera mode (if camera is
installed)
When a camera is installed, if [F3] is pressed, the
multi-display changes to the camera image (Set the
connection of the camera in the service mode).
Operation to display clock and service meter
While the ordinary screen is displayed, press [F4],
and section (a) changes to the service meter and
clock alternately.
a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the summer
time with the user mode function.

a If the camera mode is selected, however, only

the image of camera 1 is always displayed.

a If a caution is generated in the camera mode, the

caution monitor is displayed at the left upper of
the screen (The low hydraulic oil temperature
caution is not displayed there, however).

a When an error that there is a user code occurs in

the camera mode, if you do not touch any control
lever for 10 seconds, the screen changes to the
ordinary screen and displays the error informa-
tion.

30-80 HB205-1, HB215LC-1

(01)
 81
Electrical system
Special functions of machine monitor

Check of maintenance information Setting and display of user mode

While the maintenance monitor or ordinary screen is (Including KOMTRAX messages for user)
displayed, press [F5], and the maintenance table While the ordinary screen is displayed, press [F6],
screen is displayed. and the user menu screen is displayed.

a To reset the time left after finishing maintenance a There are following items in the user menu.
(oil/filter replacement) more operations are nec- Breaker/Attachment Settings
essary. User Message
Screen Adjustment
Clock Adjustment
Language
Economy Mode Adjustment
Reset Average Fuel Consumption Logs
Auto Decel Setting

a The breaker/attachment setting menu is dis-

played only when "With attachment" is set in
the service mode.

HB205-1, HB215LC-1 30-81

(01)
 82
Electrical system
Special functions of machine monitor
[KOMTRAX message]
q There are 2 types of KOMTRAX message; 1 is
for the user and the other is for the service.
q For user:
A message transmitted from the KOMTRAX
base station for the user. If it is received, the
message monitor is displayed on the ordinary
screen. To see the contents of the message,
operate "User Message" in the above user
menu.
q For service:
A message transmitted from the KOMTRAX
base station for the service. Even if it is
received, nothing is displayed on the ordinary
screen. To see the contents of the message,
operate "KOMTRAX message" display in the
service menu.
30-82
Display of energy-saving guidance
When the machine is set in a certain operating con-
dition, the energy-saving guidance screen is dis-
played automatically to urge the operator to the
energy-saving operation.
a The energy-saving guidance is displayed when
the following condition is satisfied while the
display setting is set effective in the service
mode.
a Condition for display:
Engine is running + All levers have been in
neutral for 5 minutes + Caution (Note) or user
code is not generated (Note)
Note: Excluding hydraulic oil low temperature
caution
a If any lever or pedal is operated, or [F5] is
pressed, the screen returns to the ordinary
screen.
Display of caution monitor
If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a
moment and then displayed at (a) in the screen.
a On the camera mode screen, the caution mon-
itor flashes at the left upper of the screen when
the caution is generated.
HB205-1, HB215LC-1
(01)
 83
Display of automatic judgment of breaker
If the operator performs breaker work in an
improper working mode, the breaker automatic
judgment screen is displayed to urge the operator
to select a proper working mode.
a The breaker automatic judgment is displayed
when the following condition is satisfied while
the display setting is set effective in the service
mode.
a Condition for display:
When the pump controller measures the rear
pump pressure for a certain time, the obtained
value is similar to the pulsation wave form of
breaker operation which is held in the control-
ler in advance.
a The breaker automatic judgment function is set
to Not used (Not displayed) when delivered.
a If this screen is displayed, check the setting of
the working mode. If the breaker is being
used, select the breaker mode [B].
a To return to the ordinary screen, press [F5].
HB205-1, HB215LC-1
(01)
Electrical system
Special functions of machine monitor
Display of user code and failure code
If an abnormality which displays a user code and a
failure code occurs on the ordinary screen or cam-
era mode screen, all the information of the abnor-
mality is displayed.
(a): User code (3 digits)
(b): Failure code (5 or 6 digits)
(c): Telephone mark
(d): Telephone No.
a This screen is displayed only when an abnor-
mality (failure code) for which a user code is
set occurs.
a The telephone mark and telephone No. are
displayed only when the telephone No. is reg-
istered in the service mode.
a If multiple abnormalities occur simultaneously,
all the codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the abnormality record in
the service mode, check the details in the ser-
vice mode.
a When the caution monitor is also displayed,
the telephone mark is not displayed.
30-83
 84
Electrical system
Special functions of machine monitor

a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
When emergency pump drive switch is at the upper (emergency)
E02 Pump control system error position, normal operations become possible, but have inspection
carried out immediately.
E03 Swing brake system error Have inspection carried out immediately.
Operate machine to a safe posture and have inspection carried out
E09* Hybrid system error
immediately.
Engine controller power source
error
E10 Engine controller drive system Have inspection carried out immediately.
circuit error
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried out
E11
Output reduced to protect engine immediately.
Abnormality in throttle system Operate machine to a safe posture and have inspection carried out
E14
(fuel dial abnormality) immediately.
Engine sensor
E15 (coolant temperature, fuel pres- Operations are possible, but have inspection carried out immediately.
sure, oil pressure) system error
Operate machine to a safe posture and have inspection carried out
E0E Network error
immediately.
Operate machine to a safe posture and have inspection carried out
E20 Abnormality in travel system
immediately.

*: User code E09 is a exclusive mode for hybrid model.

30-84 HB205-1, HB215LC-1

(01)
 85
Function of checking display of LCD (Liquid
Crystal Display)
While the ordinary screen is displayed, if the follow-
ing numeral input switch and function switch are
operated as follows, all the LCD (Liquid Crystal Dis-
play) lights up in white.
q Operation of switches (simultaneous): [4] + [F2]
a When finishing the operation of the switches,
release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
a The LCD panel sometimes has black points
(points which are not lighted) and bright points
(points which do not go off) for the reason of its
characteristics. If the number of the bright
points and black points does not exceed 10,
those points are not a failure or a defect.
a To return to the former screen, press the func-
tion switch.
HB205-1, HB215LC-1
(01)
Electrical system
Special functions of machine monitor
Function of checking service meter
To check the service meter while the starting switch
is turned OFF, operate the numeral input switches
as follows. At this time, only the service meter sec-
tion displays.
q Operation of switches (simultaneous): [4] + [1]
a Since there is some time lag in start of the
LCD, hold down the switches until the LCD dis-
plays normally.
a After the machine monitor is used continu-
ously, blue points (points which do not go off)
may be seen on this screen. This phenomenon
does not indicate a failure or a defect.
30-85
 86
Electrical system
Special functions of machine monitor

Function of changing attachment/maintenance
password
When changing the attachment/maintenance pass-
word used for the attachment setting function and
maintenance setting function, follow these proce-
dures.
1. While the ordinary screen is displayed, perform
the following operation with the numeral input
switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
3. After the New password input screen is dis-
played, input a new password with the numeral
input switches and confirm it with the function
switch.
a Set a new password of 4 6 digits (If it
has only 3 or less digits or has 7 or more
digits, it is not accepted).
q [F5]: Reset input numeral/Return to ordi-
nary screen
q [F6]: Confirm input numeral

4. After the New password input screen is dis-

played again, input a new password again with
the numeral input switches and confirm it with
the function switch.
q [F5]: Reset input numeral/Return to ordi-
2. After the Attachment/Maintenance PASS- nary screen
WORD screen is displayed, input the current q [F6]: Confirm input numeral
password with the numeral input switches and a If a password different from the password
confirm it with the function switch. input before is input, the message to input
q [F5]: Reset input numeral/Return to ordi- again is displayed.
nary screen
q [F6]: Confirm input numeral
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.

30-86 HB205-1, HB215LC-1

(01)
 87
Electrical system
Special functions of machine monitor

5. If the screen to notify completion of setting is

displayed and then the ordinary screen is dis-
played, the password is changed successfully.

HB205-1, HB215LC-1 30-87

(01)
 88
Electrical system
Special functions of machine monitor

t Service mode a The items which can be selected in the

To change the operator mode to the service mode, service menu are as follows (including
perform the following operation. some items which need special opera-
This operation is always required when you use the tions).
service mode.
01 Monitoring
1. Check of display of screen and operation of Mechanical Systems
switches 02 Abnormality Electrical Systems
While the ordinary screen is displayed, perform Record Air-conditioning System/Heater
the following operation with the numeral input System
switches. 03 Maintenance Record
q Operation of switches (While pressing [4], 04 Maintenance Mode Change
perform the operation in order): 05 Phone Number Entry
[4] + [1] o [2] o [3]
Key-on Mode
a This operation of the switches is accepted
only while the ordinary screen is displayed. Unit
With/Without Attachment
Attachment/Maintenance
06 Default
Password
Camera
ECO Display
Breaker Detect
Pump Absorption Torque (F)
Pump Absorption Torque (R)
Low Speed
07 Adjustment Attachment Flow Adjustment
Swing Motor Starting Torque
Hoist Swing Adjustment
Pump Calibration
2. Selection of service menu 08 Discharge Capacitor
When the Service menu screen is displayed, 09 Cylinder Cut-Out
the service mode is selected. Select a service
10 No Injection
menu you use with the function switches or
numeral input switches. 11 Fuel Consumption
q [F3]: Move to lower menu Terminal Status
12 KOMTRAX
q [F4]: Move to upper menu GPS & Communication Status
Settings
q [F5]: Return to ordinary screen (operator MODEM S/N (TH300)
mode) 13 Display of service message
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the menu
of that code and confirm it with [F6].

30-88 HB205-1, HB215LC-1

(01)
 89
Electrical system
Special functions of machine monitor

Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling actuators, etc.

1. Selecting menu
Select "Monitoring" on the service menu screen.

3. Deciding monitoring items

After selecting monitoring items, perform moni-
toring by using the function switch or numeral
input switch.
a Performing by using function switch: Dou-
ble-click or hold down [F6] (about 2 sec-
onds).
a Performing by using numeral input switch: In-
put [99999] and press [F6].
2. Selecting monitoring items a When monitoring only two items, for exam-
After the "Monitoring selection menu screen" is ple, select them and enter by [F6]. If [F6] is
displayed, select items to be monitored with the pressed once more at this time, monitoring is
function switches or numeral input switches. performed.
q [F1]: Move to next page (screen) a If monitoring items are selected up to the limit
q [F2]: Move to previous page (screen) number, monitoring is performed automati-
q [F3]: Move to lower item cally.
q [F4]: Move to upper item
q [F5]: Delete input numeral/Return to service
menu screen
q [F6]: Enter selection
a Selection by using function switches: Select
an item by using [F3] or [F4] and enter it by
using [F6].
a Selection by using numeral input switches:
Enter a 5-digit code, and the item of that code
is selected directly. Enter that item by using
[F6].
a If the color of the selected box changes from
yellow to red, selection of the item of that box
is accepted.
a Up to six monitoring items can be selected at
a time. You may not able to set up to six
items, however, depending on the display
form of those items.

HB205-1, HB215LC-1 30-89

(01)
 90
Electrical system
Special functions of machine monitor
4. Performing monitoring
After the "Performing monitoring" screen is
displayed, perform the necessary operation of
the machine and check the monitoring informa-
tion.
a Monitoring information is indicated by value,
ON/OFF, or special display.
a The unit of display can be set to SI unit, met-
ric unit, or inch unit by the Initialization func-
tion in the service mode.
5. Holding monitoring information
The monitoring information can be held and
reset by the function switches.
q [F3]: Cancel holding
q [F4]: Hold information (displayed data is
fixed)
q [F5]: Return to monitoring item selection
menu screen
30-90
6. Changing machine mode setting
To change the setting of the working mode,
travel speed, or auto-deceleration during moni-
toring, operate the corresponding switch under
the current condition, and the mode setting
screen is displayed.
While this screen is displayed, if the corre-
sponding switch is operated further, the corre-
sponding mode is changed.
a After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after monitor-
ing is finished.
HB205-1, HB215LC-1
(01)
 91
Electrical system
Special functions of machine monitor

Monitoring items table

Unit (Initial setting: ISO) Compo-
Code
Monitoring item (Display on screen) nent in Remarks
No. ISO meter inch charge
01002 Engine speed r/min rpm rpm ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F Pump Pressure MPa kg/cm2 psi PUMP
01101 R Pump Pressure MPa kg/cm2 psi PUMP
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
07300 Bucket Curl PPC Pressure MPa kg/cm2 psi PUMP
07301 Bucket Dump PPC Pressure MPa kg/cm2 psi PUMP
09001 Swing left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing right PPC Pressure MPa kg/cm2 psi PUMP
04107 Coolant Temperature C C F ENG
04401 Hydr. Oil Temperature C C F PUMP
01300 PC-EPC Sol. Curr. (F) mA mA mA PUMP
01302 PC-EPC Sol. Curr. (R) mA mA mA PUMP
01500 LS-EPC Sol. Curr. mA mA mA PUMP
08000 Merge-divider Sol. Curr. (Main) mA mA mA PUMP
08001 Merge-divider Sol. Curr. (LS) mA mA mA PUMP
01700 Service Sol. Curr. mA mA mA PUMP
03200 Battery Voltage V V V PUMP
03203 Battery Power Supply V V V ENG
04300 Battery Charge Vol. V V V MON
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18500 Charge Temperature C C F ENG
Absolute value indica-
36500 Boost Pressure kPa kg/cm2 psi ENG tion (including atmo-
spheric pressure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Fuel Dial Pos Sens Volt V V V ENG
04200 Fuel Level Sensor Vol. V V V MON
04105 Eng. Water Temp. Vol. Lo V V V ENG
04402 Hydr. Temp. Sonser Vol. V V V PUMP
37401 Ambient Press Sens Volt V V V ENG
18501 Charge Temp Sens Volt V V V ENG
36501 Charge Press Sens Volt V V V ENG
36401 Rail Pressure Sens Volt V V V ENG
17500 Engine Power Mode ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Press Command MPa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
37300 Fuel Rate l/h l/h gal/h ENG
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
01337 PC-EPC Cal Torque 1 (Factory) Nm kgm lbft PUMP
01338 PC-EPC Cal Torque 2 (Factory) Nm kgm lbft PUMP
01339 PC-EPC Cal Torque 3 (Factory) Nm kgm lbft PUMP
01341 PC-EPC Cal Current 1 (Factory) mA mA mA PUMP
01342 PC-EPC Cal Current 2 (Factory) mA mA mA PUMP
01343 PC-EPC Cal Current 3 (Factory) mA mA mA PUMP
01345 PC-EPC Cal Torque 1 Nm kgm lbft PUMP
01346 PC-EPC Cal Torque 2 Nm kgm lbft PUMP
01347 PC-EPC Cal Torque 3 Nm kgm lbft PUMP
01349 PC-EPC Cal Current 1 mA mA mA PUMP
01350 PC-EPC Cal Current 2 mA mA mA PUMP
01351 PC-EPC Cal Current 3 mA mA mA PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP

HB205-1, HB215LC-1 30-91

(03)
 92
Electrical system
Special functions of machine monitor

Monitoring items table

Unit (Initial setting: ISO) Compo-
Code
Monitoring item (Display on screen) nent in Remarks
No. ISO meter inch charge
Swing ON OFF PUMP
Travel ON OFF PUMP
Boom Lower ON OFF PUMP
01900 Pressure Switch 1
Boom Raise ON OFF PUMP
Arm Curl ON OFF PUMP
Arm Dump ON OFF PUMP
Bucket Curl ON OFF PUMP
Bucket Dump ON OFF PUMP
01901 Pressure Switch 2
Service ON OFF PUMP
Travel Steering ON OFF PUMP
Travel Junction ON OFF PUMP
Swing Brake ON OFF PUMP
02300 Solenoid Valve 1 Merge-divider ON OFF PUMP
2-Stage Relief ON OFF PUMP
Travel Speed ON OFF PUMP
02301 Solenoid Valve 2 Service Return ON OFF PUMP
Lever Sw ON OFF PUMP
02200 Switch Input 1 Swing Release Sw. ON OFF PUMP
Swing Brake Sw. ON OFF PUMP
Model Select 1 ON OFF PUMP
Model Select 2 ON OFF PUMP
Model Select 3 ON OFF PUMP
02201 Switch Input 2
Model Select 4 ON OFF PUMP
Model Select 5 ON OFF PUMP
Overload Alarm ON OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON OFF PUMP
Window Limit SW. ON OFF PUMP
02204 Switch Input 5 P Limit SW. ON OFF PUMP
W Limit SW. ON OFF PUMP
Key Switch ON OFF MON
Start ON OFF MON
04500 Monitor Input 1 Preheat ON OFF MON
Light ON OFF MON
Rad. Level ON OFF MON
Air cleaner ON OFF MON
04501 Monitor Input 2 Eng. Oil Level ON OFF MON
Battery Charge ON OFF MON
04502 Monitor Input 3 Swing Brake Sw. ON OFF MON
F1 ON OFF MON
F2 ON OFF MON
Monitor Function F3 ON OFF MON
04503
Switches F4 ON OFF MON
F5 ON OFF MON
F6 ON OFF MON
SW1 ON OFF MON
SW2 ON OFF MON
Monitor 1st & 2nd SW3 ON OFF MON
04504
Row Switches SW4 ON OFF MON
SW5 ON OFF MON
SW6 ON OFF MON
SW7 ON OFF MON
SW8 ON OFF MON
Monitor 3rd & 4th SW9 ON OFF MON
04505
Row Switches SW10 ON OFF MON
SW11 ON OFF MON
SW12 ON OFF MON
SW13 ON OFF MON
Monitor 5th Row
04506 SW14 ON OFF MON
Switches
SW15 ON OFF MON
18800 Water In Fuel ON OFF ENG WIF: Water In Fuel
20216 ECM Build Version ENG

30-92 HB205-1, HB215LC-1

(03)
 93
Electrical system
Special functions of machine monitor

Monitoring items table

Unit (Initial setting: ISO) Compo-
Code
Monitoring item (Display on screen) nent in Remarks
No. ISO meter inch charge
20217 ECM CAL Data Ver ENG
18900 ECM Internal Temp C C F ENG
20400 ECM Serial No ENG
20227 Monitor Ass'y P/N MON
20402 Monitor Serial No MON
20228 Monitor Prog. P/N MON
20229 Pump Con. Ass'y P/N PUMP
20403 Pump Con. Serial No PUMP
20230 Pump Con. Prog. P/N PUMP

Unit (Initial setting: ISO) Compo-

Code
Monitoring item (Display on screen) nent in Remarks
No. ISO meter inch charge
12301 EG0V Down Point r/min rpm rpm HYB
09008 Swing-Right PPC Pressure #2 MPa kg/cm2 psi HYB
09009 Swing-Left PPC Pressure #2 MPa kg/cm2 psi HYB
09006 Swing-Left PPC Sensor2 Volt. mV mV mV HYB
09007 Swing-Right PPC Sensor2 Volt. mV mV mV HYB
07602 Arm-Dump PPC Pres. Sen2 Voltage mV mV mV HYB
07202 Arm-Dig PPC Pres. Sen2 Voltage mV mV mV HYB
09100 Swing Motor DC Current A A A HYB
09200 DC Current, High-Voltage Side V V V HYB
09300 Capacitor Voltage V V V HYB
09400 Booster Volt., Low-Volt. Side V V V HYB
09304 Capacitor Base Temperature C C F HYB
09305 Capacitor Bus Bar Temperature C C F HYB
09306 Capacitor Cell Temperature C C F HYB
09403 Booster IGBT Base Temperature C C F HYB
09404 Booster IGBT Junc.Temperature C C F HYB
09402 Booster Inductor Temperature C C F HYB
09101 Swing Motor Coil Temperature C C F HYB
09504 Swing Motor U IGBT Base Temp. C C F HYB
09505 Swing Motor V IGBT Base Temp. C C F HYB
09506 Swing Motor W IGBT Base Temp. C C F HYB
09600 Generator Motor Temperature C C F HYB
09607 Gen. Motor IGBT Base Temp. #0 C C F HYB
09608 Gen. Motor IGBT Base Temp. #1 C C F HYB
09507 Swing Motor IGBT Junc. Temp. C C F HYB
09703 HYB Controller Caution HYB
09700 HYB Controller Relay Output HYB
09602 Generator Motor Rev. Speed r/min rpm rpm HYB
09603 Generator Motor Torque Nm kgm lbft HYB
09604 Gen. Motor Axial Output kW kW kW HYB
09605 Gen. Motor Target Rev. Speed r/min rpm rpm HYB
09606 Gen. Motor Target Torque Nm kgm lbft HYB
09303 Capacitor Target Voltage V V V HYB
09307 Capacitor Current A A A HYB
42103 Swing Lever Stroke % % % HYB
42104 Boom Lever Stroke % % % HYB
42105 Arm Lever Stroke % % % HYB
42106 Bucket Lever Stroke % % % HYB
09701 HYB Controller Control Output HYB
09702 HYB Controller SW Input HYB
09102 Swing Motor Rev. Speed r/min rpm rpm HYB
09103 Swing Motor Torque Nm kgm lbft HYB
09104 Swing Motor Axial Output kW kW kW HYB

HB205-1, HB215LC-1 30-93

(01)
 94
Electrical system
Special functions of machine monitor

Unit (Initial setting: ISO) Compo-

Code
Monitoring item (Display on screen) nent in Remarks
No. ISO meter inch charge
09105 Swing Motor Target Rev. Speed r/min rpm rpm HYB
09106 Swing Motor Torque Limit Value Nm kgm lbft HYB
09900 Bad Insulating Sensor Voltage mV mV mV HYB
20255 Ass'y Part No. (HYB Controller) HYB
20417 Serial No. (HYB Controller) HYB
20256 Prog. Part No. (HYB Control.) HYB
20257 Prog. Version (HYB Control.) HYB
20269 Prog. Part No. (HYB Swg. Mot.) HYB
20270 Prog. Version (HYB Swg. Mot.) HYB
20271 Prog. Part No. (HYB Gen. Mot.) HYB
20272 Prog. Version (HYB Gen. Mot.) HYB

a Entry order of items in table

The items are entered in the order of display on the monitoring item selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with Unit selecting in Initialization of the
service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.
HYB: The hybrid controller (inverter) is in charge of detection of monitoring information.

30-94 HB205-1, HB215LC-1

(01)
 95
Abnormality Record (Mechanical Systems)
The machine monitor classifies and records the ab-
normalities which occurred in the past or which are
occurring at present into the mechanical systems,
electrical systems, and air-conditioning system or
heater system.
To check the mechanical system abnormality
record, perform the following procedures.
a For the "Failure code table", see Troubleshoot-
ing.
1. Selecting menu
Select "Abnormality Record" on the "Service
Menu" screen.
2. Selecting sub menu
After the "Abnormality Record" screen is
displayed, select "Mechanical Systems" by the
function switches or numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Enter selection
a You may input a 2-digit code by the numeral
input switches to select the record of that
code and enter it by [F6].
a The following figure shows the display of the
machine with air conditioner.
In case of the machine with the heater and
heaterless machine are different from each
other in the display of "03 Air-conditioning
System", which may not be displayed on the
heaterless machine.
HB205-1, HB215LC-1
(01)
Electrical system
Special functions of machine monitor
3. Information displayed on "abnormality
record" screen
On the "Mechanical Systems" screen, the
following information is displayed.
(a): Occurrence order of abnormalities from
latest one/Total number of records
(b): Failure code
(c): Contents of failure
(d): Number of occurrence time (Displayable
range: 0 65,535 times)
(e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F5]: Return to abnormality record screen
a If no abnormality is recorded, "No abnormal-
ity record" is displayed.
a If the number of occurrence time is one (first
occurrence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring, or restora-
tion has not been confirmed.
a For all the failure codes that the machine
monitor can record, see the "Failure codes
table".
4. Deleting abnormality record
The contents of the mechanical system abnor-
mality record cannot be deleted.
30-95
 96
Electrical system
Special functions of machine monitor
Abnormality Record (Electrical Systems)
The machine monitor classifies and records the ab-
normalities which occurred in the past or which are
occurring at present into the mechanical systems,
electrical systems, and air-conditioning system or
heater system.
To check the electrical system abnormality record,
perform the following procedures.
a For the "Failure code table", see Troubleshoot-
ing section.
1. Selecting menu
Select "Abnormality Record" on the "Service
Menu" Screen.
2. Selecting sub menu
After the "Abnormality Record" screen is
displayed, select "Electrical Systems" by the
function switches or numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Enter selection
a You may input a 2-digit code by the numeral
input switches to select the record of that
code and enter it by [F6].
a The following figure shows the display of the
machine with air conditioner. In the case of
the machine with the heater and heaterless
machine are different from each other in the
display of "03 Air-conditioning System",
which may not be displayed on the heater-
less machine.
30-96
3. Information displayed on "abnormality
record" screen
On the "Electrical Systems" screen, the following
information is displayed.
(a): Occurrence order of abnormalities from
latest one/Total number of records
(b): Failure code
(c): Contents of failure
(d): Number of occurrence time (Displayable
range: 0 65,535 times)
(e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to "abnormality record" screen
a If no abnormality is recorded, "No abnormal-
ity record" is displayed.
a If the number of occurrence time is one (first
occurrence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring, or restora-
tion has not been confirmed.
a For all the failure codes that the machine
monitor can record, see the "Failure codes
table".
HB205-1, HB215LC-1
(01)
 97
Electrical system
Special functions of machine monitor

4. Deleting abnormality record
1) While the "Electrical Systems" screen is
displayed, perform the following operation by
the numeral input switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4] + [1] o [2] o [3]
3) After the "Electrical Sys. Error Reset" screen
is displayed, operate the function switches.
q [F5]: Return to "Electrical systems"
screen (Reset mode)
q [F6]: Perform deletion
a The following figure shows the screen
displayed when the items are deleted one
by one (which is a little different from the
screen displayed when all the items are
deleted together).

2) Check that the screen is set in the deletion

mode, and then delete the items one by one
or all items together by the function switches.
a If the screen is switched to the deletion 4) If the screen to notify completion of deletion
mode, [CLEAR] graphic is indicated at is displayed and then the "Electrical
[F2]. Systems" (reset mode) screen is displayed,
q [F2]: Delete all items the deletion of the abnormality record is
q [F3]: Move to lower item completed.
q [F4]: Move to upper item a After a while, the screen returns to the
q [F5]: Return to abnormality record screen "Electrical Systems" screen.
q [F6]: Delete selected item
a To delete items one by one: Select the
item to be deleted by [F3] or [F4] and
press [F6].
a To delete all items together: Press [F2],
and all the items are deleted, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the deleting operation is accepted
but the information is not deleted.

HB205-1, HB215LC-1 30-97

(01)
 98
Electrical system
Special functions of machine monitor
Abnormality Record (Air-conditioning System)
The machine monitor classifies and records the ab-
normalities which occurred in the past or which are
occurring at present into the mechanical systems,
electrical systems, and air-conditioning abnormali-
ties or heater abnormalities.
To check the air-conditioning abnormality record or
heater abnormality record, perform the following
procedures.
a For the "Failure code table", see Troubleshoot-
ing section.
a All the following figures apply to the machine
with the air conditioner.
1. Selecting menu
Select "Abnormality Record" on the "Service
Menu" screen.
2. Selecting sub menu
After the "Abnormality Record" screen is
displayed, select "Air-conditioning System" by
using the function switches or numeral input
switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a You may input a 2-digit code by using the nu-
meral input switches to select the record of
that code and enter it by [F6].
30-98
3. Information displayed on "abnormality
record" screen
On the "Air-conditioning System", the following
information is displayed.
(a): System/Component name
(b): Number of occurrence time
(c): Condition (Normal or abnormal)
q [F2]: Delete abnormality record
q [F5]: Return to abnormality record screen
a If [E] is displayed on the left of a condition, the
abnormality is still occurring, or restoration
has not been confirmed.
a If CAN open circuit is displayed in Communi-
cation condition, communication cannot be
carried out. Accordingly, the conditions of
other items are not displayed.
4. Deleting abnormality record
While the "abnormality record" screen is
displayed, press [F2], and the number of occur-
rence time of abnormality is deleted. If it is
confirmed at this time that the problem has been
resolved, the display changes to Normal.
HB205-1, HB215LC-1
(01)
 99
Electrical system
Special functions of machine monitor

Maintenance Record a The following items can be selected from the

The machine monitor records the maintenance (re- maintenance record.
placement) information of the filters, oils, etc., which 01 Engine oil change
can be displayed for checking by the following oper- 02 Engine oil filter change
ations. When maintenance is carried out, if the timer 03 Fuel main filter change
is reset in the operator mode, the number of the 41 Fuel pre-filter change
times of oil/filter replacement is recorded in this sec- 04 Hydraulic oil filter change
tion. 05 Hydraulic tank breather change
06 Corrosion resistor change
1. Selecting menu 08 Final drive case oil change int.
Select "Maintenance Record" on the "Service 09 Machinery case oil change
Menu" screen. 10 Hydraulic oil change
45 Gen. oil change, filter cleaning
46 Swing motor oil change

3. Information items displayed on maintenance

record screen
The following items are displayed.
(a): Maintenance items
(b): Number of times of replacement up to now
(c): Service meter reading (SMR) at previous
replacement

2. Selecting maintenance record item

After the "Maintenance Record" screen is
displayed, select an item to be checked by the
function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
a You may enter a 2-digit code by the numeral
input switches to select the item of that code.

HB205-1, HB215LC-1 30-99

(01)
 100
Electrical system
Special functions of machine monitor
Maintenance Mode Change
The operating condition for maintenance function in
the operation mode can be set and changed by this
menu.
q Set function effective or ineffective
q Change replacement interval (by items)
q Initialize all replacement intervals
1. Selecting menu
Select "Maintenance Mode Change" on the
"Service Menu" screen.
3. Setting of Maintenance mode on/off
2. Selecting sub menu
After the "Maintenance Mode Change" screen is
displayed, select an item to change the setting
by the function switches or numeral input
switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a You may input a 2-digit code by the numeral
input switches to select the item of that code
and enter it by [F6].
30-100
a The following items can be selected on the
Change of maintenance mode screen.
00 Maintenance mode on/off
01 Engine oil change int.
02 Engine oil filter change int.
03 Fuel main filter change int.
41 Fuel pre filter change int.
04 Hyd oil filter change int.
05 Hyd tank breather change int.
06 Corrosion resistor change int.
08 Final drive case oil change int.
09 Machinery case oil change int.
10 Hydraulic oil change int.
45 Gen. oil change, filter cleaning
46 Swing motor oil change
99 Initialize all items
After selecting "Maintenance Mode On/Off", if
the screen is displayed, set the mode to ON or
OFF by the function switches.
q ON: Functions of all maintenance items are
set effective in operator mode
q OFF: Functions of all maintenance items are
set ineffective in operator mode
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Mainte-
nance mode change screen
q [F6]: Enter selection and return to Mainte-
nance mode change screen
a Even if ON/OFF of each item has been set, if
the above setting is changed, it overrides the
individual setting.
HB205-1, HB215LC-1
(01)
 101
Electrical system
Special functions of machine monitor

4. Contents of setting of each maintenance

item
After selecting each maintenance item, if the
screen is displayed, perform the setting for the
item by the function switches.

5. Function of initializing all items

After selecting "99 Use Default Value", if the
screen is displayed, perform setting by the func-
tion switches.
q Initial value: Maintenance interval being set
in machine monitor (Recommended by man-
ufacturer and not changeable).
q Set value: Maintenance interval which can be
set freely. Maintenance reminder functions in
operator mode operate on basis of this set
time (which is increased or decreased by 50
hours).
q ON: Maintenance reminder function of this
item is set effective in operator mode.
q OFF: Maintenance reminder function of this
item is set ineffective in operator mode.
q [F3]: Reduce set value (Upper) or select
OFF (Lower).
q If this operation is performed, the set values
q [F4]: Increase set value (Upper) or select
of all the maintenance items are initialized.
ON (Lower).
q [F5]: Return to Maintenance mode change
q [F5]: Cancel setting before entering setting
screen
and return to "Maintenance mode
q [F6]: Perform initialization
change" screen.
a A while after [F6] is pressed, the initialization
q [F6]: Enter setting of upper or lower line.
completion screen is displayed. Then, if the
a After the setting of the upper and lower lines
"Maintenance Mode Change" screen is dis-
is entered by [F6] and the screen changes to
played, initialization is completed.
the Maintenance mode change screen by
[F5], the setting is effective.
a If the set value of an item that is set to "ON"
is changed after 1 or more operating hours
since the start of setting, the change is recog-
nized as a resetting operation.

HB205-1, HB215LC-1 30-101

(01)
 102
Electrical system
Special functions of machine monitor

Phone Number Entry a If [F6] is pressed without inputting any digit,

The telephone number, which is displayed together there is no information of telephone number.
with the user code/failure code in the operator Accordingly, no telephone number is dis-
mode, can be input and changed according to the played in the operator mode.
following procedure.
If a telephone number is not input with this function,
no telephone number is displayed in the operator
mode.

1. Selecting menu
Select "Phone Number Entry" on the "Service
Menu" screen.

2. Registering and changing telephone number

After the "Phone Number Entry" screen is
displayed, register or change the telephone
number.
q [F2]: Delete registered phone number
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Delete input digit/Return to service
menu
q [F6]: Enter input

a Up to 14 digits can be input from the left. In-

put nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (orange background) and overwrite
it with the correct digit.

30-102 HB205-1, HB215LC-1

(01)
 103
Default (Key-on Mode)
Check or change various settings related to the ma-
chine monitor and machine by using "Default".
The function of working mode with key ON is used
to set the working mode displayed on the machine
monitor when the starting switch is set to ON posi-
tion.
1. Selecting menu
Select "Default" on the "Service Menu" screen.
2. Selecting sub menu
After the "Default" screen is displayed, select
"Key-on Mode" by the function switches or
numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.
HB205-1, HB215LC-1
(01)
Electrical system
Special functions of machine monitor
3. Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set by the function
switches.
q Power Mode: [P] is displayed when the start-
ing switch is set to ON position
q Economy Mode: [E] is displayed when the
starting switch is set to ON position
q Mode at Previous Key-off: Final mode in pre-
vious operation is displayed when the start-
ing switch is set to ON position
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to "Default"
screen
q [F6]: Enter selection and return to "Default"
screen
a When the machine is shipped from the facto-
ry, "Mode at previous key-OFF is set".
30-103
 104
Electrical system
Special functions of machine monitor

Default (Unit) 3. Selecting unit

Check or change various settings related to the ma-
chine monitor and machine by using "Default".
The unit selection function is used to select the unit
of the data displayed for monitoring, etc.
1. Selecting menu
Select "Default" on the "Service Menu" screen.
After the "Unit" screen is displayed, select the
unit to be set by the function switches.
q [F3]: Move to lower unit
q [F4]: Move to upper unit
q [F5]: Cancel selection and return to "Default"
screen
q [F6]: Enter selection and return to "Default"
screen
a When the machine is shipped from the facto-
ry, the SI unit system is set.

2. Selecting sub menu

After the "Default" screen is displayed, select
"Unit" by the function switches or numeral input
switches.
a Select this item similarly to an item on the
"Service Menu" screen.

30-104 HB205-1, HB215LC-1

(01)
 105
Electrical system
Special functions of machine monitor

Default (With/Without Attachment) 3. Selecting With/Without

Check or change various settings related to the After the "With/Without Attachment" screen is
machine monitor and machine by "Default". displayed, select the setting with the function
The "With/Without attachment" function is used to switches.
set an installed or a removed attachment. q Without Attachment:
When attachment is not installed
1. Selecting menu q With Attachment:
Select "Default" on the "Service Menu" screen. When attachment is installed
q [F3] : Move to lower item
q [F4] : Move to upper item
q [F5] : Cancel selection and return to
Default screen
q [F6] : Confirm selection and return to
Default screen
a When an attachment is installed, if this
setting is not carried out normally, the
attachment cannot be set in the operator
mode. As a result, the attachment may not
work normally or the hydraulic compo-
nents may have trouble.

2. Selecting sub menu

After the "Default" screen is displayed, select
"With/Without Attachment" with the function
switches or numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

HB205-1, HB215LC-1 30-105

(01)
 106
Electrical system
Special functions of machine monitor
Default (Attachment/Maintenance Password)
Check or change various settings related to the
machine monitor and machine by "Default".
The function of setting attachment/maintenance
password is used to set the display of the password
screen when the functions related to the attach-
ment and maintenance are used in the operator
mode.
1. Selecting menu
Select "Default" on the "Service Menu" screen.
2. Selecting sub menu
After the "Default" screen is displayed, select
"Attachment/Maintenance Password" with the
function switches or numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.
30-106
3. Selecting Disable/Enable
After the Attachment/Maintenance Password
screen is displayed, select the setting with the
function switches.
q Disable : Password screen is not dis-
played
q Enable : Password screen is displayed
q [F3] : Move to lower item
q [F4] : Move to upper item
q [F5] : Cancel selection and return to
"Default" screen
q [F6] : Confirm selection and return to
"Default" screen
4. Displaying attachment/maintenance pass-
word screen
When the following operation is performed, the
password screen is displayed in the operator
mode.
q Maintenance mode: The Maintenance
table screen is changed to the Mainte-
nance interval reset screen.
q User mode: On the User menu screen, the
Breaker/Attachment setting menu is
selected and the screen is changed to the
Attachment setting menu screen.
5. Changing attachment/maintenance pass-
word
The password can be changed by operating
the switches specially in the operator mode.
a See Attachment/Maintenance password
changing function in the operator mode.
a Default password: [000000]
a If the password setting is changed from
Enable to Disable, the password is reset
to the default. When Enable is set again,
be sure to set a new password.
a The attachment/maintenance password is
different from the engine start lock pass-
word.
HB205-1, HB215LC-1
(01)
 107
Electrical system
Special functions of machine monitor

Default (Camera) 3. Selecting camera setting

Check or change various settings related to the ma-
chine monitor and machine by using "Default".
The camera setting function is used to perform nec-
essary setting when the camera is installed or re-
moved.
1. Selecting menu
Select "Default" on the "Service Menu" screen.
2. Selecting sub menu
After the "Default" screen is displayed, select
"Camera" by the function switches or numeral
input switches.
a Select this item similarly to an item on the
"Service Menu" screen.
After the "Camera" setting screen is displayed,
select the setting by the function switches.
q OFF: Camera is not used
q Original Image: Image sent from the camera
is displayed in original position (as in mirror,
used as back monitor)
q Reverse Image: Image sent from camera is
displayed in reverse position (as seen direct-
ly, used as front or side monitor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before entering the set-
ting and return to "Default" screen
q [F6]: Enter selection in each line
a After "Camera" screen is displayed, the set-
ting for the camera 1 can be made.
When two or more cameras are connected, if
setting for camera 1 is made, the screen
changes to setting for camera 2 automati-
cally.
a After entering the setting of each line by [F6],
return to the "Default" screen by [F5], and the
setting becomes effective.
a If the camera is connected but setting is not
made properly by this function, the graphic
mark of camera is not displayed at [F3] in the
operator mode. Accordingly, the image sent
from the camera cannot be used.
a If two or more cameras are connected, be
sure to make necessary settings for the use
of them from camera 1 in order.
a The function of displaying two images simul-
taneously is effective when the setting for the
use of camera 1 and camera 2 are made.
a When the camera is installed, check that the
displayed image is not inverted horizontally.

HB205-1, HB215LC-1 30-107

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 108
Electrical system
Special functions of machine monitor

Default (ECO Display) a If ECO display is turned ON, ECO is dis-

Check or change various settings related to the ma-
chine monitor and machine by using "Default".
The ECO display setting function is used to set the
display of the ECO gauge and energy saving guid-
ance.
played when the screen changes to the ordi-
nary screen. Even if the energy saving
guidance is turned ON, however, it is not dis-
played if the condition for display is not satis-
fied on the ordinary screen.

1. Selecting menu
Select "Default" on the "Service Menu" screen.

a Display of ECO gauge (a)

2. Selecting sub menu

After the "Default" screen is displayed, select
"ECO Display" by the function switches or
numeral input switches
a Select this item similarly to an item on the
"Service Menu" screen.

a Display of energy saving guidance

3. Selecting display setting

After the "ECO Display" screen is displayed,
select the setting by the function switches.
q ON: Display ECO
q OFF: Do not display ECO
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before entering the set-
ting and return to "Default" screen
q [F6]: Enter selection in each line
a After entering the setting of the upper and
lower lines by [F6], return to the "Default"
screen by [F5], and the setting becomes ef-
fective.

30-108 HB205-1, HB215LC-1

(01)
 109
Electrical system
Special functions of machine monitor

Default (Breaker Detect) 3. Selecting display setting

Check or change various settings related to the
machine monitor and machine by "Default".
The function of setting breaker automatic judgment
is used to set the display to give warning when the
breaker is used in an improper working mode.
1. Selecting menu
Select "Default on the "Service Menu" screen.
After the "Breaker Detect" screen is displayed,
select the setting with the function switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to
Default screen
q [F6]: Confirm selection and return to
Default screen
a When the machine is delivered, Disable is
set.

2. Selecting sub menu

After the "Default" screen is displayed, select a Display of "Breaker Detect"
"Breaker Detect" with the function switches or
numeral input switches.
a Select this item similarly to an item on the
"Service menu" screen.

HB205-1, HB215LC-1 30-109

(01)
 110
Electrical system
Special functions of machine monitor

Adjustment (Pump Absorption Torque (F)) 3. Selecting absorption torque

The operator can adjust various items related to the
machine with the machine monitor.
The pump absorption torque (F) function is used to
finely adjust the absorption torque on the front side
of the hydraulic pump.
1. Selecting menu
Select "Adjustment" on the "Service Menu"
screen.
After the "Pump Absorption Torque (F)" screen
is displayed, select a set value on the right side
with the function switches.
q Set value: For actual torque adjustment
value, see table
q [F3]: Increase set value
q [F4]: Decrease set value
q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

2. Selecting sub menu

After the "Adjustment" screen is displayed,
select "Pump Absorption Torque (F)" with the a Relationship between set value and
function switches or numeral input switches. torque adjustment value
a Select this item similarly to an item on the Set
Code Torque adjustment value
"Service Menu" screen. value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 9.8 Nm {1 kgm}
006 19.6 Nm {2 kgm}
007 29.4 Nm {3 kgm}
008 39.2 Nm {4 kgm}

30-110 HB205-1, HB215LC-1

(01)
 111
Electrical system
Special functions of machine monitor

Adjustment (Pump Absorption Torque (R)) 3. Selecting absorption torque

The operator can adjust various items related to the
machine with the machine monitor.
The pump absorption torque (R) function is used to
finely adjust the absorption torque on the rear side
of the hydraulic pump.
1. Selecting menu
Select "Adjustment" on the "Service Menu"
screen.
After the "Pump Absorption Torque (R)" screen
is displayed, select a set value on the right side
with the function switches.
q Set value: For actual torque adjustment
value, see table
q [F3]: Increase set value
q [F4]: Decrease set value
q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

2. Selecting sub menu

After the "Adjustment" screen is displayed,
select "Pump Absorption Torque (R)" with the a Relationship between set value and torque
function switches or numeral input switches. adjustment value
a Select this item similarly to an item on the Set
Code Torque adjustment value
"Service Menu" screen. value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
022 004 0 Nm {0 kgm}
005 9.8 Nm {1 kgm}
006 19.6 Nm {2 kgm}
007 29.4 Nm {3 kgm}
008 39.2 Nm {4 kgm}

HB205-1, HB215LC-1 30-111

(01)
 112
Electrical system
Special functions of machine monitor

Adjustment (Low Speed) 3. Selecting travel Low speed

The operator can adjust various items related to the
machine with the machine monitor.
The travel Low speed setting function is used to
finely adjust the travel Low speed.
1. Selecting menu
Select "Adjustment" on the "Service Menu"
screen.
After the "Low Speed" setting screen is dis-
played, select a set value on the right side with
the function switches.
q Set value: For actual travel Low speed
value, see table
q [F3]: Increase set value
q [F4]: Decrease set value
q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

2. Selecting sub menu

After the "Adjustment" screen is displayed,
select "Low speed" with the function switches
or numeral input switches. a Relationship between set value and travel
a Select this item similarly to an item on the Low speed value
"Service Menu" screen. Set
Code Travel Low speed value
value
000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h

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 113
Electrical system
Special functions of machine monitor

Adjustment (Attachment Flow Adjustment) 3. Selecting distribution of oil flow

The operator can adjust various items related to the
machine with the machine monitor.
The function of "Attachment Flow Adjustment" is
used to finely adjust the oil flow to the attachment in
compound operation.
1. Selecting menu
Select "Adjustment" on the "Service Menu"
screen.
After the screen of "Attachment Flow Adjust-
ment" is displayed, select a set value on the
right side with the function switches.
q Set value: For actual distribution of flow,
see table
q [F3]: Increase set value
q [F4]: Decrease set value
q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

2. Selecting sub menu

After the "Adjustment" screen is displayed,
select "Attachment Flow Adjustment" with the
function switches or numeral input switches. a Relationship between set value and distri-
a Select this item similarly to an item on the bution of flow to attachment
"Service Menu" screen. Set Distribution of flow to
Code
value attachment
000 50 %
001 70 %
044
002 100 %
003 40 %

HB205-1, HB215LC-1 30-113

(01)
 114
Electrical system
Special functions of machine monitor

Adjustment (Swing Motor Starting Torque)
Various adjustments of the machine can be per-
formed on the machine monitor.
The function of setting the swing starting torque is
used to finely adjust the maximum swing motor
torque at the start of swinging.
The acceleration time at the start of swinging can be
adjusted finely with this function.
1. Selection of menu
Select "Adjustment" on the "Service menu"
screen.
3. After the "Swing motor starting torque"
screen is displayed, select a set value on the
right side with the function switches.
q Set value: For the actual swing motor torque,
see the table.
q [F3]: Increase the set value.
q [F4]: Decrease the set value.
q [F6]: Confirm or enter and return to the ad-
justment menu screen.
a The three digits on the left side do not change
since they are the code of this function.

a Relationship between set value and swing

2. Selection of submenu starting torque
After the "Adjustment menu" screen is Adjustment value for
displayed, select "Swing motor starting torque" Set
Code maximum torque generated
with the function switches or numeral input value
by swing motor.
switches. 000 100% 0 Nm {0 kgm}
a Select similarly as on the "Service menu" 001 93% -8 Nm {-0.8 kgm}
screen. 058
002 85% -18 Nm {-1.8 kgm}
003 77% -28 Nm {-2.9 kgm}
q Maximum torque generated by swing mo-
tor decreases according to the adjust-
ment value.
q The initial set value is the maximum swing
starting torque of "000".
q Since the maximum swing motor torque is
adjusted, the swing acceleration does not
change during fine swing operation.

30-114 HB205-1, HB215LC-1

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 115
Electrical system
Special functions of machine monitor

Adjustment (Hoist Swing Adjustment)
Various adjustments of the machine can be per-
formed on the machine monitor.
The function of adjusting hoist swing is used to ad-
just the maximum swing motor torque generated at
combined operations of swing and boom to adjust
the hoist swing acceleration finely.
1. Selection of menu
Select "Adjustment" on the "Service menu"
screen.
3. After the "Hoist swing adjustment" screen is
displayed, select a set value on the right side
with the function switches.
q Set value: For the actual swing motor torque,
see the table.
q [F3]: Increase the set value.
q [F4]: Decrease the set value.
q [F6]: Confirm or enter and return to the ad-
justment menu screen.
a The three digits on the left side do not change
since they are the code of this function.

2. Selection of submenu a Relationship between set value and hoist

After the "Adjustment menu" screen is swing torque
displayed, select "Hoist swing adjustment" with Set Adjustment value of hoist
the function switches or numeral input switches. Code
value swing torque
a Select similarly as on the "Service menu" 000 100%
screen. 001 90%
059
002 80%
003 70%
q The initial set value is "001".
q This function is used to adjust the swing
acceleration during hoist swing operation.

HB205-1, HB215LC-1 30-115

(01)
 116
Electrical system
Special functions of machine monitor

Adjustment (Pump Calibration)

Various adjustments of the machine can be performed on the machine monitor.
The purposes of the pump calibration function are as follows.
q Check the matching speed at relief.
q Set most suitable matching speed with the engine when the pump or pump controller is replaced.

a The pump (matching speed) needs to be calibrated in the following cases.

Calibration of
pump
Replacement of engine
Replacement of main pump
Necessary
assembly
Replacement of pump controller Necessary
Adjustment or disassembly of front
Necessary
pump PC valve
Adjustment or disassembly of rear
Necessary
pump PC valve
Replacement of main valve
Adjustment or replacement of relief

valve of main valve

a The flow of the pump calibration is outlined below.

Inside of adjustment menu of service menu

Selection of menu in pump calibration

Check of matching speed Calibration of matching speed Return to initial value Return to value at delivery

Check of matching speed Check of matching speed Setting screen Setting screen
<Operation> <Operation>
Relieve by arm-in operation Relieve by arm-in operation
<Condition> <Condition>
Repeat 3 times

Repeat 3 times

Hydraulic oil temperature: Hydraulic oil temperature:

& &
Swing emergency stop Swing emergency stop
switch: ON switch: ON
P mode P mode
Fuel control dial: FULL Fuel control dial: FULL
Swing lock switch: ON Swing lock switch: ON

Display of matching speed result Display of matching speed result

Check of matching speed Check of matching speed

<Operation> <Operation>
Relieve by bucket-curl operation Relieve by bucket-curl operation
<Condition> <Condition>
Repeat 3 times

Repeat 3 times

Hydraulic oil temperature: Hydraulic oil temperature:

& &
Swing emergency stop Swing emergency stop
switch: ON switch: ON
P mode P mode
Fuel control dial: FULL Fuel control dial: FULL
Swing lock switch: ON Swing lock switch: ON

Display of matching speed result Display of matching speed result

Update setting

30-116 HB205-1, HB215LC-1

(01)
 117
1. Preparation for calibration
Before starting calibration, set the following
condition.
q Hydraulic oil temperature: 50C
q Working mode: P mode
q Swing emergency stop switch: ON
q Fuel control dial: FULL
q Swing lock switch: ON
q Air conditioner: OFF
2. Selection of menu
Select "Adjustment" on the "Service menu"
screen.
3. Selection of submenu
After the "Adjustment menu" screen is
displayed, input "40" with the numeral input
switches.
Since this function is necessary only after the
pump is replaced or PC valve is adjusted or
disassembled or pump controller is replaced, it is
not displayed in the menu list.
a Input "40" in the adjustment menu.
HB205-1, HB215LC-1
(01)
Electrical system
Special functions of machine monitor
4. Selection of menu in pump calibration
1) When it is necessary to check the abnor-
mality and condition of the machine, select
"Matching Speed Check".
a Select similarly as on the "Service menu"
screen.
a The alphabet letter at the right top of the
screen indicates the following condition.
D: Initial value
F: Value at delivery: State when delivered
(normal)
U: User calibration value
5. Check of matching speed
1) After the "Matching Speed Check" screen is
displayed, check the matching speed by
performing arm-in relief operation or
bucket-curl operation and using the function
switches.
[F1]: Start
[F5]: Return to the previous screen
[F6]: Enter the contents of setting.
Check of matching speed (1/6 to 3/6)
30-117
 118
Electrical system
Special functions of machine monitor

Check of matching speed (4/6 to 6/6)
3) While performing arm-in relief or bucket-curl
relief operation, when the engine speed is
stabilized, hold down "F1" of the machine
monitor to start the calibration.
The screen displays the bar while the
matching speed is being checked. Continue
the relief operation until checking is
completed. (About 10 seconds)

2) Check the relief matching by operating the

arm control lever or bucket control lever
under the following condition.
(Operation)
Perform arm-in relief or bucket-curl relief
operation according to the direction on the
screen.
a Perform arm-in relief matching first, and 4) If checking is completed normally, the result
then perform bucket-curl relief matching. is displayed.
q Arm control lever: Move in fully (Operate Check of matching speed (1/6 to 5/6):
for arm-in relief matching) To check the next matching point, press [F6]
q Bucket control lever: Move in fully (Oper- and following the instruction.
ate for bucket-curl relief matching) Check of matching speed (6/6):
(Condition) To finish, press [F6] and following the instruc-
q Hydraulic oil temperature: 50C tion.
q Working mode: P mode
q Swing emergency stop switch: ON
q Fuel control dial: FULL
q Swing lock switch: ON
q Air conditioner: OFF

k Secure a sufficient area since the work

equipment must be operated during
inspection.
k When operating the work equipment,
take extreme care for safety around
the machine.

30-118 HB205-1, HB215LC-1

(01)
 119
Electrical system
Special functions of machine monitor

a The standard values of the check result of

the matching speed are shown in Table 1.

If checking is finished abnormally, the

checking condition becomes NG and the
failure cause code is displayed. In this case,
check for the cause by referring to the failure
cause code in Table 2, and then repeat the
check of the matching speed.

Table 1. Standard values of check result of matching speed

Item Unit Standard value
Check of matching speed (1/6) rpm 1,850 50
Check of matching speed (2/6) rpm 1,960 50
Check of matching speed (3/6) rpm 2,000 50
Engine speed
Check of matching speed (4/6) rpm 1,850 50
Check of matching speed (5/6) rpm 1,960 50
Check of matching speed (6/6) rpm 2,000 50
High pressure side MPa {kg/cm2} 33.8 36.3 {345 370}
Pump pressure
Low pressure side MPa {kg/cm2} 3.5 1.0 {36 10}

HB205-1, HB215LC-1 30-119

(01)
 120
Electrical system
Special functions of machine monitor

Table 2. Failure cause code table

Failure
Contents Standard value Countermeasures
code
A-1 Engine speed signal is 0 rpm 0 rpm Check start of engine

Check hydraulic oil temperature

A-2 Hydraulic oil temperature is low Max. 39C (Reset at 40C or above)
(Min. 45C)
Check hydraulic oil temperature
A-3 Hydraulic oil temperature is high Min. 60C
(Max. 55C)
Connected to engine coolant
A-4 Overheat Check for overheat
temperature
Perform troubleshooting for pump
A-6 Pump pressure sensor (F, R) is abnormal Connected to troubleshooting
pressure sensor
Perform troubleshooting for arm-in
A-8 Arm-in PPC pressure sensor is abnormal Connected to troubleshooting
PPC pressure sensor
A-9 PC-EPC is abnormal Connected to troubleshooting Perform troubleshooting for PC-EPC
CAN communication is defective
A-A Connected to troubleshooting Perform troubleshooting for CAN
(Engine, Monitor, Pump)
Bucket-curl PPC pressure sensor is Perform troubleshooting for
A-B Connected to troubleshooting
abnormal bucket-curl PPC pressure sensor
Check fuel control dial is at FULL
C-3 Fuel control dial is not FULL position Other than throttle 100%
position
During arm-in relief operation, arm-in
PPC pressure is below specified value or Below 2.2 MPa {22 kg/cm2} or sensor Check arm control lever is at FULL
E-1
in normal range of arm-in PPC pressure voltage is out of 0.5 to 4.5 [V] (*1) position
sensor
Pump pressure on relief side is below
33.3 MPa {340 kg/cm2} or above
Pump pressure (F, R) is out of specified 37.3 MPa {380 kg/cm2} (*2), or pump Perform troubleshooting for relief
E-2
range pressure on MIN side is above valve and pump
5.9 MPa {60 kg/cm2} (*3) or below
2.0 MPa {20 kg/cm2}

E-3 Engine speed is out of specified range Out of target speed 200 rpm Check engine high idle speed
Out of target torque 100 Nm { 10 Perform troubleshooting for engine
E-4 Engine torque is out of specified range
kgm} and pump
Perform troubleshooting for PC-EPC
E-5 PC-EPC current is out of specified range Out of 400 to 650 mA
current
During bucket-curl relief operation,
bucket-curl PPC pressure is below Below 2.2 MPa {22 kg/cm2} or sensor Check bucket control lever is at FULL
E-6
specified value or in normal range of voltage is out of 0.5 to 4.5 [V] (*1) position
bucket-curl PPC pressure sensor
E-7 Working mode is not P or ATT/P Mode other than P and ATT/P Check working mode is P or ATT/P
Swing emergency stop switch is not Check swing emergency stop switch
E-8 Swing emergency stop switch is not ON
at ON position is ON
Swing lock switch is not at ON
E-9 Swing lock switch is not ON Check swing lock switch is ON
position
*1: When the sensor voltage is other than the standard range (0.5 4.5 V), pump controller recognizes the
voltage as 0 MPa {0 kg/cm2}, perform troubleshooting referring to the section "Troubleshooting" (failure
codes [DHPAMA] and [DHPBMA])
*2: Relief side standard value [35.3 MPa {360 kg/cm2}] 2.0 MPa {20 kg/cm2}
*3: MIN side standard value [3.9 MPa {40 kg/cm2}] 2.0 MPa {20 kg/cm2}

30-120 HB205-1, HB215LC-1

(01)
 121
6. Calibration of matching speed
1) After the "Calibration of matching speed"
screen is displayed, check the matching
speed by performing arm-in relief operation
or bucket-curl operation and using the func-
tion switches.
[F1]: Start
[F5]: Return to adjustment menu screen
[F6]: Enter the contents of setting.
Calibration of matching speed (1/6 to 3/6)
Calibration of matching speed (4/6 to 6/6)
HB205-1, HB215LC-1
(01)
Electrical system
Special functions of machine monitor
2) Check the relief matching by operating the
arm control lever or bucket control lever
under the following condition.
(Operation)
Operate according to the instruction on the
screen.
q Arm control lever: Fully IN
q Bucket control lever: Fully CURL
(Condition)
q Hydraulic oil temperature: 50C
q Working mode: P mode
q Swing emergency stop switch: ON
q Fuel control dial: FULL
q Swing lock switch: ON
q Air conditioner: OFF
k Secure a sufficient area since the work
equipment must be operated during
inspection.
k When operating the work equipment,
take extreme care for safety around
the machine.
3) While performing arm-in relief or bucket-curl
relief operation, when the engine speed is
stabilized, hold down "F1" of the machine
monitor to start the calibration.
The screen displays the bar while the
matching speed is being checked. Continue
the relief operation until checking is
completed. (About 10 seconds)
30-121
 122
Electrical system
Special functions of machine monitor

4) If checking is completed normally, the result

is displayed.
Check of matching speed (1/6 to 5/6):
To check the next matching point, press [F6]
and following the instruction.
Check of matching speed (6/6):
To finish, press [F6] and following the instruc-
tion.

a The standard values of the check result of the

matching speed are shown in Table 1 (in
"5. Check of matching speed").

If checking is finished abnormally, the checking

condition becomes NG and the failure cause
code is displayed. In this case, check for the
cause by referring to the failure cause code in
Table 2 (in "5. Check of matching speed"), and
then repeat the check of the matching speed.

30-122 HB205-1, HB215LC-1

(01)
 123
Electrical system
Special functions of machine monitor

Discharging capacitor
The capacitor can be discharged by operating the
machine monitor.

1. Selecting menu
Select "Discharge capacitor" on the "Service
menu" screen.

2. Discharge operation
See 00 Foreword, Safety, Basic information
"Discharging capacitor" in "Handling hybrid
devices or high-voltage wirings".

HB205-1, HB215LC-1 30-123

(03)
 124
Electrical system
Special functions of machine monitor

Cylinder Cut-Out
The technician can perform "Cylinder Cut-Out" op-
eration by using the machine monitor.
"Cylinder Cut-Out" operation means to run the en-
gine with one or more fuel injectors disabled electri-
cally to reduce the number of active cylinders. This
operation is used to find out a cylinder which does
not output power properly (combustion in it is abnor-
mal).

1. Selecting menu
Select "Cylinder Cut-Out" on the "Service Menu"
screen.

3. Canceling cut-out cylinder

2. Selecting cylinder to be cut out
After the "Cylinder Cut-Out" screen is displayed,
select a cylinder to be cut out by the function
switches.
q [F1]: Move selection mark (R) to left
q [F2]: Move selection mark (R) to right
q [F3]: Cancel holding
q [F4]: Hold
q [F5]: Return to service menu screen
q [F6]: Enter selection
a This operation may be performed while the
engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder number becomes white,
the cylinder is cut out.
a If the machine monitor cuts out a cylinder but
the engine controller cannot cuts out that cyl-
inder, the background (a) of the cylinder
number becomes yellow.
a One or more cylinders can be cut out.
a In the cylinder cut-out operation, the auto-de-
celeration function can be used. If the au-
to-deceleration is turned ON, auto-
deceleration monitor (b) is displayed.
When changing a cylinder to be cut out or when
cylinder cut-out operation is finished, select a cut
out cylinder to be resumed by the function
switches.
a This operation may be performed while the
engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder number becomes blue,
the cylinder is resumed.
a If the machine monitor cancels cut-out of a
cylinder but the engine controller cannot can-
cel the cut-out of cylinder, the background (a)
of the cylinder number becomes red.
a The cut-out operation is not automatically
canceled after the screen returns to the oper-
ator mode. Accordingly, be sure to perform
the canceling operation after the cylinder
cut-out operation is finished.
4. Function of holding displayed information
If [F4] is pressed during the cylinder cut-out
operation, the displayed information is held (c)
(The real-time information is kept displayed on
the left side).
While the information is held, if [F3] is pressed,
the holding function is canceled.
a The holding function is effective, regardless
of setting of the cylinder cut-out mode opera-
tion.

30-124 HB205-1, HB215LC-1

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 125
[Reference]
q If a properly operating cylinder is cut out, the
following phenomena occur.
1) Lowering of engine speed
2) Increase of final injection rate command
(increase in fuel amount)
q If the engine is running near the high idle
speed, however, the engine speed may not
lower for the reason of engine control func-
tion.
q In this case, lower the engine speed by using
the fuel control dial and judge by monitoring
the increase of the injection rate command.
HB205-1, HB215LC-1
(01)
Electrical system
Special functions of machine monitor
No Injection cranking
If the engine is operated after long storage of the
machine, it may be worn or damaged because of in-
sufficient lubrication. To prevent this problem, the
function to lubricate the engine before starting it by
cranking it without injecting fuel is provided.
Set the no injection cranking while the engine is
stopped.
1. Selecting menu
Select "No Injection" on the "Service Menu"
screen.
2. Displaying check screen
If the "No injection" screen is displayed, the
machine monitor asks you if no injection
cranking should be performed. Answer by using
the function switch.
q [F5]: Do not perform (Return to Service menu
screen)
q [F6]: Perform
a Before the screen is changed to the following
screen, the screen of "Communication be-
tween controllers is being checked" is dis-
played.
30-125
 126
Electrical system
Special functions of machine monitor

3. Starting no injection cranking 5. Prohibiting no injection cranking

If no injection cranking (Fuel injection in no cylin-
ders) becomes effective, that is displayed on the
screen. Under this condition, crank the engine
by the starting motor.
a Before the screen is changed to the following
screen, the screen of "Setting is being pre-
pared" is displayed.
a Limit the cranking time to 20 seconds to pro-
tect the starting motor.
If the no injection cranking is attempted while the
engine is running, the message that the "Engine
is running" is displayed and the no injection
cranking is not set effective.
a This function can be selected even while the
engine is running. If the no injection cranking
is attempted, however, the "Engine is run-
ning" message is displayed on the screen.

4. Finishing no injection cranking

After completing the no injection cranking opera-
tion, press [F6], and finish of no injection
cranking is displayed and the screen returns to
the "Service Menu" screen automatically.

30-126 HB205-1, HB215LC-1

(01)
 127
Fuel Consumption
This function calculates the hourly fuel consumption
from the actual fuel consumption in the measuring
period and indicates it.
1. Selecting menu
Select "Fuel Consumption" on the "Service
Menu" screen.
2. Starting measurement
After the screen of "Fuel Consumption" is
displayed, start measurement by the function
switches.
q [F1]: START
q [F2]: CLEAR
q [F5]: Return to Service menu screen
a When "Fuel consumption" screen is dis-
played, if a data is indicated, it is the data of
the previous measurement. This data is not
an obstacle to new measurement and can be
deleted by pressing [F2].
a If [F1] is pressed, the data is displayed on the
"Start Time" side and measurement starts.
a The display unit of the fuel differs depending
on the unit selection by the default (unit set-
ting) function.
Metric or Imperial: l/h or gal/h
HB205-1, HB215LC-1
(01)
Electrical system
Special functions of machine monitor
3. Display and function during measurement
Clock mark (a) flashes during measurement.
a While the fuel consumption is being mea-
sured, you can work with the operator mode
or other service function. However, measure-
ment is not finished until this screen is dis-
played again and [F1] is pressed.
(Even if the starting switch is turned OFF, this
function is kept effective, but fuel consump-
tion is measured only while the engine is
running).
4. Finishing measurement
Press [F1], and measurement is finished and the
data are displayed on the "Stop Time".
5. Displaying fuel consumption
If the measurement is finished, the hourly fuel
consumption obtained from the fuel consump-
tion calculated by the engine controller and the
elapsed time are displayed.
30-127
 128
Electrical system
Special functions of machine monitor

KOMTRAX Settings (Terminal Status) 3. Contents of display of terminal status

The setting condition and operating condition of KO-
MTRAX can be checked by Display of KOMTRAX
setting.
Terminal Status is used to check the setting condi-
tion of the KOMTRAX terminal.
1. Selecting menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.
On the "Terminal Status" screen, the following
items are displayed.
q Terminal type: model name of KOMTRAX
communication modem
q KOMTRAX communication: station opening
inspection status
q GMT time: Greenwich Mean Time
q [F5]: Return to KOMTRAX settings screen

2. Selecting sub menu

After the "KOMTRAX Settings" screen is
displayed, select "Terminal Status" by the func-
tion switches or numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.
a The following figure shows the display when
Model TH300 KOMTRAX is installed.

30-128 HB205-1, HB215LC-1

(01)
 129
Electrical system
Special functions of machine monitor

KOMTRAX Settings (GPS & Communication Sta-
tus)
The setting condition and operating condition of KO-
MTRAX can be checked with "KOMTRAX Settings".
GPS & communication status is used to check the
condition of positioning and communication of the
KOMTRAX terminal.
1. Selecting menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.
3. Contents of display of GPS & communication
status
On the screen of "GPS & Communication
Status", the following items are displayed.
q Positioning: positioning condition by GPS
q Communication: communication environ-
ment of communication modem and connect-
ing condition of communication modem
q Number of message not yet sent: number of
mails which are stored in the machine moni-
tor but not transmitted yet
q [F5]: Return to KOMTRAX settings screen

2. Selecting sub menu

After the "KOMTRAX Settings" screen is
displayed, select GPS & communication status
by the function switches or numeral input
switches.
a Select this item similarly to an item on the
"Service Menu" screen.
a The following figure shows the display when
Model TH300 KOMTRAX is installed.

HB205-1, HB215LC-1 30-129

(01)
 130
Electrical system
Special functions of machine monitor

KOMTRAX Setting (MODEM S/N: TH300) 3. Contents of display of Modem S/N

The setting condition and operating condition of KO-
MTRAX can be checked by Display of KOMTRAX
Settings.
MODEM S/N is used to check the serial number of
the KOMTRAX communication modem.
The serial number of TH300 modem is
displayed.
q [F5]: Return to KOMTRAX settings screen

1. Selecting menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.

2. Selecting sub menu

After the "KOMTRAX Settings" screen is
displayed, select "Modem S/N" by the function
switches or numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

30-130 HB205-1, HB215LC-1

(01)
 131
Electrical system
Special functions of machine monitor

Display of Service message 3. Display of message (with return mail function)

Special messages for the technician sent from the
KOMTRAX base station (a distributor, etc.) can be
checked by this function.
If there is setting in a message, a return mail can be
sent by using numeral input switches.
1. Operation to display menu
Select "Service Message" on the service menu
screen.
If a box to enter a value by the numeral keys is
displayed under the message, input a proper
number by the numeral input switches and func-
tion switches and enter it, and the information is
returned to the KOMTRAX base station.
q [F5]: Return to service menu screen
q [F6]: Enter and send input value as a return
message
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the techni-
cian, the message monitor is not displayed
when it is received as in the operator mode.

2. Display of message (read-only)

If there is a message, its contents are displayed.
If there is no message, "No message" is
displayed.
q [F5]: Return to service menu screen
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the techni-
cian, the message monitor is not displayed
when it is received as in the operator mode.

HB205-1, HB215LC-1 30-131

(01)
 132
Electrical system
Handling voltage circuit of engine controller

Handling voltage circuit of engine

controller 132

1. Before disconnecting or connecting a connector

between the engine controller and engine, be
sure to turn the starting switch to OFF position.

2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.

30-132 HB205-1, HB215LC-1

(01)
 133
Electrical system
Precautions related to hybrid machines

Precautions related to hybrid

machines 13

k When testing or adjusting a hybrid machine,

ensure you fully understand the following
items.

1. Never disassemble the hybrid devices for quality

assurance purposes.

2. The hybrid devices and high-voltage wiring

(wound with orange conduits) must be replaced
by the unit.

3. When handling hybrid devices, be sure to

discharge the capacitor completely first.
(For details, see 00 Index and foreword, Fore-
word and general information, Handling of hybrid
devices and high-voltage wirings, "Procedure for
discharging capacitor", or Testing and adjusting,
Special functions of machine monitor,
"Discharge of capacitor".)

k Since the items with the above mark are relat-

ed to handling of the hybrid devices, ensure
you understand the contents of 00 Index and
foreword, Foreword and general information,
"Handling of hybrid devices and high-voltage
wirings", before beginning work on them.

HB205-1, HB215LC-1 30-133

(01)
 134
Electrical system
Preparation work for troubleshooting of electrical system

Preparation work for

troubleshooting of electrical
system 134

a When carrying out troubleshooting for an electri-

cal circuit related to the machine monitor, engine
controller, pump controller, hybrid controller (in-
verter), or KOMTRAX communication MODEM,
expose the related connectors according to the
following procedure.
a Disconnect and connect the connectors, which
have a special locking device, according to the
following procedure.
3) Remove the one mounting bolt and duct (6).
1. Machine monitor
1) Remove the three mounting bolts and cover
(1).
a One of the mounting bolt is installed in-
side the cover on the right of the sunlight
sensor.
a While removing the cover, disconnect
connector P31 of the sunlight sensor.
2) Remove cover (2).
a Since the cover is fixed with the clip, pull
it up to remove.

a While removing the cover, disconnect the
body and operation portion of emergency
stop switch (3).
4) Insert or connect test T-adapters into or to
connectors CM01, CM02, and CM03 of
machine monitor (7).
a Connectors CM02 and CM03 are the
same type. When returning them, check
the mark plates on the mounting brackets
and exercise care to connect them cor-
rectly.

a Disconnect the operating knob portion

from the body of emergency stop switch
(3) using the following method; While
pressing knob (4) toward the harness
HS01 side, push up lock part (5) of the
switch body and rotate the switch body by
45 in the direction of arrow (a).

30-134 HB205-1, HB215LC-1

(01)
 135
Electrical system
Preparation work for troubleshooting of electrical system

2. Engine controller 3) Remove the mounting bolts for diode

1) Open the engine hood. mounting bracket (8) and harness clamp
a The engine controller is mounted on the bracket (9) and slide them to forward.
engine (on the counterweight side).
2) Insert or connect test T-adapters into or to
connectors CE01, CE02, and CE03 of
engine controller (5).
a When disconnecting connectors CE01
and CE02, loosen their screws first.
a When returning CE01 and CE02, tighten
their screws to the specified torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}

4) Connect test adapters to connectors C01

and C02 of pump controller (10).
a Install the adapters to only the wiring har-
ness side.

3. Pump controller
1) Slide the operator seat and seat stand to the
forward end.
2) Remove fuse box cover (6), remove the three
mounting bolts and cover (7).
a Since cover (7) is fixed with a clamp at its
bottom, pull it up to remove.
a Disconnect each pump controller connec-
tor, which has a special locking device, in
the order of (a) (c) in the following figure
and connect in the order of (d) (f).
Disconnection: (a) Unlock (b) Slide
lever (c) Disconnect connector.
Connection: (d) Position connector (e)
Slide lever (f) Engage lock.

HB205-1, HB215LC-1 30-135

(01)
 136
Electrical system
Preparation work for troubleshooting of electrical system

5. KOMTRAX communication module

1) Slide the operator's seat and seat stand to
the forward end.
4. Hybrid controller (inverter)
2) Remove the five mounting bolts and cool &
1) Open the radiator door.
hot box (1).
a The hybrid controller is mounted in front
a While removing the cool & hot box, dis-
of the radiator.
connect the drain hose.
2) Remove the three mounting bolts (1) and
3) Remove the two mounting bolts, one
cover (2).
fastener, and magazine box (2).
4) Remove fuse box cover (3), remove the three
mounting bolts and cover (4).
a Since the underside of cover (4) is
clamped, pull it up to remove.
5) Remove the seven mounting bolts and cover
(5).

3) Insert or connect test T-adapters into or to

connectors HC01 and HC02 of hybrid
controller (3).
a When disconnecting connectors HC01
and HC02, loosen their screws first.
a When returning HC01 and HC02, tighten
their screws to the specified torque.
3 Connector mounting screw:
6) Connect test T-adapters to connectors CK01
and CK02 of KOMTRAX communication
2.6 3.1 Nm {0.27 0.32 kgm}
module (6).
a Cable (7) is for the communication anten-
na.

30-136 HB205-1, HB215LC-1

(01)
 137
6. Ambient pressure sensor
(AMBAIR PRESURE)
Engine Ne speed sensor (CRANK SENSOR)
Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
a Disconnection and connection of connec-
tors
The connectors of the ambient pressure
sensor, engine Ne speed sensor, engine
Bkup speed sensor, engine oil pressure
switch have a special locking device. Discon-
nect them in the order of steps (a) (c) and
connect them in the order of steps (d) (f) as
shown below.
Disconnection: (a) Slide lever (b) Unlock
(c) Disconnect connector.
Connection: (d) Connect connector (e)
Engage lock (f) Slide lever.
a Removal and installation of sensor
A deep socket is necessary for removal and
installation of the engine oil pressure switch.
See "Tools for testing, adjusting, and trouble-
shooting".
HB205-1, HB215LC-1
(01)
Electrical system
Preparation work for troubleshooting of electrical system
7. Boost pressure and temperature sensor
(BOOST PRES & IMT)
a Disconnection and connection of connec-
tor
The connector of the boost pressure and
temperature sensor has a special locking
device. Disconnect it in the order of steps (a)
(b) and connect it in the order of steps (c)
(d) as shown below.
Disconnection: (a) Unlock (b) Disconnect
connector.
Connection: (c) Connect connector (d)
Engage lock.
a Removal and installation of sensor
A torque wrench is necessary for removal
and installation of the boost pressure and
temperature sensor. See "Tools for testing,
adjusting and troubleshooting".
30-137
 138
Electrical system
Preparation work for troubleshooting of electrical system
8. Supply pump IMV solenoid (FUEL REGU-
LATOR)
a Disconnection and connection of connec-
tor
The connector of the supply pump IMV sole-
noid has a special locking device. Disconnect
it in the order of steps (a) (b) and connect it
in the order of steps (c) (d) as shown below.
Disconnection: (a) Unlock (b) Disconnect
connector.
Connection: (c) Connect connector (d)
Engage lock.
30-138
9. Common rail pressure sensor (FUEL RAIL
PRESS)
a Disconnection and connection of connec-
tor
The connector of the common rail pressure
sensor has a special locking device. Discon-
nect it in the order of steps (a) (b) and
connect it in the order of steps (c) (d) as
shown below.
Disconnection: (a) Unlock (b) Disconnect
connector.
Connection: (c) Connect connector (d)
Engage lock.
a Precautions for disconnecting connector
The direction of the lock of the connector
varies with the tightened position of the
sensor and the lock may be in a direction in
which it is difficult to release (on the under-
side or engine side).
In this case, pinch the lock in direction (a)
with bent-nose nippers [1] (available on the
market), and the lock is released.
Since the lock clicks when it is released,
disconnect the connector after a click is
heard.
HB205-1, HB215LC-1
(01)
 139
a Precautions for connecting connector
Take care not to connect the connector
upside down.
Engage lock (e) on the harness side with
triangular notch (f) on the sensor side (Do not
engage lock (e) with square guide (g) on the
opposite side of triangular notch (f)).
HB205-1, HB215LC-1
(01)
Electrical system
Preparation work for troubleshooting of electrical system
10. Engine coolant temperature sensor
(COOLANT TEMP)
a Disconnection and connection of connec-
tor
The connector of the engine coolant temper-
ature sensor has a special locking device.
Disconnect it in the order of steps (a) (b)
and connect it in the order of steps (c) (d)
as shown below.
Disconnection: (a) Unlock (b) Disconnect
connector.
Connection: (c) Connect connector (d)
Engage lock.
a Removal and installation of sensor
A deep socket is necessary for removal and
installation of the engine coolant temperature
sensor. See "Tools for testing, adjusting and
troubleshooting".
30-139

Electrical system
Procedure for testing diodes
Procedure for testing diodes
a Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
procedure.
a The conductible directions of the assem-
bled-type diode are as follows.
a The conductible direction of the single diode is
indicated on the surface of the diode.
30-140
140
140
1. When using digital multimeter
1) Set the tester in the diode range and check
the indicated value.
a When an ordinary multimeter is used, the
voltage of the internal battery is indicated.
2) Apply the red (+) lead of the multimeter to the
anode (P) side of the diode and apply the
black (-) lead to the cathode (N) side and
check the indicated value.
3) Judge the quality of the diode by the indi-
cated value.
q The indicated value does not change: No
continuity (defective)
q The indicated value changes: continuity
(normal)
Note: In the case of a silicon diode, a value
in the range from 460 to 600 is indicated.
2. When using analog multimeter
1) Set the multimeter in the resistance range.
2) Apply the leads of the multimeter as
explained below and check the movement of
the pointer.
1] Apply the red (+) lead of the multimeter to
the anode (P) side of the diode and apply
the black (-) lead to the cathode (N) side.
2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and
apply the black (-) lead to the anode (P)
side.
3) Judge the quality of the diode by the move-
ment of the pointer.
q The pointer does not move in 1] but
moves in 2]:
The diode is normal (The moving range
(resistance) depends on the type and
selected range of the tester, however).
q The pointer moves in both 1] and 2]:
The diode is defective (internal short
circuit).
q The pointer moves in neither of 1] and 2]:
The diode is defective (internal disconti-
nuity).
HB205-1, HB215LC-1
(01)
 141
Pm Clinic
Pm Clinic service

Pm Clinic 141

Pm Clinic service 141

Model Serial No. Service meter

HB205, 215LC-1 h
User's name Date of clinic Inspector
/ /
Specifications
Main components Shoe width
Boom Standard ( ) 600 mm
Arm Standard ( ) 700 mm
Bucket Standard ( ) ( )
Check of oil/coolant level
Radiator coolant When necessary
Machinery case oil
Hybrid radiator coolant Final drive case oil
Motor-generator case oil
Engine oil
Swing electric motor case oil
Hydraulic oil ( )
Ambient temperature Height above sea level

C m

Operator's comment

Visual check

Mechanical equipment system failure record Electrical equipment system failure record
989EKX time/1st time h/last h time/1st time h/last h
AA10NX time/1st time h/last h time/1st time h/last h
AB00KE time/1st time h/last h time/1st time h/last h
B@BAZG time/1st time h/last h time/1st time h/last h
B@BAZK time/1st time h/last h time/1st time h/last h
B@BCNS time/1st time h/last h time/1st time h/last h
B@BCZK time/1st time h/last h time/1st time h/last h
B@HANS time/1st time h/last h time/1st time h/last h
CA234 time/1st time h/last h time/1st time h/last h

Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge

HB205-1, HB215LC-1 30-141

(01)
 142
Pm Clinic
Pm Clinic service

Items related to engine

30-142 HB205-1, HB215LC-1

(01)
 143
Pm Clinic
Pm Clinic service

Items related to oil pressure

HB205-1, HB215LC-1 30-143

(01)
 144
Pm Clinic
Pm Clinic service

Check sheet
Model Serial No. Service meter User's name Date of check Inspector
/ /

1. Engine
Checking condition Standard

Good
value for Service Measured

NG
No. Check item Fuel Working Auto- Left Operation Unit
control mode deceler- knob of work new limit value value
dial ation switch equipment machine
1,990 1,990
1 Engine speed All levers in rpm
2,130 2,130
MAX the neutral
Engine oil position MPa Min. 0.29 0.25
2
pressure {kg/cm2} {Min.3.0} {2.5}
OFF
1,000 1,000
3 Engine speed All levers in rpm
1,100 1,100
MIN the neutral
Engine oil position MPa Min. 0.10 0.07
4 OFF
pressure {kg/cm2} {Min.1.0} {0.7}
P
1,700 1,700
5 Engine speed rpm
Arm IN 1,900 1,900
ON
relief kPa Max.0.98 1.96
6 Blowby pressure
{mmH2O} {Max.100} {200}
MAX
1,150 1,150
7 Engine speed All levers in 1,350 1,350
OFF the neutral rpm
8 Engine speed ON position 650 750 650 750

2. Work equipment speed

Checking condition Standard

Good
value for Service Measured

NG
No. Check item Fuel Working Unit
control mode Checking posture, etc. new limit value value
dial machine
Work equipment extended
1 Boom RAISE sec. 3.1 3.9 Max. 4.9
P fully
sec. 3.3 4.1 Max. 4.7
3 Arm IN
E sec. 3.4 4.2 Max. 4.6
Boom top horizontal
4 Arm OUT sec. 2.4 3.0 Max. 3.5
Boom top horizontal
6 Bucket CURL MAX sec. 2.3 2.9 Max. 3.3
Arm cylinder retracted fully
Work equipment extended
6 Swing (5 turns) P fully sec. 21.7 26.7 Max. 30
Swing right and left
One side of track LO sec. 46.2 56.4 Max. 60.4
Travel
5 raised and turned MI sec. 33.7 41.3 Max. 45.3
(five idle turns)
forward and backward HI sec. 25.2 27.8 Max. 29.8

3. Hydraulic drift of work equipment

Checking condition Standard
Good

value for Service Measured

NG

No. Check item Fuel Unit

control Working Checking posture, etc. new limit value value
dial mode machine
Boom top horizontal
Hydraulic drift of mm/
1 Engine stopped Arm cylinder retracted fully Max. 600 Max. 900
bucket tip 15 min
Bucket loaded

30-144 HB205-1, HB215LC-1

(01)
 145
Pm Clinic
Pm Clinic service

4. Hydraulic circuit
[1] [2] [3] [4] [5]
Checking condition 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
{600 {600 {600 {600 {60

Good
NG
No. Check item kg/cm2} kg/cm2} kg/cm2} kg/cm2} kg/cm2}
Fuel Working Auto- Operation of work F pump R pump F pump R pump
control mode deceler- equipment main main main main Control
dial ation
Self-pressure All levers in the A
1 - - - -
reducing valve neutral position
OFF
Main relief valve B B B B
2 -
(Low pressure)
Arm OUT relief
Main relief valve C C C C
3 ON -
(High pressure)
All levers in the D1 D1 D2 D2
4 Unload valve -
neutral position
Right track driven idle E1 E2
- - -
Lever moved halfway
5 LS valve MAX P
Left track driven idle E1 E2
- - -
Lever moved halfway
Right travel lock F
OFF - - - -
Main relief Right forward relief
valve Right travel lock F
- - - -
Travel motor Right reverse relief
6
Safety valve Left travel lock F
Travel junction - - - -
Left forward relief
valve Left travel lock F
- - - -
Left reverse relief

Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit source
2.93 3.43 {30 35} 2.74 3.43 {28 35}
pressure)
Standard value

B (Work equipment relief

33.8 36.3 {345 370} 33.3 36.8 {340 375}
pressure, low)
C (Work equipment relief MPa
{kg/cm2} 36.3 38.7 {370 395} 36.3 39.2 {370 400}
pressure, high)
D (Unload pressure) D1 D2 = 2.5 4.5 {26 46} D1 D2 = 2.5 4.5 {26 46}
E (LS differential pressure) E1 E2 = 1.7 1.9 {17 19} E1 E2 = 1.7 1.9 {17 19}
F (Travel relief pressure) 36.8 40.2 {375 410} 36.8 40.2 {375 410}

HB205-1, HB215LC-1 30-145

(01)
 146
Pm Clinic
Pm Clinic service

* Gauge changing work: Change hoses of gauges [3] and [4].

[1] [2] [3a] [4a] [5]
Checking condition 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
{600 {600 {600 {600 {60

Good
NG
No. Check item kg/cm2} kg/cm2} kg/cm2} kg/cm2} kg/cm2}
Fuel Working Auto- Operation of work F pump R pump F pump R pump
control mode deceler- equipment main main main main Control
dial ation
H1 H1 H2 H2
7 Servo piston MAX P OFF Arm OUT relief -

Checked oil pressure Unit Standard value for new machine Service limit value
Standard
value

H1: H2 = 1 : 0.6
H (Servo control pressure) -
(Oil pressure ratio)

* Gauge changing work: Change [3] and [4] to 6 MPa {60 kg/cm2} and change hoses of [3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Checking condition 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
{600 {600 {600 {600 {60

Good
NG
No. Check item kg/cm2} kg/cm2} kg/cm2} kg/cm2} kg/cm2}
Fuel Auto-
control Working deceler- Operation of work F pump R pump F pump R pump LS-EPC
dial mode ation equipment main main (F) (R)
J1 J1
MIN - - -
PC-EPC
P
(F) valve All levers in the J2 J2
8 - - -
PC-EPC neutral position
(R) valve J3 J3
E - - -
Travel speed: LO K1
OFF Travel lever in the - - - -
MAX neutral position
K2
Travel speed: MI
9 LS-EPC valve P - - - -
Travel lever operated
K3
Travel speed: HI
- - - -
Travel lever operated

Checked oil pressure Unit Standard value for new machine Service limit value
J1 (PC-EPC valve output
pressure 1) Approx. 2.9 {Approx. 30}
J2 (PC-EPC valve output
Approx. 0.7 {Approx. 7}
Standard value

pressure 2)
J3 (PC-EPC valve output
pressure 3) Approx. 0.78 {Approx. 8}
MPa
K1 (LS-EPC valve output {kg/cm2}
pressure 1) Approx. 2.45 {Approx. 25}
K2 (LS-EPC valve output
pressure 2) Approx. 0.74 {Approx. 7.5}
K3 (LS-EPC valve output
pressure 3) 0 {0}

30-146 HB205-1, HB215LC-1

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SEN0537731-00 40-1

HB205-1

HYDRAULIC EXCAVATOR
Shop Manual 4-01

HB205-1
HB215LC-1

Machine model Serial number

HB205-1 1001 and up
HB215LC-1 1001 and up

40 Troubleshooting 40-1

HB205-1, HB215LC-1 40-1

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Contents

Contents 40-2
40 Troubleshooting
General information on troubleshooting.................................................................................. 40- 10
Points to remember when troubleshooting .......................................................................... 40- 10
Sequence of events in troubleshooting................................................................................ 40- 11
Checks before troubleshooting ............................................................................................ 40- 12
Classification and procedures for troubleshooting ............................................................... 40- 41
Failure codes table............................................................................................................... 40- 44
Symptom and troubleshooting numbers .............................................................................. 40- 52
Information in troubleshooting table..................................................................................... 40- 55
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 57
Connector list and layout ..................................................................................................... 40- 59
Connection table for connector pin numbers ....................................................................... 40- 70
T- branch box and T- branch adapter table ......................................................................... 40- 106
Fuse location table............................................................................................................... 40- 109
Troubleshooting by failure code.............................................................................................. 40- 111
Failure code [989L00] Engine Controller Lock Caution 1 .................................................... 40- 111
Failure code [989M00] Engine Controller Lock Caution 2 ................................................... 40- 111
Failure code [989N00] Engine Controller Lock Caution 3.................................................... 40- 111-1
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40- 111-2
Failure code [AB00KE] Charge Voltage Low ....................................................................... 40- 112
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40- 114
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40- 115
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40- 116
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40- 118
Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40- 120
Failure code [CA111] ECM Critical Internal Failure ............................................................. 40- 121
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40- 121
Failure code [CA122] Chg Air Press Sensor High Error ...................................................... 40- 122
Failure code [CA123] Chg Air Press Sensor Low Error ....................................................... 40- 124
Failure code [CA131] Throttle Sensor High Error ................................................................ 40- 126
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40- 128
Failure code [CA144] Coolant Temp Sens High Error ......................................................... 40- 130
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40- 132
Failure code [CA153] Chg Air Temp Sensor High Error ...................................................... 40- 134
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 ......................................................... 40- 144
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 146
Failure code [CA234] Eng Overspeed ................................................................................. 40- 146
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 147
Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40- 148
Failure code [CA272] IMV/PCV1 Open Error....................................................................... 40- 150
Failure code [CA322] Inj #1(L#1) Open/Short Error............................................................. 40- 152
Failure code [CA324] Inj #3(L#3) Open/Short Error............................................................. 40- 154
Failure code [CA331] Inj #2(L#2) Open/Short Error............................................................. 40- 156
Failure code [CA332] Inj #4(L#4) Open/Short Error............................................................. 40- 158
Failure code [CA342] Calibration Code Incompatibility........................................................ 40- 160
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40- 161
Failure code [CA352] Sens Supply 1 Volt Low Error ........................................................... 40- 162

40-2 HB205-1, HB215LC-1

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 Contents

Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 164
Failure code [CA428] Water in Fuel Sensor High Error....................................................... 40- 166
Failure code [CA429] Water in Fuel Sensor Low Error........................................................ 40- 168
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40- 170
Failure code [CA441] Battery Voltage Low Error ................................................................. 40- 172
Failure code [CA442] Battery Voltage High Error ................................................................ 40- 174
Failure code [CA449] Rail Press Very High Error ................................................................ 40- 175
Failure code [CA451] Rail Press Sensor High Error ............................................................ 40- 176
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 178
Failure code [CA488] Chg Air Temp High Torque Derate ................................................... 40- 180
Failure code [CA553] Rail Press High Error ........................................................................ 40- 181
Failure code [CA559] Supply Pump Press Low Error 1....................................................... 40- 182
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 184
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 186
Failure code [CA757] All Continuous Data Lost Error ......................................................... 40- 187
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 188
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 191
Failure code [CA2185] Throt Sens Sup Volt High Error ...................................................... 40- 192
Failure code [CA2186] Throt Sens Sup Volt Low Error ....................................................... 40- 193
Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 194
Failure code [CA2311] IMV Solenoid Error.......................................................................... 40- 195
Failure code [CA2555] Grid Htr Relay Open Circuit Error ................................................... 40- 196
Failure code [CA2556] Grid Htr Relay Short Circuit Error ................................................... 40- 198
Failure code [D19JKZ] Personal Code Relay Abnormality .................................................. 40- 200
Failure code [D862KA] GPS Antenna Open Circuit............................................................. 40- 203
Failure code [DA22KK] Pump Solenoid Power Low Error ................................................... 40- 204
Failure code [DA25KP] 5V Sensor1 Power Abnormality ..................................................... 40- 206
Failure code [DA26KP] 5V Sensor2 Power Abnormality ..................................................... 40- 208
Failure code [DA29KQ] Model Selection Abnormality ......................................................... 40- 210
Failure code [DA2RMC] CAN Discon (Pump Con Detected) .............................................. 40- 212
Failure code [DAF8KB] Camera Power Supply Short Circuit .............................................. 40- 218
Failure code [DAFGMC] GPS Module Error ........................................................................ 40- 220
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40- 221
Failure code [DGH2KB] Hyd Oil Sensor Short .................................................................... 40- 228
Failure code [DHPAMA] Pump Press Sensor Abnormality.................................................. 40- 230
Failure code [DHPBMA] R Pump Press Sensor Abnormality .............................................. 40- 232
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ...................................................... 40- 234
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... 40- 242
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality .................................... 40- 244
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality .................................... 40- 246
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ............................. 40- 248
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit ... 40- 250
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir ............................. 40- 252
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir ................................... 40- 254
Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor signal abnormality40-256
Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor malfunction ..... 40- 257
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir .................................... 40- 258
Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor signal abnormality 40- 260
Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor malfunction ....... 40- 261
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir ................................ 40- 262
Failure code [DW43KA] Travel Speed Sol Open Circuit...................................................... 40- 264

HB205-1, HB215LC-1 40-3

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Contents

Failure code [DW43KB] Travel Speed Sol Short Circuit ...................................................... 40- 266
Failure code [DW45KA] Swing holding brake solenoid valve open circuit........................... 40- 268
Failure code [DW45KB] Swing holding brake solenoid valve short circuit........................... 40- 271
Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop............... 40- 274
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir ................................ 40- 276
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit .............................................. 40- 278
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit .............................................. 40- 280
Failure code [DW91KA] Travel Junction Sol. Disc............................................................... 40- 282
Failure code [DW91KB] Travel Junction Sol. S/C................................................................ 40- 284
Failure code [DWA2KA] Attachment Sol Open Circuit......................................................... 40- 286
Failure code [DWA2KB] Attachment Sol Short Circuit......................................................... 40- 288
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit..................................................... 40- 290
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit..................................................... 40- 292
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit......................................................... 40- 294
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit......................................................... 40- 296
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ........................................................ 40- 298
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ........................................................ 40- 300
Failure code [DXE0KA] LS-EPC Sol Open Circuit............................................................... 40- 302
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40- 304
Failure code [DXE4KA] Service Current EPC Disc.............................................................. 40- 306
Failure code [DXE4KB] Service Current EPC S/C............................................................... 40- 308
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ............................................. 40- 310
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ............................................. 40- 312
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit ................................................ 40- 314
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit................................................. 40- 316
Failure code [DY20KA] Wiper Working Abnormality............................................................ 40- 318
Failure code [DY20MA] Wiper Parking Abnormality ............................................................ 40- 320
Failure code [DY2CKA] Washer drive discon ...................................................................... 40- 322
Failure code [DY2CKB] Washer drive short......................................................................... 40- 324
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ..................................................... 40- 326
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...................................................... 40- 328
Troubleshooting by failure code [GA****] (code display)......................................................... 40- 330
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage
devices................................................................................................................................. 40- 330
Failure code [GA----] Hybrid devices monitoring items list and check sheet........................ 40- 355
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. Before Booster ......................................... 40- 364
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster........................................... 40- 365
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster....................................... 40- 366
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster ........................................... 40- 367
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster ........................................... 40- 368
Failure code [GA09KP] Low DC SW Output Volt. After Booster.......................................... 40- 369
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster ......................................... 40- 370
Failure code [GA0BKZ] AC Line Open/Short Circuit............................................................ 40- 371
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure ..................................................... 40- 372
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON ........................................... 40- 373
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF .......................................... 40- 374
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure ......................................... 40- 376
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure ......................................... 40- 378
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir ..................................... 40- 379
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure.......................................... 40- 379

40-4 HB205-1, HB215LC-1

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 Contents

Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit........................................... 40- 380
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit ............................................ 40- 380
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded ............................................... 40- 381
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure ......................................... 40- 381
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt ........................................ 40- 382
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure ................................. 40- 382
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. .................................. 40- 383
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction ........................................... 40- 383
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation ................................. 40- 384
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled........................................ 40- 384
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction ...................................... 40- 385
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure ....................................... 40- 385
Failure code [GA1FMA] Abnormal Swing Motor Driver ....................................................... 40- 386
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU .................................. 40- 386
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure ................................. 40- 387
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal................................... 40- 387
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction ...................................... 40- 388
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded ................................ 40- 388
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op........................................... 40- 389
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled..................................... 40- 389
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. ................................ 40- 390
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. ................................. 40- 390
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir................................. 40- 391
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir. ..................................... 40- 391
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir......................................... 40- 392
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat .............................................. 40- 393
Failure code [GA1SFS] Contactor Locked........................................................................... 40- 394
Failure code [GA1SMC] Contactor Failure .......................................................................... 40- 394
Failure code [GA1TKP] Capacitor Low Output Voltage....................................................... 40- 395
Failure code [GA1TNS] Capacitor Overheat ....................................................................... 40- 396
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir......................................... 40- 398
Failure code [GA1VFS] Capacitor Contactor Locked .......................................................... 40- 400
Failure code [GA1VMC] Capacitor Contactor Failure.......................................................... 40- 402
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. ..................................... 40- 403
Failure code [GA1YNS] Booster Inductor Overheat ............................................................ 40- 404
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. Mot. Dr. Temp. Sens.0 Opn/Short Cir. .................................. 40- 406
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir. .................................. 40- 406
Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality .......................................... 40- 407
Failure code [GA25NS] Gen. Motor Driver IGBT0 overheat................................................ 40- 407-1
Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality .......................................... 40- 407-2
Failure code [GA26NS] Gen. Motor Driver IGBT1 overheat................................................ 40- 408
Failure code [GA27KZ] DC before boosting sensor open or short circuit ............................ 40- 409
Failure code [GA28KZ] DC after boosting sensor open or short circuit............................... 40- 409
Failure code [GA60MC] Generator Motor Failure................................................................ 40- 410
Failure code [GA60MD] Gen. Mot. Defective Movement..................................................... 40- 411
Failure code [GA60N1] Generator Motor Overrun............................................................... 40- 412
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir....................................... 40- 414
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat ..................................... 40- 416
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir.................................... 40- 417
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir ..................................... 40- 418

HB205-1, HB215LC-1 40-5

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Contents

Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction ..................................... 40- 419
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.................................... 40- 419
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir ..................................... 40- 420
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction ..................................... 40- 420
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir.................................... 40- 421
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir. .................................... 40- 422
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction..................................... 40- 422
Failure code [GA70KB] HYB Swing Motor Short Circuit ...................................................... 40- 423
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion...................................... 40- 423
Failure code [GA70NS] HYB Swing Motor Overheat........................................................... 40- 424
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir................................... 40- 426
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction........................................ 40- 428
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.......................................... 40- 430
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. ...................................... 40- 430
Failure code [GAA100] Swing emergency stop switch operated ......................................... 40- 431
Failure code [GAA2KB] Swing Brake sol. Supply Line short cir. ......................................... 40- 432
Troubleshooting of electrical system (E-mode)....................................................................... 40- 434
E-1 Engine does not start (Engine does not crank) ............................................................. 40- 434
E-2 Preheater does not operate........................................................................................... 40- 440
E-3 When starting switch is turned to ON position, machine monitor displays nothing ....... 40- 445
E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up.
............................................................................................................................................. 40- 448
E-5 Precaution monitor lights up while engine is running .................................................... 40- 449
E-6 Emergency stop monitor lights up while engine is running ........................................... 40- 451
E-7 Fuel level gauge does not indicate properly.................................................................. 40- 452
E-8 Engine coolant temperature gauge does not indicate properly ..................................... 40- 454
E-9 Hydraulic oil temperature gauge does not indicate properly ......................................... 40- 456
E-10 HYB system temperature gauge does not indicate properly ....................................... 40- 458
E-11 Displays on machine monitor are different from those for actual machine.................. 40- 460
E-12 Machine monitor does not display some items ........................................................... 40- 460
E-13 Function switch does not work .................................................................................... 40- 460
E-14 Automatic warm-up system does not operate (in cold season)................................... 40- 461
E-15 Auto-decelerator does not operate normally ............................................................... 40- 462
E-16 Working mode does not change.................................................................................. 40- 463
E-17 Travel speed does not change .................................................................................... 40- 464
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 .......................................................... 40- 469
E-23 One-touch power max. function does not operate ...................................................... 40- 472
E-24 Travel alarm does not sound or does not stop sounding ............................................ 40- 476
E-25 Horn does not sound or does not stop sounding......................................................... 40- 478
E-26 Windshield wiper and window washer do not operate ................................................ 40- 480
E-27 "BOOM LOWER" indicator is not displayed properly with monitoring function ........... 40- 482
E-28 "ARM OUT" indicator is not displayed properly with monitoring function .................... 40- 484
E-29 "ARM IN" indicator is not displayed properly with monitoring function ........................ 40- 486
E-30 "BOOM RAISE" indicator is not displayed properly with monitoring function.............. 40- 486
E-31 "BUCKET CURL" indicator is not displayed properly with monitoring function ........... 40- 486
E-32 "BUCKET DUMP" indicator is not displayed properly with monitoring function .......... 40- 487
E-33 "SWING" indicator is not displayed properly with monitoring function ........................ 40- 487
E-34 "TRAVEL" indicator is not displayed properly with monitoring function....................... 40- 488
E-35 "TRAVEL STEERING" indicator is not displayed properly with monitoring function ... 40- 490
E-36 "SERVICE" indicator is not displayed properly with monitoring function..................... 40- 492

40-6 HB205-1, HB215LC-1

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 Contents

E-37 Attachment hydraulic circuit cannot be changed......................................................... 40- 494

E-38 KOMTRAX system does not operate properly ............................................................ 40- 495
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 496
Information in troubleshooting table (H mode)..................................................................... 40- 498
System diagram of hydraulic and mechanical system......................................................... 40- 496
H-1 Speed or power of all work equipment and travel is low ............................................... 40- 499
H-2 Engine speed lowers significantly or engine stalls........................................................ 40- 501
H-3 All work equipment and travel systems do not work ..................................................... 40- 502
H-4 Unusual noise comes out from around hydraulic pump................................................ 40- 502
H-5 Auto-decelerator does not operate ............................................................................... 40- 503
H-6 Fine control performance or response is low ................................................................ 40- 503
H-7 Speed or power of boom is low..................................................................................... 40- 504
H-8 Speed or power of arm is low ....................................................................................... 40- 505
H-9 Speed or power of bucket is low ................................................................................... 40- 506
H-10 Work equipment does not move in its single operation .............................................. 40- 506
H-11 Hydraulic drift of work equipment is large ................................................................... 40- 507
H-12 Time lag of work equipment is large ........................................................................... 40- 509
H-13 When part of work equipment is relieved singly, other parts of work equipment move 40- 509
H-14 Power maximizing function does not work .................................................................. 40- 510
H-15 In combined operation of work equipment, speed of part loaded more is low ............ 40- 510
H-16 When machine swings and travels simultaneously, travel speed is low ..................... 40- 510
H-17 Machine deviates during travel ................................................................................... 40- 511
H-18 Travel speed is low ..................................................................................................... 40- 512
H-19 Machine is not steered well or sterring power is low................................................... 40- 513
H-20 Travel speed does not shift or travel speed is low or high .......................................... 40- 514
H-21 Travel system does not work (only one side).............................................................. 40- 515
H-22 Upper structure does not swing .................................................................................. 40- 516
H-23 Swing acceleration or swing speed of upper structure is low ..................................... 40- 516
H-24 Upper structure overruns remarkably when it stops swinging .................................... 40- 516
H-25 Large shock is made when upper structure stops swinging ....................................... 40- 517
H-26 Large sound is made when upper structure stops swinging ....................................... 40- 517
H-27 Upper structure lowers largely by its own weight........................................................ 40- 517
Troubleshooting of engine (S-mode) ...................................................................................... 40- 518
Method of using troubleshooting chart................................................................................. 40- 518
S-1 Engine startability is poor .............................................................................................. 40- 522
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) ............................................................. 40- 530
S-8 Oil consumption is excessive (or exhaust gas is blue).................................................. 40- 531
S-9 Oil becomes contaminated quickly................................................................................ 40- 532
S-10 Fuel consumption is excessive ................................................................................... 40- 533
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) .................................. 40- 534
S-12 Oil pressure drops....................................................................................................... 40- 535
S-13 Oil level rises (coolant or fuel in oil) ............................................................................ 40- 536
S-14 Coolant temperature rises too high (overheating)....................................................... 40- 537
S-15 Unusual noise is made................................................................................................ 40- 538
S-16 Vibration is excessive.................................................................................................. 40- 539
Troubleshooting hybrid system (Y-mode) ............................................................................... 40- 540
Precautions related to hybrid machine ................................................................................ 40- 540
Y-1 Hybrid monitor does not go out ..................................................................................... 40- 542
Y-2 Upper structure does not swing .................................................................................... 40- 544

HB205-1, HB215LC-1 40-7

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Contents

Y-3 Swing acceleration or swing speed is low ..................................................................... 40- 546

Y-4 Upper structure overruns largely when stop swinging................................................... 40- 547
Y-5 Large shock is made when upper structure stops swinging.......................................... 40- 548
Y-6 Large unusual noise is made when upper structure stops swinging ............................. 40- 548
Y-7 Swing drift on a slope is large ....................................................................................... 40- 549
Y-8 Electric swing motor temperature increases abnormally............................................... 40- 550
Y-9 Motor-generator temperature increases abnormally ..................................................... 40- 552
Y-10 Inverter overheats ....................................................................................................... 40- 553
Y-11 Capacitor overheats .................................................................................................... 40- 554

40-8 HB205-1, HB215LC-1

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 Contents

HB205-1, HB215LC-1 40-9

(01)
General information on troubleshooting
Points to remember when troubleshooting

General information on troubleshooting 40-10

Points to remember when troubleshooting 40-10
(Rev. 2010/03)
k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are se-
curely fitted.
k When carrying out the operation with two or more service technitians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing the plug or cap from a component which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.

1. When carrying out troubleshooting, do not hurry
to disassemble the components.
If components are disassembled immediately
after any failure occurs:
q Parts that have no connection with the failure
or other unnecessary parts will be disassem-
bled.
q It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out trouble-
shooting, it is necessary to carry out thorough
prior investigation and to carry out trouble-
shooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure? When were these repairs carried
out?
6) Has the same kind of failure occurred
before?
3. Check before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance matters which can
be checked externally and are considered to
be necessary.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as
a problem with the method of operation, etc.
a When operating the machine to reenact the
troubleshooting symptoms, do not perform
any inspection or measurement that may
make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspec-
tion in Items 2 to 4 to narrow down the causes of
failure, then use the troubleshooting flowchart to
locate the failure exactly.
a The basic procedure for troubleshooting is as
follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or informa-
tion.
6. Measures to remove root cause of failure
Even if the immediate failure is removed, the
same failure may occur again, unless the root
cause of the failure is repaired. To prevent this,
always investigate why the cause of the failure
occurred. Then, remove the root cause.

40-10 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Sequence of events in troubleshooting

Sequence of events in troubleshooting 40-1

(Rev.2007.12)

HB205-1, HB215LC-1 40-11

(01)
General information on troubleshooting
Checks before troubleshooting

Checks before troubleshooting 40-12

No. Item Criterion Remedy

1 Check for abnormal sounds and smells Repair

2 Check for dirt around engine Remove

3 Check for water leakage around engine Repair

4 Check for oil leakage around engine Repair

5 Check for leakage from fuel line Repair

a: Engine, lubricating oil and coolant

6 Check of radiator for clogging Remove

7 Check of level and type of fuel Refill with oil

8 Check for foreign matter in fuel Clean and drain

9 Check of fuel pre-filter Replace

10 Check of fuel main filter Replace

Between H
11 Check of level (in oil pan) and type of engine oil Refill with oil
and L
Between H
12 Check of oil level in motor-generator case Refill with oil
and L
Between H
13 Check of coolant level (in sub tank) Refill with coolant
and L
Dust indi-
cator does
14 Check of air cleaner for clogging Clean or replace
not show
red piston.
1 Check for abnormal sounds and smells Repair

2 Check for oil leakage Repair

b: Hydraulic and mechanical equipment

Between H
3 Check of hydraulic oil level Refill with oil
and L

4 Check of hydraulic oil strainer Clean and drain

5 Check of hydraulic oil filter Replace

Between H
6 Check of swing machinery case oil level Refill with oil
and L
Between H
7 Check of oil level in electric swing motor case Refill with oil
and L

8 Check of final drive case oil level Refill with oil

9 Performing air bleeding operation Air bleeding

40-12 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Checks before troubleshooting

No. Item Criterion Remedy

1 Check of battery terminal for looseness and corrosion Retighten or replace

2 Check of alternator terminal for looseness and corrosion Retighten or replace

3 Check of starting motor terminal for looseness and corrosion Retighten or replace

4 Check of battery voltage (with engine stopped) 20 30 V Charge or replace

Between H
5 Check of battery electrolyte level Add or replace
and L

6 Check of wiring harness for discoloration, burn and cover peeling Repair or replace

7 Check of wiring harness for release from clamp and sagging Repair
c: Electrical equipment

8 Check of grounding Repair

9 Check for loose connector and damaged lock Repair or replace

10 Check of connector pin for corrosion, bends and deformation Repair or replace

Dry, clean or
11 Check for water and foreign matter in connector
replace

12 Check of wiring harness for open or short circuit Repair or replace

13 Check of fuse for blowing out and corrosion Replace

After sev-
eral min-
utes
14 Check of alternator voltage (When engine speed is medium or higher) Replace
operation:
27.5 29.5
V
Check of battery relay operation sound (when starting switch is turned to
15 Replace
ON or OFF position)

16 Check and cleaning of rear view camera Clean or repair

Monitor
d Hybrid devices

1 Check of hydraulic devices temperature lights up in Cool down engine

red
Between H
2 Check of coolant level Refill with coolant
and L
Two LEDs
3 Check of capacitor Charge
light up
f Interior parts e Exterior parts

1 Check of undercarriage Repair

2 Check of handrails and steps Repair

3 Check of mirrors Clean or repair

1 Check of gauges and monitors Clean or replace

2 Check of seat belt Repair

HB205-1, HB215LC-1 40-13

(01)
General information on troubleshooting
Checks before troubleshooting

Checking procedure before troubleshooting 40-14

Walk-around check 40-14

Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for loose arrangement, and the hot parts for accu-
mulated dust.

k Accumulated combustibles around hot engine parts such as the engine muffler and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
abnormalities.
a a1 and a2, ---, b1, b2, --- refer to the Nos. in the table on the previous page.

a1. and b1. Check for unusual sounds and
smells
Check for unusual sounds and smells.
Some causes of unusual sounds and smells can
damage the machine if they are left as they are.
Therefore, stop the machine immediately when
you find such abnormalities.
a2. Check for dirt around engine
Check for and remove any accumulated dirt
around the engine and any combustibles (dead
leaves, twigs, etc.) on hot engine parts such as
the engine muffler, turbocharger, etc.
a3. Check for water leakage around engine
a4. Check for oil leakage around engine
Check for any oil leaks from the engine and any
water leaks from the cooling system. If any of
them is defective, repair them.
a5. Check for leakage from fuel line
Check for any fuel leaks and damaged hoses
and tubes. If any of them is defective, repair
them.
a6. Check of radiator for clogging
Check for and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the radiator.
For removal of dirt from the radiator, see the
Operation and Maintenance Manual, "Cleaning
and testing of radiator fins, oil cooler fins, after-
cooler fins, fuel cooler fins and air conditioner
condenser fins (machine with the air condi-
tioner)".
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage
and hoses for cracks and excessive wear, check
that the clearances in them are within the normal
range, and then repair any failures.
b3. Check of hydraulic equipment, hydraulic
tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check for dirt around battery
Check for and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the battery.
c16. Check and cleaning of rear view camera
Check the rear view camera for any defect, and
repair any failures.
e1. Check of undercarriage (track, sprocket,
idler and guard) for abnormalities, wear,
loose bolts and oil leakage from roller.
Repair any failures.
e2. Check of handrails and steps for defect and
loose bolts
Repair any failures and retighten any loose
bolts.
e3. Check and cleaning of rear view mirrors
Check for and repair any defective and broken
rear view mirrors.
Clean the mirror surfaces and adjust their angles
so that the operator can see the area behind him
at the operator's seat.
f1. Check of gauges and monitors for defect
Check the gauges and monitors inside the oper-
ator cab. If any of them is defective, replace it.
Clean up the surfaces.
f2. Check of seat belt and mounting hardware
Check the hooks, locks and hook fittings for
damage. If any of them has a problem, repair it.

40-14 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Checks before troubleshooting

Checks according to checking procedure 40-15

a. Engine, lubricating oil and coolant 40-15

a7. Check of level and type of fuel

k Fuel is flammable and dangerous. Do not
bring any open flame near fuel.
k When adding fuel, take care not to let it over-
flow.
k Wipe off any spilt fuel. If fuel has spilt over
dirt and sand, remove the dirt and sand, too.
1. Turn the starting switch to the ON position and
check the fuel level with fuel level gauge (1) on
the monitor panel.
After checking, return the switch to the OFF posi-
tion.
q If breather hole (3) in the oil filler cap is
clogged, the pressure in the tank decreases
and fuel may not be supplied. To prevent this,
clean the breather hole.

2. If the fuel level is low, open oil filler cap (F) of the
fuel tank and add fuel through the oil filler port to
the necessary level, referring to the position of
float gauge (G).
a Height of tip (a): Approx. 50 mm
3. After adding the fuel, push float gauge (G)
straight down using oil filler cap (F) and tighten
oil filler cap (F) securely while taking care not to
pinch float gauge (G) with pawls (2) of the oil
filler cap (F).

HB205-1, HB215LC-1 40-15

(01)
General information on troubleshooting
Checks before troubleshooting
a8. Check for foreign matter in fuel
1. Open the side cover on the rear right side of the
machine.
2. Place a container under drain hose (1) to receive
the drained fuel.
3. Turn drain valve (2) to the "OPEN" position (O)
to drain the sediment and water in the bottom
together with the fuel.
4. When only the clean fuel flows out, turn drain
valve (2) to the "CLOSE" position (S).
5. Close the side cover.
40-16
a9. Check of fuel pre-filter
k Immediately after the engine is stopped, its
parts and oil is still very hot, and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure de-
creases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a spe-
cial filter with a high filtration efficiency. When re-
placing, be sure to use a Komatsu genuine
cartridge.
a The common rail fuel injection system of this ma-
chine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel filter cartridge other than Ko-
matsu genuine one is used, foreign matter may
enter, which can cause a trouble in the injection
system. Never use a substitute.
a When checking and servicing the fuel system,
be extremely careful that no foreign matter en-
ters. If any dirt sticks, remove it completely by
using fuel.
q Prepare a container to receive the fuel.
q Prepare the filter wrench.
Check of water separator, and drainage of water
and sediments
1. Turn valve (1) at the bottom of the fuel tank to the
"CLOSE" (S) position.
HB205-1, HB215LC-1
(01)

2. Open the side cover on the rear right side of the
machine.
q The water separator is integrated with fuel
pre-filter (1).
3. You can check the water level and pres-
ence/absence of sediments through transparent
cap (2). If water or sediments are found, place a
container under drain hose (3) to receive the
drained water and sediments.
4. Loosen drain valve (4) to drain the water.
5. If drain hose (3) starts to discharge fuel, close
drain valve (4) immediately.
a This machine is equipped with a sensor
which detects accumulation of water in trans-
parent cap (2).
a If water separator monitor (5) appears in red
on the machine monitor, it indicates that wa-
ter is accumulated in transparent cap (2).
Drain water from the cap.
HB205-1, HB215LC-1
(01)
General information on troubleshooting
Checks before troubleshooting
a If water in transparent cap (2) is frozen, the
water separator monitor may not appear.
And after the engine starts, if the frozen water
is melted into water due to the increased tem-
perature surrounding fuel pre-filter (1), water
separator monitor may suddenly appear.
Drain water frequently during the cold sea-
son even if water separator monitor (5) does
not appear on the machine monitor.
a If water in transparent cap (2) is frozen, drain
water only after confirming that it has com-
pletely melted.
a If you cannot visually check for the presence
of water due to stains on transparent cap (2),
clean transparent cap (2) when replacing fuel
pre-filter cartridge (1).
a When you have removed drain valve (4) for
the above cleaning process, coat the O-ring
with grease and tighten the drain valve until it
touches the bottom.
40-17
General information on troubleshooting
Checks before troubleshooting

Replacing fuel pre-filter cartridge 9. When installing the transparent cap, apply a thin
1. Turn valve (1) at the bottom of the fuel tank to the film of oil to the O-ring, set it against the sealing
"CLOSE" (S) position. surface of filter cartridge (4), and then tighten the
transparent cap 1/4 to 1/2 turn.
a If the transparent cap is over tightened, fuel
will leak because the O-ring will have been
damaged. If the transparent cap is not tight-
ened sufficiently, fuel will also leak through
the clearance around the O-ring. Therefore,
observe the tightening angle.
10. Clean the filter holder, fill the new filter cartridge
with clean fuel, apply a thin film of oil to the
O-ring, and then install the new filter cartridge
with the O-ring on the filter holder.
a Be sure to add fuel through eight small holes
(A) which are on the dirty side of the filter
without removing center cap (B).
a After filling with the fuel, remove center cap
2. Open the side cover on the rear right side of the
(B) before installing the fuel pre-filter.
machine.
a Add clean fuel taking care not to allow dirt to
3. Place a container under the fuel pre-filter
mix in it. Be sure to add fuel without removing
cartridge to receive the fuel.
center cap (B) which is on the clean side of
4. Loosen drain valve (2) and drain water and sedi-
the filter to prevent dirt from entering.
ments from transparent cup (3), and also drain
all the fuel from filter cartridge (4).
5. Disconnect connector (5). Wrap the removed
connector with a vinyl bag or the like to protect it
from being exposed to fuel, oil and water.
6. Using the filter wrench, rotate transparent cap
(3) to remove. (This cap is reused.)
7. Using the filter wrench, rotate filter cartridge (4)
to remove.
8. Install currently removed transparent cap (3) to
the bottom of the new filter cartridge.
a At this time, replace O-ring (6) with a new
one.

40-18 HB205-1, HB215LC-1

(01)

11. When installing the fuel pre-filter cartridge,
tighten it by 3/4 turn after the O-ring come in
contact with the sealing surface of the filter
holder.
a If the filter cartridge is over tightened, fuel will
leak because the O-ring is damaged. If the fil-
ter cartridge is not tightened sufficiently, fuel
will also leak through the clearance around
the O-ring. Therefore, observe the tightening
angle.
a When using a filter wrench for tightening,
take care not to damage and dent the filter.
12. Make sure that drain valve (2) is securely closed.
13. Remove the vinyl bag wrapping connector (5)
and connect connector (5).
a If connector (5) is exposed to water, the sen-
sor may malfunction, lighting up the water
separator monitor. Whenever disconnecting
connector (5), take care not to allow the con-
nector to come in contact with water.
a If connector (5) does come in contact with
water, dry it completely prior to connecting it.
HB205-1, HB215LC-1
(01)
General information on troubleshooting
Checks before troubleshooting
a10. Check of fuel man filter
k Immediately after the engine is stopped, its
parts and oil is still very hot, and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure de-
creases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a spe-
cial filter with a high filtration efficiency. When re-
placing, be sure to use a Komatsu genuine
cartridge.
a The common rail fuel injection system of this ma-
chine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel filter cartridge other than Ko-
matsu genuine one is used, foreign matter may
enter, which can cause a trouble in the injection
system. Never use a substitute.
a When checking and servicing the fuel system,
be extremely careful that no foreign matter en-
ters. If any dirt sticks, remove it completely by
using fuel.
q Prepare a container to receive the fuel.
q Prepare the filter wrench.
1. Turn valve (1) at the bottom of the fuel tank to the
"CLOSE" (S) position.
2. Open the engine hood.
3. Place a container under the filter cartridge to
receive the fuel.
40-19
General information on troubleshooting
Checks before troubleshooting
4. Using the filter wrench, rotate filter cartridge (2)
to remove.
5. Clean the filter holder. Apply a thin film of oil to
the packing of the new filter cartridge and install
the cartridge to the filter holder.
a Replace inside seal (3) with a new one.
a Do not fill the new filter cartridge with fuel.
a Remove center cap (A) before installing the
filter cartridge.
40-20
6. When installing the filter cartridge, tighten it by
3/4 turn after the O-ring comes in contact with
the sealing surface of the filter holder.
a If the filter cartridge is over tightened, fuel will
leak because the O-ring is damaged. If the fil-
ter cartridge is not tightened sufficiently, fuel
will also leak through the clearance around
the O-ring. Therefore, observe the tightening
angle.
7. Turn valve (1) at the fuel tank bottom to "OPEN"
(O) position.
8. Bleed air according to the following procedure.
1) Fill the fuel tank up with the fuel (until the float
is in the upper limit position).
2) Loosen feed pump knob (4) and draw it out
once, then push and pull it several times until
its movement becomes stiff.
q You do not need to remove the plugs at
the head of the fuel pre-filter and fuel
main filter.
q If fuel is used up, bleed air by operating
feed pump knob (4) in the same manner.
3) Push in and tighten feed pump knob (4).
9. After replacing the filter cartridge, run the engine
at low idle for approximately ten minutes.
HB205-1, HB215LC-1
(01)
 General information on troubleshooting
Checks before troubleshooting

10. Check the filter sealing surface for fuel leakage.
If fuel is leaking, check whether the filter
cartridge is appropriately tightened. If fuel
leakage recurs after the check, remove the filter
cartridge by following the steps 1 to 4 and check
the O-ring for damage or foreign matter being
caught. If any of the above problems are
detected on the O-ring, replace the cartridge
with a new one. Then, perform step 5 and after.
6. If the oil level is above line H, drain the extra
engine oil through drain valve (P) at the bottom
of the engine oil pan and check the oil level
again.
7. If the oil is at the correct level, tighten the oil filler
cap securely and close the engine hood.

a11. Check of level (in oil pan) and type of en-

gine oil
k Immediately after the engine is stopped, its
parts and oil is still very hot, and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.
a When checking the oil level after running the en-
gine, wait for at least 15 minutes after stopping
it, and check the oil level.
a When checking, set the machine in a horizontal
position.
1. Stop the engine.
2. Open the engine hood.
3. Remove dipstick (G) and wipe off oil on the
dipstick with a cloth.
4. Insert dipstick (G) fully and pull it out.

5. If the oil level is between stamped lines H and L

on dipstick (G), it is at the correct level.
If the oil level is below line L, add oil through oil
filler port (F).

HB205-1, HB215LC-1 40-21

(01)
General information on troubleshooting
Checks before troubleshooting

a12. Check of oil level in motor-generator case 6. After checking the oil level and adding oil, install
k Immediately after the engine is stopped, its dipstick (G) and oil filler cap (F).
parts and oil is still very hot, and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.
1. Remove dipstick (G) and wipe off oil on the
dipstick with a cloth.
2. Insert dipstick (G) fully into the guide.
3. Pull out dipstick (G) and check the oil level. If the
oil level is between stamp marks H and L on
dipstick (G), the level is correct.
q Before starting engine: use COLD SIDE
Between stamp marks H and
L
q 15 minutes after engine is stopped: use HOT
SIDE
Between stamp
marks H and L
4. If the oil level is below stamp mark L on dipstick
(G), remove the cap from oil filler port (F) and
add oil.
q Before starting engine: use COLD SIDE
Below stamp mark L
q 15 minutes after engine is stopped: use HOT
SIDE
Below stamp mark
L
5. If the oil level is above stamp mark H on dipstick
(G), loosen drain valve (P) to drain the excessive
oil.
q Before starting engine: use COLD SIDE
Above stamp mark H
q 15 minutes after engine is stopped: use HOT
SIDE
Above stamp mark
H
q When draining the oil, place an oil container
under drain valve (P).

40-22 HB205-1, HB215LC-1

(01)

a13. Check of coolant level (in sub tank)
k You do not need to open the radiator cap in
the ordinary check. Check the coolant at the
sub tank after the engine has cooled down.
k Immediately after the engine is stopped, the
coolant will be hot and pressure will have ac-
cumulated in the radiator.
If the cap is opened under these conditions,
you may be scalded. If you need to remove
the radiator cap, wait until the temperature
drops before you do. Then rotate the cap
slowly to release the pressure and remove it
with care.
1. Open the side cover at the rear left side of the
machine and check whether the coolant level is
between lines FULL and LOW on sub tank (1)
(see following figure). If there is not enough
coolant, add it through the coolant filler port of
sub tank (1) until the level reaches line FULL.
2. After adding the coolant, tighten the cap
securely.
3. If the sub tank is vacant, coolant may have
leaked.
After checking, repair any failures immediately. If
no failure is found, check the coolant level in the
radiator. If the level is low, add coolant to the
radiator first and then to the sub tank.
4. When you cannot check the coolant level due to
stains inside sub tank (1), clean the sub tank.
HB205-1, HB215LC-1
(01)
General information on troubleshooting
Checks before troubleshooting
a14. Check of air cleaner for clogging
k When using compressed air for cleaning, put
on personal protective items such as protec-
tive eyeglasses, gloves, dust mask, etc. to
protect yourself from dirt that will fly out.
k Removing the outer element from the air
cleaner body forcibly is dangerous .
When working in high places or on unstable
footing, you may fall off due to the reaction
when you pull out the outer element.
Checking
Clean the air cleaner element if air cleaner clogging
monitor (1) appears on the monitor panel.
a Do not clean the element until the air cleaner
clogging monitor appears on the monitor panel.
If the element is cleaned frequently before the air
cleaner clogging monitor appears on the monitor
panel, the true performance of the air cleaner will
not be realized and the filtration efficiency will
decrease.
a If the outer element is checked or cleaned while
the engine is running, the dirt sticking to it may
enter the inner element and damage the engine.
Be sure to stop the engine before cleaning.
40-23
General information on troubleshooting
Checks before troubleshooting

Cleaning of outer element

a Do not leave or store the element in direct sun-
light before or after cleaning it.
a Replace the outer element after cleaning it six
times or after using it for one year. When replac-
ing the outer element, replace the inner element,
too.
a If air cleaner clogging monitor (1) appears soon
after cleaning the outer element that has not
been cleaned up to six times, replace both the in-
ner and outer elements.
1. Open the side cover at the rear left side of the
engine and disengage four hooks (2) to remove
cover (3).
5. If dirt has piled up on vacuator valve (4) installed
on cover (3), remove it.

2. Hold and pull out outer element (5) while

swinging it up, down and laterally and rotating it
to the left and right.
6. Blow dry compressed air (Max. 0.69 MPa
a Never remove inner element (6). If it is re-
moved, dirt will enter and can lead to engine {7 kg/cm2}) along the inside pleats of the outer
troubles. element.
a Do not use a screwdriver or another tool. 7. Next, blow air along the outside pleats, and blow
a After removing outer element (5), check that again along the inside pleats.
the inner element has not come off or tilted. If
the inner element is tilted, push it in straight
by hand.
3. After removing outer element (5), cover the inner
element (6) with a clean cloth or tape to prevent
dirt from sticking to it.
4. Remove any dirt adhered to the inside of air
cleaner body (7) and cover (3) with a piece of
clean cloth, etc.
a When cleaning the element, do not tap it or
bump it against other objects.

40-24 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Checks before troubleshooting

a After cleaning, light up the inside of the ele-
ment to check it. If the element has a small
hole or a thin component, replace it.
11. Install cover (3) according to the following proce-
dure.
1) Set cover (3) to the element.
a Be sure to install cover (3) so that vacua-
tor (4) is at the bottom (A).

8. Remove the cloth or tape covering inner element

(6).
9. Check and remove any dirt, oil, etc. sticking to
the sealing surface of the cleaned or new
2) Hitch the ends of hooks (2) to the projection
element.
of air cleaner body (5) to lock.
a If the element or O-ring used for more than
a Hitch hooks (2) diagonally (top and bot-
one year is cleaned and reused, it can cause
tom, or right and left) to lock.
a trouble. Therefore, do not reuse it.
a After installing cover (3), check for clear-
a Do not use the element if its pleats, gasket or
ance between the air cleaner body and
seal is damaged.
cover (3). If there is any clearance, re-
10. Push the outer element straight into the air
move and install cover (3) correctly.
cleaner body while swinging it up, down and
laterally.
a Install the air cleaner element with its bottom
(end with no hole) (C) on cover (3) side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.

12. Peel off a seal after cleaning the element each

time.

HB205-1, HB215LC-1 40-25

(01)
General information on troubleshooting
Checks before troubleshooting
Replacement of element
1. Remove outer element (5). For details, see
"Cleaning of outer element".
2. Remove inner element (6) and install new inner
element (6) quickly to air cleaner body (7).
a Do not clean or reuse the inner element.
When replacing the outer element, also re-
place the inner element.
a Install the air cleaner element with its bottom
(end with no hole) (B) on cover (3) side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.
a If the outer element and cover are installed
while the inner element is not installed in po-
sition, the outer element may be broken. In-
stall the inner element securely.
40-26
3. Push the outer element straight into the air
cleaner body while swinging it up, down and
laterally.
a Install the air cleaner element with its bottom
(end with no hole) (B) on cover (3) side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.
4. Replace O-ring (8) of cover (3) with a new one.
5. Install cover (3). For details, see "Cleaning of
outer element".
6. Replace seal (9) of cover (3) with a new one.
HB205-1, HB215LC-1
(01)

b. Hydraulic and mechanical equipment 40-27
b3. Check of hydraulic oil level
k Immediately after the engine is stopped, its
parts and oil is still very hot, and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.
k If the oil filler cap is removed quickly, the oil
may spurt out. Loosen the oil filler cap of the
hydraulic tank slowly to release the pressure
in the hydraulic tank.
1. Set the work equipment in the posture as shown
below and, after stopping the engine, check the
oil level and add new oil if necessary.
a If the work equipment posture is not as
shown below, fully retract the cylinder rod for
the arm and bucket while running the engine
at low speed. Then lower the boom and stop
the engine when the bucket teeth touch the
ground.
2. Turn the starting switch to the ON position within
15 seconds after stopping the engine and
operate each control lever (work equipment and
travel) to the stroke end in each direction to
release the internal pressure.
HB205-1, HB215LC-1
(01)
General information on troubleshooting
Checks before troubleshooting
3. Sit down on the operator's seat and check sight
gauge (G) through the right window. If the oil
level is between lines H and L, there is sufficient
oil.
a If the oil level is below line L, add oil through
oil filter port (F).
a Do not add oil to above line H. If too much is
added, it may damage the hydraulic circuit
and spurt out.
a If the oil level is higher than line H, swing the
upper structure so that drain plug (P) at the
bottom of the tank comes between the left
and right tracks, and stop the engine. After
the hydraulic oil has cooled, remove cover (1)
and drain excessive oil through drain plug
(P).
Since the oil level fluctuates according to the oil
temperature, note the following when checking
it.
q Before operation (oil temperature: 10 -
30 C), the oil level should be at the center
between lines H and L.
q During normal operation (oil temperature: 50
- 80 C), the oil level should be near line H.
40-27
General information on troubleshooting
Checks before troubleshooting

b4. Check of hydraulic oil strainer b5. Check of hydraulic oil filter
k Immediately after the engine is stopped, its k Immediately after the engine is stopped, its
parts and oil is still very hot, and may cause parts and oil is still very hot, and may cause
burn injury. Accordingly, wait until they have burn injury. Accordingly, wait until they have
cooled down before starting the work. cooled down before starting the work.
k If the oil filler cap is removed quickly, the oil k If the oil filler cap is removed quickly, the oil
may spurt out. Loosen the oil filler cap of the may spurt out. Loosen the oil filler cap of the
hydraulic tank slowly to release the pressure hydraulic tank slowly to release the pressure
in the hydraulic tank. in the hydraulic tank.
1. Stop the engine and remove oil filler cap (F) of
the hydraulic tank to release the internal pres- 1. Park the machine on a level and firm ground, set
sure. the work equipment to the posture as shown
2. Remove the bolts to remove cover (1). below and stop the engine.
When removing the bolts, keep pressing down
cover (1) since it may be flung toward you by
spring (2).
3. Pull out rod (3) from the top, and take out spring
(2) and strainer (4).
4. Remove dirt from strainer (4) and clean it using
cleaning oil. If strainer (4) is damaged, replace it
with a new one.
5. Insert and set strainer (4) in projected portion (5)
of the tank.
6. While pressing down spring (2) with the projec-
tion at the bottom of cover (1), install the bolts.
7. Tighten the mounting bolts.
2. Remove oil filler cap (F) of the hydraulic tank to
release the internal pressure.

40-28 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Checks before troubleshooting

3. Remove the bolts to remove cover (1).

When removing the bolts, keep pressing down
cover (1) since it may be flung toward you by
spring (2).
4. Remove spring (2), valve (3), strainer (4) and
then remove element (5).
q Check the bottom of the filter case and re-
move dirt if there is. At this time, take extreme
care that dirt does not enter the hydraulic
tank.
5. Clean the removed parts using cleaning oil.
6. Install new element (5).
7. Set strainer (4), valve (3) and spring (2) on the
element.
8. Set cover (1) and install it with the mounting bolts
while pressing it with your hand.
9. Tighten the mounting bolts.

10. Install oil filler cap (F).

11. Run the engine at a low speed for 10 minutes to
bleed air.
12. Stop the engine.

b6. Check of swing machinery case oil level

k Immediately after the engine is stopped, its
parts and oil is still very hot, and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.
1. Remove dipstick (G) from oil filler port (F) for the
swing machinery and wipe off oil on the dipstick
with a cloth.
2. Insert dipstick (G) fully into the guide.
3. Pull out dipstick (G) and check the oil level. If the
oil level is between stamp marks H and L on
dipstick (G), the level is correct.
4. If the oil level is below stamp mark L on dipstick
(G), add oil through oil filler port (F). Dipstick (G)
must be removed when adding oil.
5. If the oil level is above stamp mark H on dipstick
(G), loosen drain valve (P) to drain the excessive
oil.
q When draining the oil, place an oil container
under drain valve (P).
6. After checking the oil level and adding oil, install
dipstick (G) and oil filler cap (F).

HB205-1, HB215LC-1 40-29

(01)
General information on troubleshooting
Checks before troubleshooting

b7. Check of oil level in electric swing motor

case
k Immediately after the engine is stopped, its
parts and oil is still very hot, and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.
1. Remove dipstick (J) and wipe off oil on the
dipstick with a cloth.
2. Insert dipstick (J) fully into the guide.
3. Pull out dipstick (J) and check the oil level. If the
oil level is between stamp marks H and L on
dipstick (J), the level is correct.
4. If the oil level is below stamp mark L on dipstick
(J), add oil through oil filler port (K). Dipstick (J)
must be removed when adding oil.
5. If the oil level is above stamp mark H on dipstick
(J), loosen drain valve (Q) to drain the excessive
oil.
q When draining the oil, put an oil container un-
der drain valve (Q).
6. After checking the oil level and adding oil, install
dipstick (J) and cap of oil filler port (K).

40-30 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Checks before troubleshooting

b8. Check of final drive case oil level b9. Performing air bleeding
k Since the oil may spurt out due to internal q For the procedure for bleeding air from the fuel
pressure, rotate the plug gradually from its system, see Testing and adjusting, "Bleeding air
side to release the internal pressure and then from fuel circuit".
remove it carefully. q For the procedure for bleeding air from the hy-
k Immediately after the engine is stopped, its draulic equipment, see Testing and adjusting,
parts and oil is still very hot, and may cause "Bleeding air from each part".
burn injury. Accordingly, wait until they have
cooled down before starting the work.
q Refill capacity (each side): 5.2 l
q Prepare the handle.
1. Set the final drive with TOP mark at the top, and
the straight line connecting the mark and plug (p)
is vertical to the ground surface.
2. Place a container under plug (P).
3. Remove plugs (P) and (F) using the handle to
drain oil.
a Check the O-ring attached to the plug for
damage. Replace damaged O-rings.
4. Tighten plug (P).
5. Supply oil through the hole for plug (F).
6. If oil flows out from the hole for plug (F), install
plug (F).
3 Tightening torque of Plugs (P) and (F):
68.6 9.8 Nm {7 1 kgm}
a Plug (F) is provided in two locations. To add
oil, use the hole that is easier to use or the in-
ternal gear can not be seen throught it.

HB205-1, HB215LC-1 40-31

(01)
General information on troubleshooting
Checks before troubleshooting

c. Electrical equipment 40-32 c4. Check of battery voltage (with engine

c1. Check of battery terminal for looseness and
corrosion
1. Open battery case cover (1) and remove battery
cable cap (2).
2. Check the battery cable terminals for looseness
and corrosion.
c2. Check of alternator terminal for looseness
and corrosion
q Open the hood cover.
q Check terminal B of alternator (1) for breakage,
looseness and corrosion.
c3. Check of starting motor terminal for loose-
ness and corrosion
q Check terminals B and C of starting motor (2) for
breakage, looseness and corrosion.
stopped)
Check the battery voltage by using the battery tester
while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
k Do not use the battery while its electrolyte
level is below LOWER LEVEL. If it is used un-
der that condition, its inside will deteriorate,
its service life will be shortened and it may
lead to an explosion.
k Since the battery produces combustible gas
that can explode, do not bring any open
flame near it.
k Battery electrolyte is dangerous. Take care
that it does not come in contact with your
eyes or skin. If it does, wash it away with wa-
ter and contact your doctor.
a Do not add battery electrolyte beyond the UP-
PER LEVEL mark. Excessive addition can
cause electrolyte leakage that damages the
painted surface and corrodes the parts.
a As purified water (example: commercially avail-
able battery fluid) added to the battery may
freeze, add it before starting work for the day so
that it does not freeze.
q When checking the electrolyte level through the
side face of the battery
1. Clean around the electrolyte level lines using a
cloth soaked in water, and check that the electro-
lyte level is between UPPER LEVEL (U.L.) and
LOWER LEVEL (L.L.)
a Do not clean the battery with a dry cloth since
static electricity may cause an explosion.

2. If the electrolyte level is below the center

between the U.L. and L.L. lines, remove cap (2)
and add purified water (example: commercially
available battery fluid) to the U.L. line immedi-
ately.

40-32 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Checks before troubleshooting

3. After adding the purified water, tighten cap (2)
securely.
a If you have added purified water above the
U.L. line, take some of it out using a syringe
or similar tool. Neutralize the liquid that has
been taken out with sodium bicarbonate or
other suitable liquid, and wash it out with a
large amount of water.

c6. Check of wiring harness for discoloration,

burn and cover peeling
q Check the wiring harness and cables for discol-
oration and burn.
a Discoloration and burn indicate that short circuit
or ground fault is in the circuit.
q Check the wiring harnesses and cables for dam-
age and peeling of the covers.
q If any failures are discovered, repair or replace
the wiring harness or cable.
a If you have added purified water above the
U.L. line, take some of it out using a syringe
c7. Check of wiring harness for release from
or similar tool. Neutralize the liquid that has
clamp and sagging
been taken out with sodium bicarbonate or
q Check the wiring harnesses for sagging and
other suitable liquid, and wash it out with a
loosening caused by holease from a clamp.
large amount of water.
a In particular, carefully check the wiring harness
q When electrolyte level cannot be checked
around the hot and movable parts.
through the side face of the battery
q If any part is off the clamp, resecure it to the
1. Remove cap (2) on the top of the battery.
clamp.
(Described previously)
2. Look into electrolyte level opening (3) to check
the electrolyte level. If the electrolyte level is
below sleeve (4), be sure to add purified water
(example: commercially available battery fluid)
up to the sleeve bottom (U.L. line).
q (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
q (B) Low: Since the electrolyte level does not
reach the sleeve bottom, the shape of the
electrode plates will appear straight.
3. After adding the purified water, tighten cap (2).

HB205-1, HB215LC-1 40-33

(01)
General information on troubleshooting
Checks before troubleshooting

c8. Check of grounding q Check the connection of ground terminals (T04)

a Check the ground terminal for looseness and to (T7), (T09), and (T10).
rust in particular.
q Open battery case cover (1).

q Open the engine hood.

a The connection of engine ground cannot be
q Check the connection of ground terminals (F04), checked because the counterweight needs to be
(F05), and (T08). removed for the check.
q Check the connection of ground cable (T12) of
engine controller (EC).

q Remove cover (2) from under the operator's cab.

q Remove the pump undercover.

q Check the connection of generator ground termi-
nal (GE).

40-34 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Checks before troubleshooting

q Remove control valve upper cover (3). q Check the connection of the following ground
terminals in the operator's cab.
q Terminals (T01) and (T11B)
A/C: Air conditioner unit

q Check the connection of ground terminal (T13B).

CV: Control valve

q Terminal (T02)
A/C: Air conditioner unit
a Fresh air duct removed

q Check the connection of ground terminal (T13A).

CV: Control valve

q Terminal (T11A)
a P: Pump controller

HB205-1, HB215LC-1 40-35

(01)
General information on troubleshooting
Checks before troubleshooting
c9. Check for loose connector and damaged
lock
q Pull the male and female connectors of the con-
nector by the hand to check the connection.
q If the connection is defective, fit them with each
other securely.
q Check that the connector is not unlocked and
check its lock and housing for cracks.
q Check lock screws (L) of engine controller (EC)
for looseness.
a Use a hexagonal wrench with 4 mm width
across flats.
40-36
c10. Check of connector pin for corrosion,
bends and deformation
q Disconnect the connector and check the pins for
corrosion, bends and recession. Check that the
female pins have not expanded.
q If any pin is found to be damaged, repair or re-
place it.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect several times
to shine them. (If the pins do not become shiny,
connect and disconnect the connector 10 times)
c11. Check for water and foreign matter in con-
nector
q Disconnect the connector and check for water,
dirt, sand, etc. in it.
a If sand or foreign matter is in the connector,
check the seal for damage.
q If the seal is defective, repair or replace it.
q Dry the moisture in the connector by using a dri-
er.
HB205-1, HB215LC-1
(01)
 General information on troubleshooting
Checks before troubleshooting

q Remove foreign matter in the connector by using Remove the cover at the left rear of the operator
a cloth or other material, and blow compressed seat, and the fuse holder is seen.
air against the inside of the connector.

Open the battery inspection cover, and fusible links

(F04) and (F05) are seen at F.
c12. Check of wiring harness for open or short
circuit
q Check the connection (crimped parts) between
each connector pin and wiring harness.
q If any open circuit is in wiring harness or connec-
tor as (A) in the figuer, repair or replace them.

(Detailed view of F)

q Check that any pin does not contact any adja-

cent pin due to peeling of the wire cover, defec-
tive crimping of the pin, etc.

c13. Check of fuse for blowout and corrosion

a Before replacing a fuse, be sure to turn off the
power (turn the starting switch to the OFF posi-
tion).
q A fusible link is a large-capacity fuse.
q If a fuse is corroded and coated with white pow-
der, or there is any play between the fuse and
fuse holder, replace the fuse.
q Replace each fuse with the one of the same ca-
pacity.

HB205-1, HB215LC-1 40-37

(01)
General information on troubleshooting
Checks before troubleshooting

c14. Check of alternator voltage (when engine

speed is medium or higher)
1. Open the engine hood.
2. Connect the positive (+) lead of the multimatter
to alternator terminal (B) and connect the nega-
tive (-) lead to the chassis ground.
3. Start and warm up the engine and measure the
voltage while running the engine at a medium or
a higher speed.
q If the voltage is out of the normal range, re-
pair or replace the alternator.

c15. Check of battery relay operation sound

1. Open the battery cover.
2. Check whether the battery relay operation sound
is heard when starting switch is turned to
ON/OFF position.
q If the operation sound is not heard, check the
related circuits, referring to E-1 described in
the E mode troubleshooting.
q If the related circuits are normal, replace the
battery relay.

40-38 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Checks before troubleshooting

d. Hybrid devices 40-39

d1. Check of hydraulic devices temperature

Monitor (1) appears in red when the temperature of

hydraulic devices rises to an abnormally high level.
If monitor (1) appears up in red, stop the work and
run the engine idle until the monitor disappears, or
shut down the engine.

d2. Check of coolant level

1. Open the rear door on the left side of the
machine. Check if the coolant level is within
"FULL - LOW" range of sub tank (1) (shown in
the right figure). If coolant is insufficient, add
coolant up to FULL level through the filler port on
sub tank (1).
2. After adding the coolant, tighten the cap
securely.
3. If the sub tank is empty, there may be water
leakage. If any abnormalities are found, repair
them immediately. If no abnormality is found,
check the coolant level in the radiator. If coolant
is insufficient, add coolant of the specified
concentration to the radiator, and then to the sub
tank.

HB205-1, HB215LC-1 40-39

(01)
General information on troubleshooting
Checks before troubleshooting

3. Turn the starting switch to START (C) position to

start the engine.
d3. Check of capacitor
1. Turn the starting switch to the ON (B) position.
a Important
Do not start the engine yet.

4. Look in capacitor check window (1) again.

Check that both LEDs are lit up.

2. Open the rear door on the left side of the

machine and look in capacitor check window (1).
Check that one of the LEDs is lit up.
a Supplementary explanation
The ON/OFF status of LEDs indicate the
following conditions.
q tt(both LEDs are lit up): High-voltage
output in progress
q Tt(one LED is lit up): Charged with high
voltage
q TT(both LEDs are off): Discharged (volt-
age is under 30 V)
q Both LEDs may be off if the engine was not
started for a long time.
If both LEDs are off, run the engine for about
two minutes. Then, shut down the engine
and perform the check again.

40-40 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Classification and procedures for troubleshooting

Classification and procedures for troubleshooting 40-41

Classification of troubleshooting 40-41

Mode Content
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Y-mode Troubleshooting of hybrid components

Procedure for troubleshooting 40-41

If a phenomenon which appears to be connected with machine trouble occurs on the machine, select a proper
troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting
section.

1. Procedure for troubleshooting to be taken when user code and failure code are displayed on
machine monitor:
If a user code and a failure code are displayed on the standard screen of the machine monitor, perform
the troubleshooting for the corresponding "Display of code" according to the displayed failure code.
a If multiple failures occur simultaneously, all the failure codes are displayed repeatedly in order. Note
down all the codes.

2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine
monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1].)
1) If a code is recorded, carry out troubleshooting for the "Display of code" corresponding to the recorded
code.
a If an electrical system failure code is recorded, delete all the codes once, follow the procedure to
reproduce the failure code, and then see if the failure is still detected. (See [*2].)
a A failure code of the mechanical system cannot be deleted.
a If an air conditioner abnormality record is displayed on the abnormality record screen, perform "In-
spection with self-diagnosis" in "Air conditioner". (See [*3].)
2) If no failure code is found in the abnormality record, a trouble that the machine cannot find out by itself
may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which appears to be connected with machine trouble again and
select the same phenomenon from the list on the next page, and then perform troubleshooting corre-
sponding to that phenomenon in the "E-mode", "H-mode", or "S-mode" troubleshooting.

3. Action to take after failure is eliminated

Clear all the failure codes in the electrical system abnormality record, referring to the next page.

HB205-1, HB215LC-1 40-41

(01)
General information on troubleshooting
Classification and procedures for troubleshooting
[*1], [*2]
1. While pressing numerical key [4] on the panel
switch on the standard screen, press [1], [2] and
[3] in order.
2. On the Service Menu screen, press [F3] switch
(R) on the panel switch once to select "02
Abnormality Record".
3. Press [F6] switch ( ) on the panel switch to
enter the selection and go to "Abnormality
Record" screen.
4. Press [F6] switch ( ) on the panel switch to
enter the selection and go to "Mechanical
System Abnormality Record" screen.
40-42
5. Press [F3] switch (R) on the panel switch to see
if the next failure code is displayed and note
down all of the failure codes.
a A failure code of the mechanical system can-
not be deleted.
6. Press [F5] switch (RETURN) on the panel switch
to return to "Abnormality Record" screen.
7. Enter the "Electrical System Abnormality
Record" screen similarly to steps 2 and 3.
8. Press the [F3] switch (R) on the panel switch to
see if the next failure code is displayed and note
down all of the failure codes.
a "E" on the left of a failure code indicates that
the failure is "active" (the failure remains or
restoration to normal has not been con-
firmed). A failure code having no "E" on its
left is a "non-active" one. Since it disappears
at the following clear step, be sure to note it
down.
9. While pressing numerical key [4] on the panel
switch, press [1], [2] and [3] in this order to enter
the "Clear mode". (Same as 1)
10. Press [F2] switch(CLEAR) on the panel switch.
11. Press [F6] switch ( ) on the panel switch to clear
all the failure codes.
12. Press [F5] switch (RETURN) on the panel switch
to return to "Electrical System Abnormality
Record" screen. See if any failure code is still
displayed and note down the displayed ones.
13. Press [F5] switch (RETURN) on the panel switch
to return to the "Abnormality Record" screen.
HB205-1, HB215LC-1
(01)
 General information on troubleshooting
Classification and procedures for troubleshooting

[*3]
a See steps 1 to 3 of [*1] and [*2] to enter the "Ab-
normality Record" screen.
1. On the Abnormality Record screen, press [F3]
switch (R) on the panel switch twice to select
"03 Air Conditioner Abnormality Record".
2. Press [F6] switch ( ) on the panel switch to
enter the selection and go to "Air Conditionser
Abnormality Record" screen.

3. Note down the information displayed in all fields.

a Same as the electrical system abnormality
record, the letter "E" displayed at the left side
of the status field indicates that the failure is
"active"
(the abnormality is present or its resolution is
not confirmed).
4. Press [F2] switch (CLEAR) on the panel switch
to clear all the failure codes. Check if "Abnormal"
is still displayed, and take a note. (Same as step
10 in [*1] and [*2].)
5. Press [F5] switch (RETURN) on the panel switch
to return to the "Abnormality Record" screen.

HB205-1, HB215LC-1 40-43

(01)
General information on troubleshooting
Failure codes table

Failure codes table 40-4

Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
989L00 Engine Controller Lock Caution 1 MON 40-111
system
Electrical
989M00 Engine Controller Lock Caution 2 MON 40-111
system
Electrical
989N00 Engine Controller Lock Caution 3 MON 40-111-1
system
Mechanical
AA10NX Air cleaner clogging MON 40-111-2
system
Mechanical
AB00KE Charging voltage low MON 40-112
system
Mechanical
B@BAZG Engine oil pressure low ENG 40-114
system
Mechanical
B@BAZK Engine oil level low MON 40-115
system
Mechanical
B@BCNS Engine coolant overheat ENG 40-116
system
Mechanical
B@BCZK Eng Water Level Low MON 40-118
system
Mechanical
B@HANS Hydraulic oil overheat MON 40-120
system
Electrical
CA111 Engine controller internal failure ENG E10 40-121
system
Electrical
CA115 Engine Ne and Bkup speed sensor error ENG E10 40-121
system
Electrical
CA122 Boost pressure sensor high error ENG E11 40-122
system
Electrical
CA123 Boost pressure sensor low error ENG E11 40-124
system
Electrical
CA131 Throttle sensor high error ENG E14 40-126
system
Electrical
CA132 Throttle sensor low error ENG E14 40-128
system
Electrical
CA144 Engine coolant temperature sensor high error ENG E15 40-130
system
Electrical
CA145 Engine coolant temperature sensor low error ENG E15 40-132
system
Electrical
CA153 Boost temperature sensor high error ENG E15 40-134
system
Electrical
CA154 Boost temperature sensor low error ENG E15 40-136
system
Electrical
CA155 Boost temperature high enough for speed derate ENG E11 40-138
system
Electrical
CA187 Sensor power supply 2 voltage low error ENG E15 40-140
system
Electrical
CA221 Ambient pressure sensor high error ENG E11 40-142
system
Electrical
CA222 Ambient pressure sensor low error ENG E11 40-144
system
Electrical
CA227 Sensor power supply 2 voltage high error ENG E15 40-146
system
Electrical
CA234 Eng Overspeed ENG 40-146
system
Electrical
CA238 Ne speed sensor supply voltage error ENG E15 40-147
system
Electrical
CA271 IMV/PCV1 Short Error ENG E10 40-148
system
Electrical
CA272 IMV/PCV1 Open Error ENG E10 40-150
system

40-44 HB205-1, HB215LC-1

(03)
 General information on troubleshooting
Failure codes table

Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
CA322 Inj #1 (L#1) Open/Short Error ENG E11 40-152
system
Electrical
CA324 Inj #3 (L#3) Open/Short Error ENG E11 40-154
system
Electrical
CA331 Inj #2 (L#2) Open/Short Error ENG E11 40-156
system
Electrical
CA332 Inj #4 (L#4) Open/Short Error ENG E11 40-158
system
Electrical
CA342 Calibration code incompatible ENG E10 40-160
system
Electrical
CA351 Injectors drive circuit error ENG E10 40-161
system
Electrical
CA352 Sensor power supply 1 voltage low error ENG E15 40-162
system
Electrical
CA386 Sensor power supply 1 high error ENG E15 40-164
system
Electrical
CA428 Water-in-fuel sensor high error ENG E15 40-166
system
Electrical
CA429 Water-in-fuel sensor low error ENG E15 40-168
system
Electrical
CA435 Engine oil pressure switch error ENG E15 40-170
system
Electrical
CA441 Battery voltage low error ENG E10 40-172
system
Electrical
CA442 Battery voltage high error ENG E10 40-174
system
Electrical
CA449 Common rail pressure sensor very high error ENG E11 40-175
system
Electrical
CA451 Common rail pressure sensor high error ENG E11 40-176
system
Electrical
CA452 Common rail pressure sensor low error ENG E11 40-178
system
Electrical
CA488 Boost temperature high error ENG E11 40-180
system
Electrical
CA553 Common rail pressure high error ENG E15 40-181
system
Electrical
CA559 Supply pump pressure low error 1 ENG E15 40-182
system
Electrical
CA689 Engine Ne speed sensor error ENG E15 40-184
system
Electrical
CA731 Engine Bkup speed sensor phase error ENG E15 40-186
system
Electrical
CA757 All Continuous Data Lost Error ENG E10 40-187
system
Electrical
CA778 Eng Bkup Speed Sensor Error ENG E15 40-188
system
Electrical
CA1633 KOMNET Datalink Timeout Error ENG E0E 40-191
system
Electrical
CA2185 Throttle sensor power supply voltage high error ENG E14 40-192
system
Electrical
CA2186 Throttle sensor power supply voltage low error ENG E14 40-193
system
Electrical
CA2249 Common rail pressure very low error ENG E11 40-194
system
Electrical
CA2311 IMV solenoid error ENG E11 40-195
system
Electrical
CA2555 Grid Htr Relay Open Circuit Error ENG E15 40-196
system
Electrical
CA2556 Grid Htr Relay Short Circuit Error ENG E15 40-198
system

HB205-1, HB215LC-1 40-45

(03)
General information on troubleshooting
Failure codes table

Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
D19JKZ Personal Code Relay Abnormality KOMTRAX E01 40-200
system
Electrical
D862KA GPS Antenna Open Circuit KOMTRAX 40-203
system
Electrical
DA22KK Pump Solenoid Power Low Error PUMP E0E 40-204
system
Electrical
DA25KP 5 V sensor power supply output 1 circuit abnormal. PUMP 40-206
system
Electrical
DA26KP 5V sensor power supply 2 output circuit abnormal PUMP 40-208
system
Electrical
DA29KQ Model Selection Abnormality PUMP 40-210
system
Electrical
DA2RMC CAN Discon (Pump Con Detected) PUMP E0E 40-212
system
Electrical
DAF8KB Camera power supply short circuit MON 40-218
system
Electrical
DAFGMC GPS module defective KOMTRAX 40-220
system
Electrical
DAFRMC CAN Discon (Monitor Detected) MON E0E 40-221
system
Electrical
DGH2KB Hyd Oil Sensor Short PUMP 40-228
system
Electrical
DHPAMA Pump Press Sensor Abnormality PUMP 40-230
system
Electrical
DHPBMA R Pump Press Sensor Abnormality PUMP 40-232
system
Electrical
DHS3MA Arm IN PPC sensor system malfunction PUMP 40-234
system
Bucket CURL PPC pressure sensor system mal- Electrical
DHS4MA PUMP 40-236
function system
Boom RAISE PPC pressure sensor system mal- Electrical
DHS8MA PUMP 40-238
function system
Swing RH PPC pressure sensor system open or Electrical
DHSAKZ PUMP E09 40-240
short circuit system
Swing LH PPC pressure sensor system open or Electrical
DHSBKZ PUMP E09 40-242
short circuit system
Electrical
DHSAMA Swing RH PPC Press Sensor Abnormality PUMP 40-244
system
Electrical
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP 40-246
system
Electrical
DHSDMA Bucket DUMP PPC pressure sensor malfunction PUMP 40-248
system
HYB system arm IN PPC pressure sensor open or Electrical
DHV3KZ HYB E09 40-250
short circuit system
Electrical
DHV9KZ HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir HYB E09 40-252
system
Electrical
DHVAKZ HYB Swing-R PPC Pr. Sen. Opn/Short Cir HYB E09 40-254
system
HYB swing RIGHT PPC pressure sensor signal Electrical
DHVAL8 HYB E09 40-256
abnormal system
Electrical
DHVAMA HYB system swing RH PPC sensor malfunction HYB E09 40-257
system
Electrical
DHVBKZ HYB Swing-L PPC Pr. Sen. Opn/short Cir HYB E09 40-258
system
HYB swing LEFT PPC pressure sensor signal Electrical
DHVBL8 HYB E09 40-260
abnormal system
Electrical
DHVBMA HYB system swing LH PPC sensor malfunction HYB E09 40-261
system
Electrical
DHVCKZ HYB Arm Dump PPC Pr. Sen. Opn/short Cir HYB E09 40-262
system

40-46 HB205-1, HB215LC-1

(03)
 General information on troubleshooting
Failure codes table

Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
DW43KA Travel speed selector solenoid system open circuit PUMP 40-264
system
Electrical
DW43KB Travel speed selector solenoid short circuit PUMP 40-266
system
Electrical
DW45KA Swing holding brake solenoid valve open circuit HYB E09 40-268
system
Electrical
DW45KB Swing holding brake solenoid valve short circuit HYB E09 40-271
system
Swing holding brake solenoid valve power voltage Electrical
DW45KK HYB E09 40-274
drop system
Electrical
DW45KY Swing holding brake solenoid valve hot short circuit HYB E09 40-276
system
Electrical
DW4WKA Bucket DUMP prohibit EPC solenoid open circuit PUMP E50 40-278
system
Electrical
DW4WKB Bucket DUMP prohibit EPC solenoid short circuit PUMP 40-280
system
Electrical
DW91KA Travel junction solenoid open circuit PUMP 40-282
system
Electrical
DW91KB Travel junction solenoid short circuit PUMP 40-284
system
Electrical
DWA2KA Attachment Sol Open Circuit PUMP 40-286
system
Electrical
DWA2KB Attachment Sol Short Circuit PUMP 40-288
system
Electrical
DWK0KA 2-stage relief solenoid system open circuit PUMP 40-290
system
Electrical
DWK0KB 2-stage relief solenoid system short circuit PUMP 40-292
system
Electrical
DXA8KA PC-EPC (F) Sol Open Circuit PUMP E02 40-294
system
Electrical
DXA8KB PC-EPC (F) Sol Short Circuit PUMP E02 40-296
system
Electrical
DXA9KA PC-EPC (R) Sol Open Circuit PUMP E02 40-298
system
Electrical
DXA9KB PC-EPC (R) Sol Short Circuit PUMP E02 40-300
system
Electrical
DXE0KA LS-EPC solenoid system open circuit PUMP 40-302
system
Electrical
DXE0KB LS-EPC solenoid system short circuit PUMP 40-304
system
Electrical
DXE4KA Service Current EPC Disc. PUMP 40-306
system
Electrical
DXE4KB Service Current EPC S/C PUMP 40-308
system
Electrical
DXE5KA Merge-divider main solenoid open circuit PUMP 40-310
system
Electrical
DXE5KB Merge-divider main solenoid short circuit PUMP 40-312
system
Electrical
DXE6KA Merge-divider LS Sol Open Circuit PUMP 40-314
system
Electrical
DXE6KB Merge-divider LS Sol Short Circuit PUMP 40-316
system
Electrical
DY20KA Wiper Working Abnormality PUMP 40-318
system
Electrical
DY20MA Wiper Parking Abnormality PUMP 40-320
system
Electrical
DY2CKA Window washer drive system open circuit PUMP 40-322
system
Electrical
DY2CKB Window washer drive system short circuit PUMP 40-324
system

HB205-1, HB215LC-1 40-47

(03)
General information on troubleshooting
Failure codes table

Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
DY2DKB Wiper Drive (Fwd) Short Circuit PUMP 40-326
system
Electrical
DY2EKB Wiper Drive (Rev) Short Circuit PUMP 40-328
system
Electrical
GA00NS HYB device overheat HYB E09 40-359 *
system
Electrical
GA01KA Open circuit in power cable interlock HYB E09 40-360 *
system
Electrical
GA02KZ DC Line Open/Short Circuit HYB E09 40-362 *
system
High power supply voltage error detected by hard- Electrical
GA04KG HYB E09 40-363 *
ware in DC line before booster system
High power supply voltage error detected by soft- Electrical
GA05KG HYB E09 40-364 *
ware in DC line before booster system
Electrical
GA05KP Low DC SW Output Volt. Bef. Booster HYB E09 40-365 *
system
Electrical
GA06KZ DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster HYB E09 40-366 *
system
High power supply voltage error detected by hard- Electrical
GA08KG HYB E09 40-367 *
ware in DC line after booster system
Low power supply voltage error detected by soft- Electrical
GA09KG HYB E09 40-368 *
ware in DC line after booster system
Electrical
GA09KP Low DC SW Output Volt. After Booster HYB E09 40-369 *
system
Electrical
GA0AKZ DC Volt. Sen. Op./Shrt cir. Aft. Booster HYB E09 40-370 *
system
Electrical
GA0BKZ AC Line Open/Short Circuit HYB E09 40-371 *
system
Electrical
GA12MC Malfunction of HYB controller high power supply HYB E09 40-372 *
system
Failure in voltage increase of HYB controller high Electrical
GA12NK HYB E09 40-373 *
power supply system
Failure in voltage drop of HYB controller high Electrical
GA12NL HYB E09 40-374 *
power supply system
Electrical
GA13MC Malfunction of HYB controller sensor power supply HYB E09 40-376 *
system
Electrical
GA14KR KOMNET communication error of HYB controller HYB E09 40-378
system
Electrical
GA15KZ HYB Cont. Bad Insul. Sen. Opn/Short. Cir HYB E09 40-379
system
Electrical
GA17KR Communication error of motor-generator driver HYB E09 40-379 *
system
Electrical
GA17KY Short circuit in motor-generator driver power line HYB E09 40-380 *
system
Electrical
GA17KZ Gen. Motor Driver Open/Short Circuit HYB E09 40-380 *
system
Electrical
GA17MB Reduced performance of motor-generator driver HYB E09 40-381 *
system
Malfunction of motor-generator driver excitation Electrical
GA18MC HYB E09 40-381 *
power supply system
Motor-generator driver sub-CPU power supply volt- Electrical
GA19KK HYB E09 40-382 *
age drop system
Electrical
GA19KR Gen. Motor Driver Sub-CPU Comm. Failure HYB E09 40-382 *
system
Internal failure of motor-generator driver sub-CPU Electrical
GA19KT HYB E09 40-383 *
controller system
Electrical
GA19MA Malfunction of motor-generator driver sub-CPU HYB E09 40-383 *
system
Electrical
GA19MC Malfunction of motor-generator driver sub-CPU HYB E09 40-384 *
system

40-48 HB205-1, HB215LC-1

(03)
 General information on troubleshooting
Failure codes table

Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
GA19NA Startup failure of motor-generator driver sub-CPU HYB E09 40-384
system
Malfunction of motor-generator driver DC voltage Electrical
GA1BMA HYB E09 40-385 *
sensor system
Electrical
GA1FKR Communication failure of swing motor driver HYB E09 40-385 *
system
Electrical
GA1FMA Failure of swing motor driver HYB E09 40-386 *
system
Voltage drop of swing motor driver sub-CPU power Electrical
GA1GKK HYB E09 40-386 *
supply system
Communication failure of swing motor driver Electrical
GA1GKR HYB E09 40-387 *
sub-CPU system
Internal failure of swing motor driver sub-CPU con- Electrical
GA1GKT HYB E09 40-387 *
troller system
Electrical
GA1GMA Malfunction of swing motor driver sub-CPU HYB E09 40-388 *
system
Electrical
GA1GMB Performance drop of swing motor driver sub-CPU HYB E09 40-388
system
Electrical
GA1GMC Malfunction of swing motor driver sub-CPU HYB E09 40-389 *
system
Electrical
GA1GNA Startup failure of swing motor driver sub-CPU HYB E09 40-389 *
system
Electrical
GA1HKZ Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. HYB E09 40-390
system
Electrical
GA1JKZ Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. HYB E09 40-390
system
Electrical
GA1KKZ Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir HYB E09 40-391
system
Electrical
GA1LKZ Swg Mot. Dr. Current. Sens Opn/Shrt Cir. HYB E09 40-391 *
system
Electrical
GA1MKZ Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir. HYB E09 40-392 *
system
Electrical
GA1NNS Swing Motor Driver IGBT Overheat HYB 40-393
system
Electrical
GA1SFS Contactor locked HYB E09 40-394
system
Electrical
GA1SMC Malfunction of contactor HYB E09 40-394 *
system
Electrical
GA1TKP Capacitor output voltage drop HYB E09 40-395 *
system
Electrical
GA1TNS Capacitor Low Output Voltage HYB 40-396
system
Electrical
GA1UKZ Capacitor Temp. Sensor Opn/Short Cir. HYB E09 40-398
system
Electrical
GA1VFS Capacitor contactor locked HYB E09 40-400
system
Electrical
GA1VMC Malfunction of capacitor contactor HYB E09 40-402 *
system
Open or short circuit in booster inductor tempera- Electrical
GA1XKZ HYB E09 40-403
ture sensor system
Electrical
GA1YNS Booster Inductor Overheat HYB 40-404
system
Electrical
GA1ZKZ Booster IGBT Temp. Sens. Opn/Shrt. Circ. HYB E09 40-404-1
system
Electrical
GA1ZNS Booster IGBT Temp. Sens. Overheat HYB 40-404-2
system
Electrical
GA21KB Short circuit in booster IGBT HYB E09 40-404-3 *
system
Electrical
GA22NS Booster IGBT Junction Overheat HYB 40-405
system

HB205-1, HB215LC-1 40-49

(03)
General information on troubleshooting
Failure codes table

Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
GA23KZ Gen. Mot. Dr. Temp. Sens. Opn/Short Cir. HYB E09 40-406
system
Motor-generator driver temperature sensor 1 open Electrical
GA24KZ HYB E09 40-406
or short circuit system
Electrical
GA25MA Gen. Motor Driver IGBT0 Abnormality HYB E09 40-407 *
system
Electrical
GA25NS Motor-generator driver IGBT 0 overheat HYB 40-407-1
system
Electrical
GA26MA Gen. Motor Driver IGBT1 Abnormality HYB E09 40-407-2 *
system
Electrical
GA26NS Motor-generator driver IGBT 1 overheat HYB 40-408
system
Electrical
GA27KZ DC before boosting sensor open or short circuit HYB E09 40-409
system
Electrical
GA28KZ DC after boosting sensor open or short circuit HYB E09 40-409
system
Electrical
GA60MC Malfunction of motor-generator HYB E09 40-410
system
Electrical
GA60MD Gen. Mot. Defective Movement HYB E09 40-411
system
Electrical
GA60N1 Overrun of motor-generator HYB E09 40-412 *
system
Electrical
GA61KZ Gen. Motor Temp. Sens. Open/Short Cir. HYB E09 40-414
system
Electrical
GA61NS Motor-generator temperature sensor overheat HYB 40-416
system
Short circuit in A-phase current sensor power line Electrical
GA62KY HYB E09 40-417 *
of motor-generator system
Electrical
GA62KZ Gen. Mot. Ph-A Cur. Sen. Open/Short Cir HYB E09 40-418 *
system
Malfunction of motor-generator A-phase current Electrical
GA62MA HYB E09 40-419 *
sensor system
Short circuit in B-phase current sensor power line Electrical
GA63KY HYB E09 40-419 *
of motor-generator system
Electrical
GA63KZ Gen. Mot. Ph-B Cur. Sen. Open/Short Cir HYB E09 40-420 *
system
Malfunction of motor-generator B-phase current Electrical
GA63MA HYB E09 40-420 *
sensor system
Short circuit in C-phase current sensor power line Electrical
GA64KY HYB E09 40-421 *
of motor-generator system
Electrical
GA64KZ Gen. Mot. Ph-C Cur. Sen. Open/Short Cir. HYB E09 40-422 *
system
Malfunction of motor-generator C-phase current Electrical
GA64MA HYB E09 40-422 *
sensor system
Electrical
GA70KB Short circuit in HYB swing motor HYB E09 40-423 *
system
Electrical
GA70MD Malfunction of HYB swing motor HYB E09 40-423
system
Electrical
GA70NS HYB swing motor overheat HYB 40-424 *
system
Electrical
GA71KZ HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. HYB E09 40-426 *
system
Electrical
GA72MA Malfunction of HYB swing motor resolver HYB E09 40-428 *
system
Electrical
GA72MC Malfunction of HYB swing motor resolver HYB E09 40-430 *
system
Electrical
GA81KZ Swing Motor Power Cable Opn/Shrt Circ. HYB E09 40-430 *
system
Electrical
GAA100 Swing emergency stop switch operated HYB 40-431 *
system

40-50 HB205-1, HB215LC-1

(03)
 General information on troubleshooting
Failure codes table

Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Swing holding brake solenoid power line short cir- Electrical
GAA2KB PUMP E03 40-432 *
cuit system

a In this table, failure codes are arranged in the order of characters from numeric to alphabelic character.
a A component in charge means a controller or the machine monitor that is in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PUMP: Pump controller
HYB: Hybrid controller (inverter)
KOMTRAX: KOMTRAX part of machine monitor
a The failure codes that do not have user codes in the user code columns are not displayed on the standard
screen even if a failure code is generated. They are just recorded in the abnormality record (electrical sys-
tem and mechanical system) on the service menu.
a The "Category of record" shows the abnormality record into which the failure is classified, the electrical
system or mechanical system, when it is recorded in the abnormality record of the service menu.
For details, see "Troubleshooting by failure code (Display of code)".

* If any problem occurs, the swing brake actuates suddenly and this may cause an abnormal wear on the
swing holding brake disc. Always perform the check referring to Testing and adjusting "Testing swing holding
brake".

HB205-1, HB215LC-1 40-51

(03)
General information on troubleshooting
Symptom and troubleshooting numbers

Symptom and troubleshooting numbers 40-52

Symptom and troubleshooting number
Troubleshooting
No. Symptom of failure Reference document
Index
page
User code and failure code
1 User code and failure code are displayed on machine monitor
The failure code is displayed on the mechanical system abnormality Follow the troubleshooting procedure for
2
record screen the failure code.
The failure code is displayed on the electrical system abnormality
3
record screen
The failure code is displayed on the air conditioner or heater abnor- "Inspection by self-diagnosis function" in
4
mality record screen Chapter 80

Troubleshooting
No. Symptom of failure Reference document
Index
page
Symptom related to engine
5 Engine starting performance becomes deteriorated. S-1 40-522
6 Engine does not start. E-1, S-2 40-434, 40-523
7 Engine does not pick up smoothly S-3 40-526
8 Engine stops during operation S-4, H-2 40-527, 40-501
9 Engine does not rotate smoothly (hunting) S-5 40-528
10 Engine lacks power S-6 40-529
11 Exhaust smoke is black (incomplete combustion) S-7 40-530
12 Oil consumption is too much (or exhaust smoke is blue) S-8 40-531
13 Oil becomes contaminated quickly S-9 40-532
14 Fuel consumption is excessive S-10 40-533
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11 40-534
16 Oil pressure drops S-12 40-535
17 Oil level rises (coolant or fuel in oil) S-13 40-536
18 Coolant temperature rises too high (overheating) S-14 40-537
19 Unusual noise is heard S-15 40-538
20 Vibration is excessive S-16 40-539
21 Preheater does not operate E-2 40-440
22 Automatic warm-up system does not operate (in cold season) E-14 40-461
23 Auto-decelerator does not operate normally E-15 40-462
Symptom related to hybrid system
24 Motor-generator temperature increases abnormally Y-9 40-552
25 Inverter temperature increases abnormally Y-10 40-553
26 Capacitor temperature increases abnormally Y-11 40-554
Symptom related to work equipment, swing and travel
27 All work equipment, swing and travel do not operate E-21, H-3 40-466, 40-502
28 All work equipment, swing and travel operate slowly or lack power H-1 40-499
29 Engine speed lowers significantly or engine stalls H-2, S-6 40-501, 40-529
30 Working mode does not change E-16 40-463
31 Unusual sound is heard from around hydraulic pump H-4 40-502
32 Fine control performance or response is poor H-5 40-503
Symptom related to work equipment
33 Speed or power of boom is low H-6 40-503
34 Speed or power of arm is low H-7 40-504

40-52 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Symptom and troubleshooting numbers

Troubleshooting
No. Symptom of failure Reference document
Index
page
35 Speed or power of bucket is low H-8 40-505
36 Work equipment does not move in single operation H-9 40-506
37 Hydraulic drift of work equipment is large H-10 40-506
38 Time lag of work equipment is large H-11 40-507
39 Other wok equipment moves when one of work equipment is relieved H-12 40-509
40 One-touch power maximizing function does not work.
41 Attachment circuit can not be changed E-37 40-494
Symptom related to combined operation
42 Work equipment loaded more is slower during combined operation H-14 40-510
In combined operations of swing and boom RAISE, boom rising speed
43 H-15 40-510
is low
44 Travel speed drops largely in combined operation of swing and travel H-16 40-510
Symptom related to travel
45 Machine deviates during travel H-17 40-511
46 Travel speed is low H-18 40-512
47 Machine is not steered well or steering power is low H-19 40-513
48 Travel speed does not change or travel speed is too low or high H-20, E-17 40-514, 40-464
49 Travel system does not work (only one side) H-21 40-515
50 Travel alarm does not sound or does not stop sounding E-24 40-476
Symptom related to swing
51 Upper structure does not swing H-22, Y-2 40-516, 40-544
52 Swing acceleration is poor or swing speed is low H-23, Y-3 40-516, 40-546
53 Upper structure overruns excessively when it stops swinging H-24, Y-4 40-516, 40-547
54 Large shock is made when upper structure stops swinging H-25, Y-5 40-517, 40-548
55 Large sound is made when upper structure stops swinging H-26, Y-6 40-517, 40-548
Swing brake does not operate properly 40-469, 40-517,
56 E-22, H-27, Y-7
Hydraulic drift of swing is large 40-549
57 Electric swing motor overheats Y-8 40-550
Symptom is related to machine monitor
When starting switch is turned to ON position, machine monitor dis-
58 E-3 40-445
plays nothing
When starting switch is turned to ON position (with engine stopped),
59 E-4 40-448
basic check monitor lights up
60 Precaution monitor lights up while engine is running E-5 40-449
61 Emergency stop monitor lights up while engine is running E-6 40-451
62 Engine coolant temperature gauge does not indicate properly E-8 40-454
63 Hydraulic oil temperature gauge does not indicate properly E-9 40-456
64 Fuel level gauge does not indicate properly E-7 40-452
65 Hybrid temperature gauge does not indicate normally E-10 40-458
Displays on machine monitor are different from conditions of actual
66 E-11 40-460
machine
67 Machine monitor does not display some items E-12 40-460
68 Function switch does not work E-13 40-460
69 Alarm buzzer cannot be canceled E-18 40-465
70 Service meter is not displayed with starting switch at OFF position E-19 40-465
71 Machine monitor cannot be set in service mode E-20 40-465
72 Horn does not sound or does not stop sounding E-25 40-478
73 Windshield wiper and window washer do not operate E-26 40-480

HB205-1, HB215LC-1 40-53

(01)
General information on troubleshooting
Symptom and troubleshooting numbers

Troubleshooting
No. Symptom of failure Reference document
Index
page
Air conditioner does not operate normally (including air conditioner "Testing and troubleshooting procedure" in
74
abnormality record) Chapter 80
75 Monitoring function does not display lever control signal normally E-2736 40-482 - 40-492
76 Hybrid monitor does not go off Y-1 40-542
Others
77 KOMTRAX system does not operate properly E-38 40-495

40-54 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Information in troubleshooting table

Information in troubleshooting table 40-5

(Rev. 2010/03)
a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
User code Failure code
Display on Failure name displayed on the Abnormality Record screen of the
Display on machine Failure
machine moni- machine monitor
monitor
tor
Detail of failure Description of the failure detected by the machine monitor or controller
Action of
Action to be taken to protect the system and equipment when the machine monitor or controller detects
machine moni-
a trouble
tor or controller
Problem on
Problem that appears on machine as result of action (above) taken by machine monitor or controller
machine
Related infor-
Information related to detected failure or troubleshooting
mation
Cause Procedure, measuring location, criteria and remarks
<Details of description>
q Procedure
q Measuring location
1 Defective component a "Between A and B" means the measurement of voltage, resistance or oth-
ers between terminals A and B.
q Criteria to judge probable causes (normal value)
q Remarks for judgment
<How to use troubleshooting sheet>
Open or short circuit in wiring q Perform troubleshooting procedures in numerical order.
2 q If the check result does not meet the criteria, the probable cause described
harness
on the left column is the actual cause of the failure.
q If the check result shows no abnormality, and unless otherwise specified, pro-
ceed to the next step (next cause item).
q Check that the failure is fixed after a failure was found and repaired.
Open circuit in wiring harness <Failures in wiring harness>
3 (wire breakage or defective con- q Open circuit in wiring
tact of connector) The connector connection is defective or the wire is broken.
q Ground fault
A harness not connected to ground circuit contacts the ground wiring or
machine.
q Hot short circuit
Ground fault in wiring harness A harness not connected to the power circuit (24 V) contacts with the power
4
(contact with ground circuit) circuit.
q Short circuit
An independent wire in the harness contacts with other wire.
(poor insulation at connector and others)
<Precautions for troubleshooting>
Hot short circuit (1) Connector number indication method and handling of T-adapter
5
(contact with 24 V circuit) For troubleshooting, insert or connect T-adapter as follows unless otherwise
specified.
q When "male" or "female" is not indicated with a connector number, dis-
connect the connector, and insert T-adapter between the male and fe-
male connectors.
q When "male" or "female" is indicated with a connector number, discon-
6 Short circuit in wiring harness
nect the connector, and connect T-adapter only to either male or femae
connector.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads as shown
below unless otherwise specified.
q Connect the positive (+) lead to pin or wire indicated first.
7 Defective controller q Connect the negative (-) lead to a pin or wire indicated second.

HB205-1, HB215LC-1 40-55

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General information on troubleshooting
Information in troubleshooting table

Related circuit diagram 40-56

This is the excerpted circuit diagram related to trouble-

shooting
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed

40-56 HB205-1, HB215LC-1

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 General information on troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure sensor system

Troubleshooting method for open circuit in wiring harness of pressure

sensor system 40-57

a Since pressure sensors consisting not only of resistor but also electronic circuit components such as am-
plifiers have variation in measured value and its own polarities. So troubleshooting must be performed
carefully.

Failure codes applicable to this diagnosis

q CA123: Charge air pressure sensor low error
q CA451: Common rail pressure sensor high error

Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore,
when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor
connector so that their polarities match these of the sensor.
a If measured value is infinite, take measurements by applying the probes of opposite polarities and
record the finite value obtained as a measured value.
a Since measured values may be dispersed, take several measurements.
Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times.
Consider this dispersion when judging whether the wiring harness is open in step 3.

2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller
connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side,
and connect T-adapter (4) to the harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.

3. Judging open circuit

If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is open".
a "Apparent difference" means a difference of 10 or more times.

HB205-1, HB215LC-1 40-57

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General information on troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure sensor system

List of pressure sensor measuring locations and reference values

Measuring location at sen-
Sensor Measured internal resis- Remarks
sor pin
tance of sensor (reference)
Charge pressure sen- R2: between (2) and (4) Approx. 100 z Sensor is common to engine models
sor R1: between (1) and (4) Approx. 200 z 107 and 114
Sensor is common to engine models
R2: Between (3) and (1) Approx. 23 kz
Common rail pressure 107 and 114
sensor R1: Between (1) (+) and If polarities are inverted, resistance is
Approx. 10 Mz
(2) (-) infinite

*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each
failure code)
q When measuring R2' of charge pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water sepa-
rator)
q When measuring R2' of common rail pressure sensor (CA451):
Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator)

Measurement record (For measuring locations, see circuit diagram related to each failure code.)
Sensor + Wiring harness
Sensor unit
(Measuring location on wir-
Sensor (Measuring location on sen- Measured value Measured value
ing harness side connector
sor pin side connetor)
of engine controller)
R2': Between (37) and (47)
Charge pressure sen- R2: between (2) and (4)
(*)
sor
R1: between (1) and (4) R1': Between (44) and (47)
R2': Between (37) and (47)
R2: Between (3) and (1)
Common rail pressure (*)
sensor R1: Between (1) (+) and R1': between (47)(+) and
(2) (-) (25)(-)

40-58 HB205-1, HB215LC-1

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 General information on troubleshooting
Connector list and layout

Connector list and layout 40-59

Num-
Connector No. Type ber of Equipment name Layout address
pins
A08 SWP 12 Intermediate connector I-1
A13 DT 2 Intermediate connector J-1
A15 DT 2 Intermediate connector K-9
A40 DT 4 Rear view camera I-9
A41 DT 4 Camera 2 S-1
A42 DT 4 Camera 3 S-1
A43 S 8 Rear view camera S-9
AB Terminal 2 Alternator (B terminal) AH-8
AC01 YAZAKI 8 Air conditioner unit X-5
AC02 X 1 Air conditioner compressor electromagnetic clutch AG-4
AIR(AMB. AIR
3 Ambient pressure sensor AF-2
PRESSURE)
BOOST(BOOST
SUMITOMO 4 Boost pressure and boost temperature sensor AF-4
PRESS & IMT)
C01 AMP 81 Pump controller V-9
C02 AMP 40 Pump controller W-9
CAM(CAM SEN-
3 Engine Bkup speed sensor AF-1
SOR)
CAMERA2 DT 4 Camera 2
CAMERA3 DT 4 Camera 3
CE02 DRC 50 Engine controller AF-1
CE03 DTP 4 Engine controller AG-1
CK01 AMP 14 KOMTRAX communication module X-7
CK02 AMP 10 KOMTRAX communication module X-6
CM01 070 18 Machine monitor O-6
CM02 070 12 Machine monitor O-5
CM03 070 18 Machine monitor O-5
CM04 070 12 Machine monitor O-5
CM05 070 8 Machine monitor (for camera connection) O-7
CM06 070 4 Machine monitor (GPS antenna) O-7
CRANK(CRANK
3 Engine Ne speed sensor AF-1
SENSOR)
D01 SWP 8 Diode array M-8
D02 SWP 8 Diode array M-8
D03 SWP 8 Diode array M-9
D10 M 2 Diode W-9
D11 M 2 Diode W-9
E01 Terminal 1 Electrical intake air heater (ribbon heater) AG-5
E08 X 1 Intermediate connector AF-5
E10 D 1 Intermediate connector AE-5
E12 2 Alternator (terminal IG, L) AH-8
ECM(CE01) DRC 60 Engine controller AH-1
F01 Fuse box T-9
F04 L 2 Fusible link (65 A) A-9

HB205-1, HB215LC-1 40-59

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General information on troubleshooting
Connector list and layout

Num-
Connector No. Type ber of Equipment name Layout address
pins
F05 M 2 Fusible link (30 A) A-7
GM01 DT 8 Motor-generator K-9, AJ-2
GM02 3 Motor-generator J-9
GM03 3 Motor-generator J-9
GT5 1 GPS antenna
H08 M 4 Intermediate connector
H09 M 8 Intermediate connector X-4
H15A DT 12 Intermediate connector (R.H. console) S-9
H15B DT 12 Intermediate connector (R.H. console) S-9
H16 S 12 Intermediate connector X-3
HB01 2 Capacitor L-4
HC01 DRC 24 Inverter L-4
HC02 DRC 64 Inverter L-7
HC03 3 Inverter L-6
HC04 3 Inverter L-5
HC05 3 Inverter L-5
HC06 2 Inverter L-5
HH05 DT 4 Intermediate connector (for service) X-8
HK01 DT 2 Capacitor L-3
HK02 DT 3 CAN terminating resistor L-8
HP01 DT 12 Capacitor L-4
HP03 AMP 3 Arm OUT pressure sensor A-1
HP04 AMP 3 Swing (L) pressure sensor A-2
HP05 AMP 3 Arm IN pressure sensor A-2
HP06 AMP 3 Swing (R) pressure sensor A-2
HP07 AMP 3 Boom LOWER pressure sensor A-3
HS01 Terminal - Emergency stop switch O-6
INJ1 DT 2 Injector #1 and #2 AF-4
INJ2 DT 2 Injector #3 and #4 AH-5
J01 20 Junction connector (black) X-3
J02 20 Junction connector (black) W-2
J03 20 Junction connector (green) W-3
J04 20 Junction connector (green) X-5
J05 20 Junction connector (pink) X-6
J06 20 Junction connector (orange) X-6
J1939(TOOL
3 CAN AG-1
PORT)
K01 M 2 Pump (PC) resistor O-7
L01 DT 2 Working lamp (boom) E-8
L02 DT 2 Right headlamp E-1
L03 M 2 Room lamp AA-8
Intermediate connector [revolving warning lamp/arm
L05 SWP 2 AB-9
crane specifications]
L09 DT 2 Rear working lamp [rear working lamp specification] J-9
Revolving warning lamp [revolving warning lamp/arm
L15 DT 2 AC-9
crane specifications] AG-9
M01 PA 9 Radio V-2

40-60 HB205-1, HB215LC-1

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 General information on troubleshooting
Connector list and layout

Num-
Connector No. Type ber of Equipment name Layout address
pins
M02 M 2 Speaker (L.H.) AD-8
M03 M 2 Speaker (L.H.) AC-9
M04 2 Cigarette lighter T-9
M05 M 6 Wiper motor Y-5
M06 KESO 2 Window washer motor L-2
M07 090 2 Horn (high tone) I-1
M08 090 2 Horn (low tone) H-1
M09 M 2 Optional power supply connector (1) X-3
M10 M 2 Optional power supply connector (2) X-5
M11 M 4 DC/DC converter X-4
M12 M 2 Optional power supply connector (12 V) X-4
M13 M 2 12 V socket X-5
M14 D 2 Travel alarm J-1
M40 X 2 Headlamp [machines with headlamps] Z-8
M41 X 2 Headlamp [machines with headlamps] Y-7
N08 D 12 Service connector T-9
N10 SUMITOMO 4 Air conditioner unit X-7
O.P.S(OIL PRES-
Terminal 2 Engine oil pressure switch (low pressure) AI-1
SURE SWITCH)
P01 AMP 3 Bucket CURL PPC pressure sensor C-3
P02 X 2 Boom LOWER PPC pressure switch C-3
P03 AMP 3 Swing LEFT pressure sensor C-2
P04 AMP 3 Arm IN pressure sensor C-2
P05 AMP 3 Bucket DUMP PPC pressure sensor C-2
P06 AMP 3 Boom RAISE PPC pressure sensor C-2
P07 AMP 3 Swing RIGHT pressure sensor C-3
P08 X 2 Arm DUMP PPC pressure switch C-4
P09 X 2 Travel PPC pressure switch P-1
P10 X 2 Travel steering PPC pressure switch Q-1
P13 X 2 Intermediate connector O-4
P14 X 2 Service PPC pressure switch (OP) O-1
P15 X 2 Service PPC pressure switch (OP) P-1
P17 2 Air conditioner high/low pressure switch V-2
P20 M 3 Fuel control dial P-8
P21 X 1 Fuel level sensor G-9
P22 D 2 Hydraulic oil temperature sensor AJ-3
P23 DT 2 Air cleaner clogging switch L-8
P24 X 2 Radiator coolant level switch L-3
P25 AMP 3 F pump pressure sensor K-9
P26 AMP 3 R pump pressure sensor K-9
P31 2 Air conditioner sunlight sensor O-6
P44 DT 2 Engine oil temperature sensor AF-5
P47 DT 2 Water-in-fuel sensor AJ-5
P48 DT Fuel refractive index sensor AJ4

HB205-1, HB215LC-1 40-61

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General information on troubleshooting
Connector list and layout

Num-
Connector No. Type ber of Equipment name Layout address
pins
PM01 DT 12 Swing motor H-9
PM02 3 Swing motor H-9
PUMP(PUMP
2 Supply pump solenoid (IMV) AJ-2
REGULATOR)
R01 Terminal 1 Battery relay (terminal E) A-7
R02 Terminal 1 Battery relay (terminal BR) A-8
R03 Terminal 1 Battery relay (terminal M) A-8
R03B Terminal 1 Battery relay
R04 Terminal 1 Battery relay (terminal B) A-7
R05 Relay 5 Lamp relay T-9
R06 Relay 5 Starting motor cut-off relay (PPC lock) N-9
R07 Relay 5 Starting motor cut-off relay (Personal code) N-9
R08 Relay 5 Horn relay U-9
R10 Relay 5 Rear lamp relay [machines with rear lamp] U-9
R12 Relay 5 Cab lamp relay [machines with cab lamp] T-9
Electrical intake air heater (ribbon heater) relay (coil cir-
R15 Terminal 1 B-7
cuit)
Electrical intake air heater (ribbon heater) relay (switch
R16 Terminal 1 D-7
circuit)
R17 X 2 Starting motor safety relay (terminal S, R) B-7
R18 Relay 5 Auto preheater relay V-9
R20 Relay 5 Air conditioner blower relay X-8
R21 Relay 5 Air conditioner compressor relay X-8
R22 Relay 5 Arm crane relay [arm crane specification] V-9
R23 Relay 5 Engine controller relay (1) V-9
R24 Relay 5 Engine controller relay (2) V-9
R28 Terminal 1 Starting motor safety relay (terminal C) D-9
RAIL(FUEL RAIL
3 Common rail pressure sensor AH-5
PRESS)
S01 Terminal 6 Starting switch P-7
S02 SWP 6 Light switch Q-8
S04 SWP 6 Swing lock switch Q-8
Revolving warning lamp switch [machines with revolving
S07 SWP 6 Q-8
warning lamp]
S10 090 2 R.H. knob switch P-8
S11 2 L.H. knob switch V-1
S14 M 3 PPC pressure lock switch U-1
S21 12 Emergency pump drive switch N-9
S22 6 Swing holding brake cancel switch N-9
S25 090 8 Intermediate connector O-9
S30 S 8 Model selection connector U-9
SB Terminal 2 Starting motor (terminal B) AE-7
SC Terminal 1 Starting motor (terminal C) AE-6
T01 Terminal 2 Floor frame ground W-2
T02 Terminal 1 Cab ground AD-3
T03 Terminal 1 Intermediate connector

40-62 HB205-1, HB215LC-1

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 General information on troubleshooting
Connector list and layout

Num-
Connector No. Type ber of Equipment name Layout address
pins
T03A Terminal 1 Radio body ground
T04 Terminal 1 Revolving frame ground S-1
T05 Terminal 1 Revolving frame ground T-1
T06 Terminal 1 Revolving frame ground T-1
T07 Terminal 1 Revolving frame ground U-1
T08 Terminal 1 Revolving frame ground D-8
T09 Terminal 1 Revolving frame ground U-1
T10 Terminal 1 Revolving frame ground U-1
T11A Terminal 1 Floor frame ground
T11B Terminal 1 Floor frame ground W-2
T12 Terminal 1 Engine cylinder block ground AH-1
T13A Terminal 1 C-1
T13B Terminal 1 Revolving frame ground K-2
TEMP(COOLANT
2 Engine coolant temperature sensor AF-3
TEMP)
V01 D 2 PPC lock solenoid valve G-9
V02 D 2 2-stage relief solenoid valve J-2
V03 D 2 Swing holding brake solenoid valve K-2
V04 D 2 Travel speed selector solenoid valve H-9
V05 D 2 Travel junction solenoid valve K-2
Attachment return selector solenoid valve
V06 D 2 H-9
[machine with provision for attachment]
V11 D 2 F-PC-EPC valve AJ-3
V12 D 2 R-PC-EPC valve AJ-2
V19 D 2 VLS-EPC valve AJ-4
V23 D 2 Pump merge-divider EPC valve (main) I-9
V24 D 2 Pump merge-divider EPC valve (LS) I-9
Oil flow adjuster EPC valve for attachment
V30 DT 2 O-3
[machine with provision for attachment]
W03 M 2 Window rear limit switch AC-9
WIF[E06] DT 2 Intermediate connector AI-1

HB205-1, HB215LC-1 40-63

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General information on troubleshooting
Connector list and layout

Layout of connector (1/6)

40-64 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connector list and layout

(2/6)

HB205-1, HB215LC-1 40-65

(01)
General information on troubleshooting
Connector list and layout

(3/6)

40-66 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connector list and layout

(4/6)

HB205-1, HB215LC-1 40-67

(01)
General information on troubleshooting
Connector list and layout

(5/6)

40-68 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connector list and layout

(6/6)

HB205-1, HB215LC-1 40-69

(01)
General information on troubleshooting
Connection table for connector pin numbers

Connection table for connector pin numbers 40-70

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.

40-70 HB205-1, HB215LC-1

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 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-71

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-72 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-73

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-74 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-75

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-76 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-77

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-78 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-79

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-80 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-81

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-82 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-83

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-84 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-85

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-86 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-87

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-88 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-89

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-90 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-91

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-92 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-93

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-94 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-95

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-96 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-97

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-98 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-99

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-100 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-101

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-102 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-103

(01)
General information on troubleshooting
Connection table for connector pin numbers

40-104 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Connection table for connector pin numbers

HB205-1, HB215LC-1 40-105

(01)
General information on troubleshooting
T- branch box and T- branch adapter table

T- branch box and T- branch adapter table 40-106

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal col-
umn indicates a part number of harness checker assembly.

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
Part No. Part name cati-on
symbol

799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3420 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3430 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3440 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3450 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3460 Adapter for BENDIX (MS) 10 MS-10P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3520 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3530 Adapter for BENDIX (MS) 19 MS-19P q
799-601-2910 Adapter for BENDIX (MS) 14 MS-14P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2760 Adapter for ECONO 3 ECONO3P q q
799-601-2770 Adapter for ECONO 4 ECONO4P q q
799-601-2780 Adapter for ECONO 8 ECONO8P q q
ECONO12
799-601-2790 Adapter for ECONO 12
P
q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2820 Adapter for DLI 12 DLI-12P q q
799-601-2830 Adapter for DLI 16 DLI-16P q q
ECONO12
799-601-2840 Extension cable (ECONO type) 12
P
q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7030 Adapter for X 3 X3P q q q q
799-601-7040 Adapter for X 4 X4P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799 -601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799 -601-7090 Adapter for M 2 M2P q q q q
799-601-7110 Adapter for M 3 M3P q q q q
799-601-7120 Adapter for M 4 M4P q q q q
799-601-7130 Adapter for M 6 M6P q q q q
799-601-7340 Adapter for M 8 M8P q

40-106 HB205-1, HB215LC-1

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 General information on troubleshooting
T- branch box and T- branch adapter table

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
Part No. Part name cati-on
symbol

799-601-7140 Adapter for M 8 S8P q q q q

799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601- 9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9220 Adapter for HD30-18 14 D18-14 q q
799-601-9230 Adapter for HD30-18 20 D18-20 q q
799-601-9240 Adapter for HD30-18 21 D18-21 q q
799-601-9250 Adapter for HD30-24 9 D24-9 q q
799-601-9260 Adapter for HD30-24 16 D24-16 q q
799-601-9270 Adapter for HD30-24 21 D24-21 q q
799-601-9280 Adapter for HD30-24 23 D24-23 q q
799-601-9290 Adapter for HD30-24 31 D24-31 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 P q q

HB205-1, HB215LC-1 40-107

(01)
General information on troubleshooting
T- branch box and T- branch adapter table

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
Part No. Part name cati-on
symbol

799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q

795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 q
795-799-5470 Cable for engine (HPI-T2) 3 q
795-799-5480 Cable for engine (HPI-T2) 3 q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140
Ambient pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190*
Common rail pressure
3 1, 2, 3 L q q
Socket for engine (CRI-T3)
799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4 C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3 A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3 B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1, 2, 3, G q q
Socket for engine (CRI-T3)
799-601-4340*
Pump actuator
2 2, PA q q
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
4 1, 2, 3, 4T q
799 -601-4260 Adapter for controller (ENG) 4 DTP4 q q
799 -601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 q
799-601-4280* Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 to 4 and DTM2 3, q
4
* Shows not T-adapter but socket.

40-108 HB205-1, HB215LC-1

(01)
 General information on troubleshooting
Fuse location table

Fuse location table 40-109

Connection table of fuse box 40-109

a This connection table shows the fuse box and the devices which receive the power from the fuse box ( A
switched power supply is the power source which supplies power while the starting switch is in ON position
and a continuous power supply is the power source which supplies power while the starting switch is in
OFF and ON positions).
a When performing troubleshooting related to the electrical system, check the fuses and fusible links to see
if the power is supplied properly.
Type of power Fuse
Fusible link Fuse No. Destination of power
supply capacity
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
1 10 A [When emergency pump drive switch is operated]
Swing holding brake solenoid valve
[When swing brake cancel switch is operated]
Pump controller (solenoid power supply)
2 30 A Hybrid controller (solenoid power supply)
Switched F04 Capacitor (terminal M), Inverter (terminal M)
power supply (60 A)
PPC pressure lock solenoid valve
3 10 A Starting motor cut-off relay (PPC lock)
Starting motor cut-off relay (personal code)
Cigarette lighter
4 10 A
Window washer motor
5 10 A Horn relay and horn
6 10 A Electrical intake air heater relay (ribbon heater)
7 10 A Revolving warning lamp
Switched F04 8 20 A R.H. headlamp, working lamp (boom), working lamp (rear)
power supply (60 A) Radio
9 10 A
L.H. knob switch (pump controller input)
10 10 A (Spare)
Air conditioner unit
11 20 A
Air conditioner compressor electromagnetic clutch
12 10 A (Spare)
Switched F04
13 10 A Headlamp
power supply (60 A)
14 10 A Optional power supply (1)
Travel alarm
15 10 A
Optional power supply (2)
Radio (backup power supply)
16 10 A
Room lamp
Starting switch

Continuous F05 Machine monitor, Invertor

17 20 A
power supply (30 A) Pump controller
Hybrid controller
18 10 A (Spare)
19 30 A Engine controller
Switched Starting switch
20 5A Engine controller (ACC signal), Invertor (ACC signal)
power supply ACC

HB205-1, HB215LC-1 40-109

(01)
General information on troubleshooting
Fuse location table

Locations of fusible link 40-1 0

Location of fuse box and fuse number 40-1 0

40-110 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [989L00] Engine Controller Lock Caution 1

Troubleshooting by failure code 40-1 1

Failure code [989L00] Engine Controller Lock Caution 1 40-1 1

User code Failure code Engine controller lock caution 1

Trouble
989L00 (Machine monitor system)
Failure descrip-
q Engine controller lock is detected (Factor 1).
tion
Action of
q None in particular.
machine moni-
q If cause of failure disappears, system resets itself.
tor
Problem that
appears on q Engine cannot be started.
machine
q If this failure code is displayed after machine monitor is replaced, user password must be changed
Related infor-
to one before replacement.
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Probable Cause Standard value in normal condition/Remarks on troubleshooting

causes and
standard value Replacement of machine
1 This trouble may be caused by replacement of machine monitor.
in normal con- monitor
dition

Failure code [989M00] Engine Controller Lock Caution 2 40-1 1

User code Failure code Engine controller lock caution 2

Trouble
989M00 (Machine monitor system)
Failure descrip-
q Engine controller lock is detected (Factor 2).
tion
Action of
q None in particular.
machine moni-
q If cause of failure disappears, system resets itself.
tor
Problem that
appears on q Engine cannot be started.
machine
q If this failure code is displayed after machine monitor is replaced, user password must be changed
Related infor-
to one before replacement.
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Standard value in normal condition/Remarks on troubleshooting

Probable
Replacement of machine
causes and 1 This trouble may be caused by replacement of machine monitor.
monitor
standard value
If this failure code is displayed while machine monitor is not
in normal condi-
2 Defective machine monitor replaced, machine monitor may be defective. (Since trouble is in
tion
system, troubleshooting cannot be performed.)

HB205-1, HB215LC-1 40-111

(03)
Troubleshooting by failure code
Failure code [989N00] Engine Controller Lock Caution 3

Failure code [989N00] Engine Controller Lock Caution 3 40-1 1

User code Failure code Engine controller lock caution 3

Trouble
989N00 (Machine monitor system)
Failure descrip-
q Engine controller lock is detected (Factor 3).
tion
Action of
q Tries automatic resetting.
machine moni-
q If cause of failure disappears, system resets itself.
tor
Problem that
appears on
machine
Related infor- q Method of reproducing failure code: Failure code is not reproduced since system is reset automat-
mation ically.

Probable Cause Standard value in normal condition/Remarks on troubleshooting

causes and
If this failure code is displayed repeatedly, engine controller may be
standard value
1 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot be
in normal condi-
performed.)
tion

40-111-1 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code
Failure code [AA10NX] Air Cleaner Clogging

Failure code [AA10NX] Air Cleaner Clogging 40-1 1

User code Failure code Air cleaner clogging

Failure
(Machine monitor system)
AA10NX
q Machine monitor determines that air cleaner is clogged from signal voltage from air cleaner clog-
Detail of failure
ging switch (open of switch contacts).
Action of
q Displays air cleaner clogging monitor on machine monitor.
machine moni-
q If cause of failure disappears, machine becomes normal by itself.
tor
Problem on
q If machine is operated as it is, engine may be damaged.
machine
q Input signal (ON/OFF) from air cleaner clogging switch can be checked with monitoring function.
Related infor-
(Code: 04501 Monitor input 2)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Clogging of air cleaner
Air cleaner may be clogged. Check it for clogging and then clean or replace if
1 (when system works prop-
clogged.
erly)
If no failure is found by check on cause 1, air cleaner clogging monitoring system may
Defective air cleaner clog-
2 be defective. Perform trouble shooting for "E-6 Precaution monitor lights up while
ging monitoring system
engine is running" in E-mode troubleshooting.

HB205-1, HB215LC-1 40-111-2

(03)
Troubleshooting by failure code
Failure code [AB00KE] Charge Voltage Low

Failure code [AB00KE] Charge Voltage Low 40-1 2

User code Failure code Charging voltage low

Failure
(Machine monitor system)
AB00KE
q While engine is running, machine monitor detects low charge voltage (below 7.8 V) from signal volt-
Detail of failure
age from alternator.
Action of q Displays charge level monitor red on machine monitor.
machine moni- q Even if cause of failure disappears, machine does not become normal until starting switch is turned
tor to OFF position.
Problem on
q If machine is operated as it is, battery may not be charged.
machine
q Signal voltage from alternator can be checked with monitoring function.
Related infor-
(Code: 04300 Charge voltage)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Loose alternator terminal or open 1. Turn starting switch to OFF position.
1
circuit at terminal 2. Check terminal.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector E12.
Defective generation by alternator a Connector E08 may be used for diagnosis.
2 3. Start engine.
(when system works properly)
Between E12 (1) and Engine speed: Medium
Voltage 27.5 29.5 V
ground or higher
1. Turn starting switch to OFF position.
Defective wiring harness or 2. Insert T-adapters into connector CM01.
3 3. Start engine.
machine monitor
Between CM01 (11) and ground Voltage 20 30 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness
2. Disconnect connectors CM01 and E12, and connect T-adapters to each
4 (wire breakage or defective con-
female side.
tact of connector)
Resis-
Between CM01 (female) (11) and E12 (female) (1) Max. 1 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors CM01 and E02, and connect T-adapters to either
5
(contact with ground circuit) female side.
Between CM01 (female) (11) or E12 (female) (1) Resis-
Min. 1 Mz
and ground tance
If no failure is found by above checks, machine monitor is defective. (Since
6 Defective machine monitor
this is an internal defect, troubleshooting cannot be performed.)

40-112 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [AB00KE] Charge Voltage Low

Electrical diagram related to charging cricuit 40-1 3

HB205-1, HB215LC-1 40-113

(01)
Troubleshooting by failure code
Failure code [B@BAZG] Eng Oil Press Low

Failure code [B@BAZG] Eng Oil Press Low 40-1 4

User code Failure code Engine oil pressure low
Failure
(Engine controller system)
B@BAZG
q While engine is running, engine controller detects engine oil pressure drop (sensor contact is
Detail of failure
closed) from signal voltage of engine oil pressure switch.
Action of con- q Displays engine oil pressure monitor red on machine monitor.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q If machine is operated as it is, engine may be damaged.
machine
q Signal from engine oil pressure switch is input to engine controller. If engine oil pressure switch is
Related infor- determined to be closed (ON) while engine is running, engine controller transmitts this signal to
mation machine monitor to display this failure code.
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Dropped engine oil pres-
1 sure (when system works Engine oil pressure may be low. Check it and remove cause if it is low.
properly)
If no failure is found by check on cause 1, engine oil pressure monitoring system may
Defective engine oil pres-
2 be defective. Perform troubleshooting for "E-6 Emergency stop monitor lights up while
sure monitoring system
engine is running".

40-114 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [B@BAZK] Eng Oil Level Low

Failure code [B@BAZK] Eng Oil Level Low 40-1 5

User code Failure code Engine oil level low

Failure
(Machine monitor system)
B@BAZK
q While engine is running, signal voltage from engine oil level switch does not remain below 1 V, so
Detail of failure
machine monitor determines that engine oil level is low (oil level switch is open).
Action of con-
q Displays engine oil level monitor red on machine monitor.
troller
Problem on
q If machine is operated as it is, engine may seize up.
machine
q Input (ON/OFF) from engine oil level switch can be checked with monitoring function.
Related infor-
(Code: 04501 Monitor input 2)
mation
q Method of reproducing failure code: Start engine

Cause Procedure, measuring location, criteria and remarks

Lowered engine oil level (when
1 Check engine oil level. If it is low, remove cause.
system works properly)
1. Turn starting switch to OFF position.
Defective engine oil level switch 2. Disconnect connector P44.
2 3. Turn starting switch to ON position.
(internal defect)
Between P44 (male) (1) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors CM02 and P44, and connect T-adapters to each
3 (wire breakage or defective con- female side.
tact of connector)
Between CM02 (female) (2) and P44 (female) (1) Resistance Max. 1 z
If no failure is found by above checks, machine monitor is defective.
q Reference
1. Turn starting switch to OFF position.
4 Defective machine monitor 2. Insert T-adapters into connectors CM01 and CM02.
3. Turn starting switch to ON position.
Between CM02 (2) and CM01 (3) Voltage Max. 1 V

Circuit diagram related to engine oil level switch40-1 5

HB205-1, HB215LC-1 40-115

(01)
Troubleshooting by failure code
Failure code [B@BCNS] Eng Water Overheat

Failure code [B@BCNS] Eng Water Overheat 40-1 6

User code Failure code Engine coolant overheat
Failure
(Engine controller system)
B@BCNS
q While engine is running, engine controller detects overheating of engine coolant (above approx.
Detail of failure
105 C) from signal of engine coolant temperature sensor.
Action of con- q Displays engine coolant temperature monitor red on machine monitor.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q If machine is operated as it is, engine may seize up.
machine

q Signal from engine coolant temperature sensor is input to engine controller and then data is trans-
mitted to machine monitor through CAN communication system.
Related infor-
q Engine coolant temperature can be checked with monitoring function.
mation
(Code: 04107 Engine coolant temperature)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Overheating of engine cool-
1 ant (when system works Engine coolant may overheat. Check it and remove cause if it overheats.
properly)
Defective engine coolant If no failure is found by check on cause 1, engine coolant temperature monitoring
2 temperature monitoring sys- system may be defective. Perform troubleshooting for "E-8 Engine coolant tempera-
tem ture gauge does not indicate properly".

40-116 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code
Failure code [B@BCNS] Eng Water Overheat

HB205-1, HB215LC-1 40-117

(01)
Troubleshooting by failure code
Failure code [B@BCZK] Eng Water Level Low

Failure code [B@BCZK] Eng Water Level Low 40-1 8

User code Failure code Radiator coolant level low

Failure
(Machine monitor system)
B@BCZK
q While starting switch is at ON position (with engine stopped) or engine is running, radiator coolant
Detail of failure level switch signal voltage does not remain below 1 V, so machine monitor determines that radiator
coolant level is low (sensor contact is open).
Action of con-
q Displays radiator coolant level monitor red on machine monitor.
troller
Problem on
q If machine is operated as it is, engine may overheat.
machine
q Input (ON/OFF) from radiator coolant level switch can be checked with monitoring function.
Related infor-
(Code: 04500 Monitor input 1)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Lowered radiator coolant level Check radiator sub tank for lowering of coolant level. If coolant level is low, add
1
(when system works properly) coolant.
1. Turn starting switch to OFF position.
2. Disconnect connector P24 and connect T-adapters to male side.
Defective coolant level switch Between FULL
2 Resistance Max. 1 z
(internal defect) Between P24 (male) (1) and and LOW lines
(2) Below LOW
Resistance Min. 1 Mz
line
1. Turn starting switch to OFF position.
2. Disconnect connectors CM02 and P24, and connect T-adapters to each
Open circuit in wiring harness female side.
3
(open circuit or defective contact) Between CM02 (female) (3) and P24 Resistance Max. 1 z
(female) (1)
Between P24 (female) (2) and ground Resistance Max. 1 z
If no failure is found by above checks, machine monitor is defective.
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector CM02.
3. Turn starting switch to ON position.
4 Defective machine monitor
Between FULL
Voltage Max. 1 V
Between CM02 (3) and and LOW lines
CM01 (3) Below LOW
Voltage 7 11 V
line

40-118 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [B@BCZK] Eng Water Level Low

Circuit diagram related to radiator coolant level switch 40-1 9

HB205-1, HB215LC-1 40-119

(01)
Troubleshooting by failure code
Failure code [B@HANS] Hyd Oil Overheat

Failure code [B@HANS] Hyd Oil Overheat 40-120

User code Failure code Hydraulic oil overheat
Failure
(Pump controller system)
B@HANS
q While engine is running, overheating of hydraulic oil (above approx. 102 C) is detected from signal
Detail of failure
voltage of hydraulic oil temperature sensor.
Action of con- q Displays hydraulic oil temperature monitor red on machine monitor.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q If machine is operated as it is, hydraulic components may be damaged.
machine
q Signal from hydraulic oil temperature sensor is input to pump controller and then data is transmitted
to machine monitor through CAN communication system.
Related infor- q Hydraulic oil temperature can be checked with monitoring function.
mation (Code: 04401 Hydraulic oil temperature)
q See "E-9 Hydraulic oil temperature gauge does not display normally" in E-mode troubleshooting.
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Overheating of hydraulic oil
1 Hydraulic oil may overheat. Check it and remove cause if it overheats
(when system works properly)
Defective hydraulic oil tempera- If no failure is found by check on cause 1, hydraulic oil temperature monitoring
2
ture monitoring system system may be defective. Perform troubleshooting for failure code [DGH2KB].

40-120 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA111] ECM Critical Internal Failure

Failure code [CA111] ECM Critical Internal Failure 40-121

User code Failure code Engine controller internal failure

Failure
(Engine controller system)
E10 CA111
Detail of failure q Memory or power supply circuit in engine controller is defective.
Action of con-
q None in particular
troller
Problem on
q Engine may stop during operation or may not be able to start.
machine
q Power supply voltage of engine controller can be checked with moniitoring funtion.
Related infor-
(Code: 03203 Battery voltage)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code appears, perform troubleshooting for it.

2 Perform troubleshooting for failure code [CA441].

Failure code [CA115] Eng Ne and Bkup Speed Sens Error 40-121

User code Failure code Engine Ne and Bkup speed sensor error
Failure
(Engine controller system)
E10 CA115
Detail of failure q Signals from both engine Ne and Bkup speed sensors are abnormal.
Action of con-
q None in particular
troller
Problem on q Engine stops.
machine q Engine does not start
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective connection of sensorConnectors of Ne speed sensor and Bkup speed sensor may be connected
1
connector defectively (wrong connection). Check them directly.
Perform troubleshooting for troubleshooting Nos. 1 to 10 of failure code
2 Defective Ne speed sensor system
[CA689].
Defective Bkup speed sensor sys-
3 Perform troubleshooting for failure code [CA778].
tem
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is an internal defect, troubleshooting cannot be performed.)

HB205-1, HB215LC-1 40-121

(01)
Troubleshooting by failure code
Failure code [CA122] Chg Air Press Sensor High Error

Failure code [CA122] Chg Air Press Sensor High Error 40-12

User code Failure code Boost pressure sensor high error

Failure
(Engine controller system)
E11 CA122
Detail of failure q High voltage appears in signal circuit of boost pressure & temperature sensor.
Action of con-
q Takes boost pressure to be at fixed value and allows engine to run.
troller
Problem on
q Engine output lowers.
machine
q Input voltage from boost pressure sensor can be checked with monitoring function.
(Code: 36501 (V))
q Boost pressure sensed by boost pressure sensor can be checked with monitoring function.
Related infor-
(Code: 36500 (kPa))
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal con-
dition.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective sensor power supply 2
2 If failure code [CA227] is also displayed, perform troubleshooting for it first.
line
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST.
3. Turn starting switch to ON position.
Defective boost pressure & tem-
3 If failure code changes from [CA122] to [CA123] ,boost pressure sensor is
perature sensor
defective.
a Failure code [CA153] for temperature sensor is displayed at the same time.
Ignore this failure code since it appears because of disconnection of sensor.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and BOOST and connect T-adapters to
4 Short circuit in wiring harness female side of ECM.
Between ECM (female) (37) and (44) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector BOOST and insert T-adapters into connector ECM.
5 3. Turn starting switch to ON position (with connector BOOST disconnected).
(contact with 24 V circuit)
Between ECM (44) and (47) Voltage Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this
6 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

40-122 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA122] Chg Air Press Sensor High Error

Circuit diagram related to boost pressure sensor 40-123

HB205-1, HB215LC-1 40-123

(01)
Troubleshooting by failure code
Failure code [CA123] Chg Air Press Sensor Low Error

Failure code [CA123] Chg Air Press Sensor Low Error 40-124

User code Failure code Boost pressure sensor low error

Failure
(Engine controller system)
E11 CA123
Detail of failure q Low voltage appears in pressure signal circuit of boost pressure & temperature sensor.
Action of con-
q Takes boost pressure to be at fixed value and allows engine to run.
troller
Problem on
q Engine output lowers.
machine
q Input voltage from boost pressure sensor can be checked with monitoring function.
(Code: 36501 (V))
q Boost pressure sensed by boost pressure sensor can be checked with function.
(Code: 36500 (kPa))
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for
checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).
q If sensor connector is disconnected, this failure code is displayed.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective power supply system of If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it
2
boost pressure sensor first.
1. Turn starting switch to OFF position.
2. Disconnect connectors CAM, RAIL, BOOST, amd ECM.
3. Connect T-adapters to female side of ECM.
3 Short circuit in wiring harness
Between ECM (female) (37) and (47) Resistance Min. 100 kz
Between ECM (female) (44) and (47) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and BOOST and connect T-adapters to
4 female side of ECM.
(contact with ground circuit)
Between ECM (female) (44) and ground Resistance Min. 100 kz
If no failure is found by above checks, there may be open circuit in wiring har-
5 Open circuit in wiring harness
ness. (*)
a If no failure is found by checks on causes 1 - 5 and check result on cause 6
is abnormal, sensor is defective.
Defective boost pressure & tem-
1. Turn starting switch to OFF position.
perature sensor
6 2. Insert T-adapters to connector ECM.
(improper input voltage to engine
3. Turn starting switch to ON position.
controller)
Sensor out-
Between ECM (44) and (47) Voltage 0.3 4.7 V
put
If no failure is found by above checks, engine controller is defective. (Since this
7 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General in-
formation on troubleshooting".

40-124 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA123] Chg Air Press Sensor Low Error

Circuit diagram related to boost pressure sensor 40-125

HB205-1, HB215LC-1 40-125

(01)
Troubleshooting by failure code
Failure code [CA131] Throttle Sensor High Error

Failure code [CA131] Throttle Sensor High Error 40-126

User code Failure code Throttle sensor high error

Failure
(Engine controller system)
E14 CA131
Detail of failure q High voltage appears in fuel control dial circuit.
q Uses throttle value obtained before failure detection to run engine if failure is detected with starting
Action of con-
switch at ON position.
troller
q Uses full throttle value to run engine if starting switch is set to ON position after failure detection.
Problem on
q Engine speed cannot be controlled by using fuel control dial.
machine
q Signal voltage from fuel control dial can be checked with monitoring function.
Related infor-
(Code: 03000 Fuel control dial voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equip-
Defective wiring harness connec-
1 ment"of "Checks before troubleshooting" in "General information on trouble-
tor
shooting", and check them directly.
Defective throttle sensor power
2 If failure code [CA2185] is also displayed, perform troubleshooting for it first.
supply system
1. Turn starting switch to OFF position.
2. Disconnect connector P20 and connect T-adapters to male side.
Defective fuel control dial (throttle Between P20 (male) (1) and (3) Resistance 4.0 6.0 kz
3
sensor)
Between P20 (male) (2) and (3) Resistance 0.25 5.0 kz
Between P20 (male) (1) and (2) Resistance 0.25 5.0 kz
1. Turn starting switch to OFF position.
2. Disconnect connector CE02, and connect T-adapters to female side.
Open or short circuit in wiring har-
4
ness Between CE02 (famale) (22) and (23) Resistance 4.0 6.0 kz
Between CE02 (famale) (9) and (23) Resistance 0.25 5.0 kz
a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapters to either
5 Short circuit in wiring harness female side.
Between CE02 (female) (9) and (22), or
Resistance Min. 1 Mz
between P20 (female) (1) and (2)
1. Turn starting switch to OFF position.
Hot short circuit in harness 2. Disconnect connector P20 and connect T-adapters to female side.
6 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between P20 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector CE02.
7 Defective engine controller
3. Turn starting switch to ON position.
4. Operate fuel control dial and perform troubleshooting.
Between CE02 (22) and (23) Power supply Voltage 4.75 5.25 V
Between CE02 (9) and (23) Sensor output Voltage 0.5 4.5 V

40-126 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA131] Throttle Sensor High Error

Circuit diagram related to throttle sensor 40-127

HB205-1, HB215LC-1 40-127

(01)
Troubleshooting by failure code
Failure code [CA132] Throttle Sensor Low Error

Failure code [CA132] Throttle Sensor Low Error 40-128

User code Failure code Throttle sensor low error

Failure
(Engine controller system)
E14 CA132
Detail of failure q Low voltage appears in fuel control dial circuit.
q Uses throttle value obtained before failure detection to run engine if failure is detected with starting
Action of con-
switch at ON position.
troller
q Uses full throttle value to run engine if starting switch is set to ON position after failure detection.
Problem on
q Engine speed cannot be controlled by using fuel control dial.
machine
q Signal voltage from fuel control dial can be checked with monitoring function.
Related infor-
(Code: 03000 Fuel control dial votage)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equip-
Defective wiring harness connec-
1 ment"of "Checks before troubleshooting" in "General information on trouble-
tor
shooting", and check them directly.
Defective throttle sensor power
2 If failure code [CA2186] is also displayed, perform troubleshooting for it first.
supply system
1. Turn starting switch to OFF position.
2. Disconnect connector P20 and connect T-adapters to male side.
Defective fuel control dial (throttle Between P20 (male) (1) and (3) Resistance 4.0 6.0 kz
3
sensor)
Between P20 (male) (2) and (3) Resistance 0.25 5.0 kz
Between P20 (male) (1) and (2) Resistance 0.25 5.0 kz
1. Turn starting switch to OFF position.
2. Disconnect connector CE02, and connect T-adapters to female side.
Open or short circuit in wiring har-
4
ness Between CE02 (famale) (22) and (23) Resistance 4.0 6.0 kz
Between CE02 (famale) (9) and (23) Resistance 0.25 5.0 kz
a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapters to each
female side .
Open circuit in wiring harness
Between CE02 (female) (22) and P20
5 (wire breakage or defective con- Resistance Max. 1 z
(female) (1)
tact of connector)
Between CE02 (female) (9) and P20 (female)
Resistance Max. 1 z
(2)
Between CE02 (female) (23) and P20
Resistance Max. 1 z
(female) (3)
a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapters to either
6 Short circuit in wiring harness female side.
Between CE02 (female) (9) and (23), or
Resistance Min. 1 Mz
between P20 (female) (2) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapters to either
Ground fault of wiring harness female side.
7
(contact with ground circuit)
Between CE02 (female) (9) or P20 (female)
Resistance Min. 1 Mz
(2) and ground

40-128 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA132] Throttle Sensor Low Error

Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector CE02.
8 Defective engine controller
3. Turn starting switch to ON position.
4. Operate fuel control dial and perform troubleshooting.
Between CE02 (22) and (23) Power supply Voltage 4.75 5.25 V
Between CE02 (9) and (23) Sensor output Voltage 0.5 4.5 V

Circuit diagram related to throttle sensor 40-129

HB205-1, HB215LC-1 40-129

(01)
Troubleshooting by failure code
Failure code [CA144] Coolant Temp Sens High Error

Failure code [CA144] Coolant Temp Sens High Error 40-130

User code Failure code Engine coolant temperature sensor high error
Failure
(Engine controller system)
E15 CA144
Detail of failure q High voltage appears in signal circuit of coolant temperature sensor .
Action of con-
q Takes coolant temperature to be at fixed value and allows engine to run.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Input voltage from engine coolant temperature sensor can be checked with monitoring function.
(Code: 04105 (V))
q Temperature sensed by engine coolant temperature sensor can be checked with monitoring func-
tion.
Related infor- (Code: 04107 (C))
mation q Method of reproducing failure code: Turn starting switch to ON position.
q This failure code is displayed if temperature sensor connector is disconnected.
q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector TEMP and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 C, regard coolant temperature sensor as normal.
0 C Resistance 30 37 kz
Defective coolant temperature
2 Between TEMP (male)
sensor 25 C Resistance 9.3 10.7 kz
(A) and (B)
a Coolant temperature 50 C Resistance 3.2 3.8 kz
-Resistaure charac-
80 C Resistance 1.0 1.3 kz
teristics
95 C Resistance 700 800 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to female side.
Open or short circuit in wiring har- Between ECM (female) (15) and (38) (Coolant tem-
3 perature: Min. 0C)
ness Resis-
a Use "Coolant temperature-Resistance charac- 700 z 37 kz
tance
teristics" table shown above as resistance crite-
ria.
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is an internal defect, troubleshooting cannot be performed.)

40-130 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA144] Coolant Temp Sens High Error

Circuit diagram related to coolant temperature sensor 40-131

HB205-1, HB215LC-1 40-131

(01)
Troubleshooting by failure code
Failure code [CA145] Coolant Temp Sens Low Error

Failure code [CA145] Coolant Temp Sens Low Error 40-132

User code Failure code Engine coolant temperature sensor low error
Failure
(Engine controller system)
E15 CA145
Detail of failure q Low voltage appears in signal circuit of coolant temperature sensor .
Action of con-
q Takes coolant temperature to be at fixed value and allows engine to run.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Input voltage from engine coolant temperature sensor can be checked with monitoring function.
(Code: 04105 (V))
q Temperature sensed by engine coolant temperature sensor can be checked with monitoring func-
Related infor- tion.
mation (Code: 04107(C) )
q Method of reproducing failure code: Turn starting switch to ON position.
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA144] for "High Error" is displayed.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector TEMP and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 z 37 kz with coolant
temperature above 0 C, regard coolant temperature sensor as normal.
0 C Resistance 30 37 kz
Between TEMP (male)
Defective coolant temperature 25 C Resistance 9.3 10.7 kz
2 (A) and (B)
sensor a Coolant temperature 50 C Resistance 3.2 3.8 kz
-Resistaure charac-
80 C Resistance 1.0 1.3 kz
teristics
95 C Resistance 700 800 z
Whole cool-
Between (B) and ground ant temper- Resistance Min. 100 kz
ature range
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to female side.
Between ECM (female) (15) and (38) (Coolant tem-
3 Short circuit in wiring harness perature: Min. 0 C)
Resis-
a Use "Coolant temperature-Resistance charac- 700 z 37 kz
tance
teristics" table shown above as resistance crite-
ria.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and TEMP and connect T-adapters to female
Ground fault in wiring harness
4 side of ECM.
(contact with ground circuit)
Resis-
Between ECM (female) (15) and ground Min. 100 kz
tance
If no failure is found by above checks, engine controller is defective. (Since
5 Defective engine controller
this is an internal defect, troubleshooting cannot be performed.)

40-132 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA145] Coolant Temp Sens Low Error

Circuit diagram related to coolant temperature sensor 40-13

HB205-1, HB215LC-1 40-133

(01)
Troubleshooting by failure code
Failure code [CA153] Chg Air Temp Sensor High Error

Failure code [CA153] Chg Air Temp Sensor High Error 40-134

User code Failure code Boost temperature sensor high error

Failure
(Engine controller system)
E15 CA153
Detail of failure q High voltage appears in temperature signal circuit of boost pressure & temperature sensor.
Action of con-
q Takes boost temperature to be at fixed value and allows engine to run.
troller
Problem on
q Engine protection function based on boost temperature does not work.
machine
q Input voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
q Temperature sensed by boost temperature sensor can be checked with monitoring function.
(Code: 18500( C))
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).
q This failure code is displayed if temperature sensor connector is disconnected.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST and connect socket to male side of
connector.
-40 C Resistance 41 48 kz
-20 C Resistance 14 16 kz
Defective boost temperature sen- Between BOOST (male)
2 0 C Resistance 5.4 6.1 kz
sor (3) and (4)
a Boost tempera- 30 C Resistance 1.6 1.8 kz
ture-Resistance cha-
60 C Resistance 560 600 z
riacteristic
90 C Resistance 230 250 z
130 C Resistance 80 90 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to female side.
Open or short circuit in wiring har-
3 Between ECM (female) (23) and (47)
ness 80 z
a Use "Boost temperature-Resistance character- Resistance
48 kz
istics" table shown above as resistance criteria.
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is an internal defect, troubleshooting cannot be performed.)

40-134 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA153] Chg Air Temp Sensor High Error

Circuit diagram related to boost temperature sensor 40-135

HB205-1, HB215LC-1 40-135

(01)
Troubleshooting by failure code
Failure code [CA154] Chg Air Temp Sensor Low Error

Failure code [CA154] Chg Air Temp Sensor Low Error 40-136

User code Failure code Boost temperature sensor low error

Failure
(Engine controller system)
E15 CA154
Detail of failure q Low voltage appears in temperature signal circuit of boost pressure & temperature sensor.
Action of con-
q Takes boost temperature to be at fixed value and allows engine to run.
troller
Problem on
q Engine protection function based on boost temperature does not work.
machine
q Input voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
q Temperature sensed by boost temperature sensor can be checked with monitoring function.
Related infor-
(Code: 18500( C))
mation
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA153] for "High Error" is displayed.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST and connect socket to male side of
connector.
-40 C Resistance 41 48 kz
-20 C Resistance 14 16 kz
Defective boost temperature sen- Between BOOST (male)
2 0 C Resistance 5.4 6.1 kz
sor (3) and (4)
a Boost tempera- 30 C Resistance 1.6 1.8 kz
ture-Resistance cha-
60 C Resistance 560 600 z
riacteristic
90 C Resistance 230 250 z
130 C Resistance 80 90 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to female side.
3 Short circuit in wiring harness Between ECM (female) (23) and (47)
80 z
a Use "Boost temperature-Resistance characteris- Resistance
48 kz
tics" table shown above as resistance criteria.
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and BOOST and connect T-adapters to
4
(contact with ground circuit) female side of ECM.
Between ECM (female) (23) and ground Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this
5 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

40-136 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA154] Chg Air Temp Sensor Low Error

Circuit diagram related to boost temperature sensor 40-137

HB205-1, HB215LC-1 40-137

(01)
Troubleshooting by failure code
Failure code [CA155] Chg Air Temp High Speed Derate

Failure code [CA155] Chg Air Temp High Speed Derate 40-138

User code Failure code Boost temperature high enough for speed derate
Failure
(Engine controller system)
E11 CA155
q Boost temperature sensed by boost pressure & temperature sensor exceeds upper limit of temper-
Detail of failure
ature control.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine stops.
q Boost temperature can be checked with monitoring function.
Related infor-
(Code: 18500 Boost temperature)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Aftercooler cooling performance may degrade. Directly check it for following
points:
Lowered cooling performance of
1 q Looseness and damage of fan belt
aftercooler
q Insufficient cooling air
q Clogging of aftercooler fins
Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related
2
let temperature parts directly.
Defective boost temperature sen- If no failure is found by above checks, boost temperature sensor system may
3
sor be defective. Perform troubleshooting for failure codes [CA153] and [CA154].

40-138 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA155] Chg Air Temp High Speed Derate

HB205-1, HB215LC-1 40-139

(01)
Troubleshooting by failure code
Failure code [CA187] Sens Supply 2 Volt Low Error

Failure code [CA187] Sens Supply 2 Volt Low Error 40-140

User code Failure code Sensor power supply 2 voltage low error
Failure
(Engine controller system)
E15 CA187
Detail of failure q Low voltage appears in sensor power supply 2 circuit.
Action of con- q Takes boost pressure & temperature to be at fixed values and allows engine to run.
troller q Limits engine output and allows engine to run.
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect following connectors sequentially one by one and turn starting
switch to ON position each time.
3. After each troubleshooting, return to step 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because of disconnection of
2 Defective sensor or wiring harness connector. Ignore failure codes other than [CA187].
Sensor or harness Connector
Boost pressure/temperature sensor BOOST
Common rail pressure sensor RAIL
Bkup sensor CAM
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to male side.
3 Defective engine controller 3. Turn starting switch to ON position with connector ECM disconnected.

Between ECM (male) (37) and (47) Voltage 4.75 5.25 V

40-140 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA187] Sens Supply 2 Volt Low Error

Circuit diagram related to sensor power supply 2 (5 V) 40-141

HB205-1, HB215LC-1 40-141

(01)
Troubleshooting by failure code
Failure code [CA221] Ambient Press Sens High Error

Failure code [CA221] Ambient Press Sens High Error 40-142

User code Failure code Ambient pressure sensor high error

Failure
(Engine controller system)
E11 CA221
Detail of failure q High voltage appears in signal circuit of ambient pressure sensor.
Action of con-
q Takes ambient pressure to be at fixed value and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
q Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related infor-
q Ambient pressure sensed by ambient pressure sensor can be checked with monitoring function.
mation
(Code: 37400 (kPa))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective sensor power supply 1 If failure code [CA352] or [CA386] is displayed simultaneously, perform trou-
2
system bleshooting for it first.
1. Turn starting switch to OFF position.
Defective ambient pressure sen- 2. Disconnect connector AIR.
3 3. Turn starting switch to ON position.
sor
If failure code changes from [CA221] to [CA222], sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AIR, and connect T-adapters to female
4 Short circuit in wiring harness side of either of them.
Between ECM (female) (33) and (3), or between
Resistance Min. 100 kz
AIR (female) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connector AIR.
3. Connect T-adapters to female side of connector AIR, or insert T-adapters
Hot short circuit in wiring harness
5 into connector ECM.
(contact with 24 V circuit)
4. Turn starting switch to ON position (with connector AIR disconnected).
Between ECM (3) and (38), or between AIR
Voltage Max. 1 V
(female) (3) and (2)
If no failure is found by above checks, engine controller is defective. (Since this
6 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

40-142 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA221] Ambient Press Sens High Error

Circuit diagram related to ambient pressure sensor 40-143

HB205-1, HB215LC-1 40-143

(01)
Troubleshooting by failure code
Failure code [CA222] Ambient Press Sens Low Error

Failure code [CA222] Ambient Press Sens Low Error 40-14

User code Failure code Ambient pressure sensor low error

Failure
(Engine controller system)
E11 CA222
Detail of failure q Low voltage appears in signal circuit of ambient pressure sensor.
Action of con-
q Takes ambient pressure to be at fixed value and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
q Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related infor- q Ambient pressure sensed by ambient pressure sensor can be checked with monitoring function.
mation (Code: 37400 (kPa))
q If sensor connector is disconnected, this failure code is displayed.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
1. Turn starting switch to OFF position.
Defective power supply system of
2 2. Disconnect connector AIR and connect T-adapters to female side.
ambient pressure sensor
3. Turn starting switch to ON position.
Short circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
4
(contact with ground circuit)
5 Short circuit in wiring harness
See descriptions of wiring harness and connectors in "c: Electrical equipment"
ing", and check them directly.
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting
for it first.
4.75
Between AIR (female) (1) and (2) Power input Voltage
5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors AIR and ECM and connect T-adapters to each
female side.
a If power supply input in checks on cause 2 is nor-
mal, this check is not required.
Resistance Max. 10 z
Between ECM (female) (33) and AIR (female)
(1)
a If power supply input in checks on cause 2 is nor-
mal, this check is not required.
Resistance Max. 10 z
Between ECM (female) (38) and AIR (female)
(2)
Between ECM (female) (3) and AIR (female) (3)
Resistance Max. 10 z
(sensor output)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AIR, and connect T-adapters to female
side of either of them.
Between ECM (female) (3), or AIR (female) (3) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AIR, and connect T-adapters to female
side of either of them.
Between ECM (female) (3) and (38), or between
Resistance Min. 100 kz
AIR (female) (2) and (3)

40-144 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA222] Ambient Press Sens Low Error

Cause Procedure, measuring location, criteria and remarks

a If no failure is found by checks on causes 1 to 5 and check result of cause
6 is abnormal, sensor is defective.
Defective ambient pressure sensor 1. Turn starting switch to OFF position.
6 (improper input voltage to engine 2. Insert T-adapters to connector ECM.
controller) 3. Turn starting switch to ON position.
Sensor out-
Between ECM (3) and (38) Voltage 0.5 4.5 V
put
If no failure is found by above checks, engine controller is defective. (Since
7 Defective engine controller
this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to ambient pressure sensor 40-145

HB205-1, HB215LC-1 40-145

(01)
Troubleshooting by failure code
Failure code [CA227] Sens Supply 2 Volt High Error

Failure code [CA227] Sens Supply 2 Volt High Error 40-146

User code Failure code Sensor power supply 2 voltage high error
Failure
(Engine controller system)
E15 CA227
Detail of failure q High voltage appears in sensor power supply 2 circuit.
Action of con- q Takes boost pressure and boost temperature to be at fixed values and allows engine to run.
troller q Runs engine with output limited.
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA187].

Failure code [CA234] Eng Overspeed 40-146

User code Failure code Engine overspeed

Failure
(Engine controller system)
CA234
Detail of failure q Engine speed exceeds upper limit of speed control.
Action of con-
q Stops injection until engine speed lowers to normal level.
troller
Problem on
q Engine speed fluctuates.
machine
q Engine speed can be checked with monitoring function.
Related infor-
(Code: 01002 Engine speed)
mation
q Method of reproducing failure code: Run engine at full speed.

Cause Procedure, measuring location, criteria and remarks

1 Use of improper fuel Fuel used may be improper. Check it directly

2 Improper use Machine may be used improperly. Instruct operator on proper way to use.

If no failure is found by checks on causes 1 and 2, engine controller may be

3 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be per-
formed.)

40-146 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA238] Ne Speed Sens Supply Volt Error

Failure code [CA238] Ne Speed Sens Supply Volt Error 40-147

User code Failure code Ne speed sensor supply voltage error

Failure
(Engine controller system)
E15 CA238
Detail of failure q Low voltage appears in power supply circuit of engine Ne speed sensor.
Action of con-
q Controls engine with signal from engine Bkup speed sensor.
troller
q Running engine stops (when Bkup speed sensor is also defective).
Problem on q Stopped engine cannot be started (when Bkup speed sensor is also defective).
machine q Engine starting performance becomes deteriorated.
q Engine hunts.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After each troubleshooting, turn starting switch to OFF position.
If this failure code is not displayed when a sensor is disconnected, sensor or
engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed, too. This is because of disconnection of
connector. Ignore failure codes other than [CA238].
Sensor or harness Connector
Ne speed sensor CRANK
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to male side.
3. Turn starting switch to ON position with engine wiring harness discon-
3 Defective engine controller nected.
4.75
Between ECM (male) (16) and (48) Voltage
5.25 V

Circuit diagram related to Ne speed sensor 40-147

HB205-1, HB215LC-1 40-147

(01)
Troubleshooting by failure code
Failure code [CA271] IMV/PCV1 Short Error

Failure code [CA271] IMV/PCV1 Short Error 40-148

User code Failure code Short circuit in IMV/PCV1

Failure
(Engine controller system)
E10 CA271
Detail of failure q Short circuit is detected in drive circuit of supply pump actuator.
Action of con-
q None in particular
troller
q Engine speed does not increase from low idle.
Problem on
q Engine output lowers.
machine
q Common rail fuel pressure rises above command value.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
2 Defective supply pump actuator
Short circuit or ground fault in wir-
3
ing harness
4 Short circuit in wiring harness
Ground fault in wiring harness
5
(contact with ground circuit)
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector PUMP.
3. Turn starting switch to ON position.
If failure code changes from [CA271] to [CA272] , supply pump actuator is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to female side.
Between ECM (female) (2) and (32) Resistance 15z
Between ECM (female) (2) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and PUMP and connect T-adapters to female
side of ECM.
Between ECM (female) (2) and (32) Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and PUMP and connect T-adapters to female
side of ECM.
Between ECM (female) (2) and ground Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-148 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA271] IMV/PCV1 Short Error

Circuit diagram related to IMV/PCV1 40-149

HB205-1, HB215LC-1 40-149

(01)
Troubleshooting by failure code
Failure code [CA272] IMV/PCV1 Open Error

Failure code [CA272] IMV/PCV1 Open Error 40-150

User code Failure code Open circuit in IMV/PCV1

Failure
(Engine controller system)
E10 CA272
Detail of failure q Open circuit is detected in drive circuit of supply pump actuator.
Action of con-
q None in particular
troller
Problem on q Engine runs but its speed does not stabilize.
machine q Common rail fuel pressure rises above command value.
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor- q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
mation able to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2 Defective supply pump actuator 2. Disconnect connector PUMP.
Between PUMP (male) (1) and (2) Resistance Max. 5 z
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapters to female side.
3
ness
Between ECM (female) (2) and (32) Resistance Max. 5 z
1. Turn starting switch to OFF position.
2. Disconnect connector PUMP.
3. Insert T-adapters to connector ECM.
Hot short circuit in wiring harness 4. Turn starting switch to ON position (with connector PUMP disconnected).
4
(contact with 24 V circuit) Leave it for more than one minute and then take measurement.
a Average voltage is displayed because of PWM.
Between ECM (2) and (32) Voltage Max. 3 V
If no failure is found by above checks, engine controller is defective. (Since this
5 Defective engine controller
is internal defect, troubleshooting cannot be performed.)

40-150 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA272] IMV/PCV1 Open Error

Circuit diagram related to IMV/PCV1 40-151

HB205-1, HB215LC-1 40-151

(01)
Troubleshooting by failure code
Failure code [CA322] Inj #1(L#1) Open/Short Error

Failure code [CA322] Inj #1(L#1) Open/Short Error 40-152

User code Failure code Injector #1 open or short circuit error

Failure
(Engine controller system)
E11 CA322
Detail of failure q Open or short circuit is detected in drive circuit of No. 1 injector.
Action of con-
q None in particular
troller
Problem on q Combustion becomes irregular or engine hunts.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is applied to injector (+) side.
mation
But it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
2 Defective No. 1 injector
Open circuit or ground fault in wir-
3
ing harness
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
5
(contact with ground circuit)
6 Short circuit in wiring harness
Defective other cylinder injectors
7
or wiring harness
8 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector INJ1 and connect T-adapters to male side.
Between INJ1 (male) (3) and (4) Resistance Max. 2 z
Between INJ1 (male) (3) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to female side.
Between ECM (female) (45) and (53) Resistance Max. 2 z
Between ECM (female) (45) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJ1, and connect T-adapters to each
female side.
Between ECM (female) (45) and INJ1 (female) (3) Resistance Max. 2 z
Between ECM (female) (53) and INJ1 (female) (4) Resistance Max. 2 z
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJ1, and connect T-adapters to female
side of either of them.
Between ECM (female) (45) or INJ1 (female) (3)
Resistance Min. 100 kz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJ1 and connect T-adapters to female
side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (45) and each pin other No continuity (no sound
than (45) is heard.)
Between ECM (female) (53) and each pin other No continuity (no sound
than (53) is heard.)
If failure codes for other injectors are displayed, perform troubleshooting for
them, too.
If no failure is found by checks on causes 1 to 7, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

40-152 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA322] Inj #1(L#1) Open/Short Error

Circuit diagram related to injector #1 40-153

HB205-1, HB215LC-1 40-153

(01)
Troubleshooting by failure code
Failure code [CA324] Inj #3(L#3) Open/Short Error

Failure code [CA324] Inj #3(L#3) Open/Short Error 40-154

User code Failure code Injectpr #3 open or short circuit error

Failure
(Engine controller system)
E11 CA324
Detail of failure q Open or short circuit is detected in drive circuit of No. 3 injector.
Action of con-
q None in particular
troller
Problem on q Combustion becomes irregular or engine hunts.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is applied to injector (+) side.
mation
But it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector INJ2 and connect T-adapters to male side.
2 Defective No. 3 injector
Between INJ2 (male) (3) and (4) Resistance Max. 2 z
Between INJ2 (male) (3) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (46) and (60) Resistance Max. 2 z
Between ECM (female) (46) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJ2, and connect T-adapters to each
4 (wire breakage or defective con- female side.
tact of connector) Between ECM (female) (46) and INJ2 (female) (3) Resistance Max. 2 z
Between ECM (female) (60) and INJ2 (female) (4) Resistance Max. 2 z
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJ2, and connect T-adapters to female
5
(contact with ground circuit) side of either of them.
Between ECM (female) (46) or INJ2 (female) (3)
Resistance Min. 100 kz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJ2 and connect T-adapters to female
side of ECM.
a Check by using multimeter in continuity mode.
6 Short circuit in wiring harness
Between ECM (female) (46) and each pin other No continuity (no sound
than (46) is heard.)
Between ECM (female) (60) and each pin other No continuity (no sound
than (60) is heard.)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no failure is found by above checks, engine controller is defective. (Since this
8 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

40-154 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA324] Inj #3(L#3) Open/Short Error

Circuit diagram related to injector #3 40-15

HB205-1, HB215LC-1 40-155

(01)
Troubleshooting by failure code
Failure code [CA331] Inj #2(L#2) Open/Short Error

Failure code [CA331] Inj #2(L#2) Open/Short Error 40-156

User code Failure code Injector #2 open or short circuit error

Failure
(Engine controller system)
E11 CA331
Detail of failure q Open or short circuit is detected in drive circuit of No. 2 injector.
Action of con-
q None in particular
troller
Problem on q Combustion becomes irregular or engine hunts.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is applied to injector (+) side.
mation
But it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector INJ1 and connect T-adapters to male side.
2 Defective No. 2 injector
Between INJ1 (male) (1) and (2) Resistance Max. 2 z
Between INJ1 (male) (2) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (57) and (59) Resistance Max. 2 z
Between ECM (female) (57) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJ1, and connect T-adapters to each
4 (wire breakage or defective con- female side.
tact of connector) Between ECM (female) (57) and INJ1 (female) (2) Resistance Max. 2 z
Between ECM (female) (59) and INJ1 (female) (1) Resistance Max. 2 z
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJ1, and connect T-adapters to female
5
(contact with ground circuit) side of either of them.
Between ECM (female) (57) or INJ1 (female) (2)
Resistance Min. 100 kz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJ1 and connect T-adapters to female
side of ECM.
a Check by using multimeter in continuity mode.
6 Short circuit in wiring harness
Between ECM (female) (57) and each pin other No continuity (no sound
than (57) is heard.)
Between ECM (female) (59) and each pin other No continuity (no sound
than (59) is heard.)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no failure is found by above checks, engine controller is defective. (Since this
8 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

40-156 HB205-1, HB215LC-1

(04)
 Troubleshooting by failure code
Failure code [CA331] Inj #2(L#2) Open/Short Error

Circuit diagram related to injector #2 40-157

HB205-1, HB215LC-1 40-157

(01)
Troubleshooting by failure code
Failure code [CA332] Inj #4(L#4) Open/Short Error

Failure code [CA332] Inj #4(L#4) Open/Short Error 40-158

User code Failure code Injector #4 open or short circuit error

Failure
(Engine controller system)
E11 CA332
Detail of failure q Open or short circuit is detected in drive circuit of No. 4 injector.
Action of con-
q None in particular
troller
Problem on q Combustion becomes irregular or engine hunts.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is applied to injector (+) side.
mation
But it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector INJ2 and connect T-adapters to male side.
2 Defective No. 4 injector
Between INJ2 (male) (1) and (2) Resistance Max. 2 z
Between INJ2 (male) (2) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (55) and (52) Resistance Max. 2 z
Between ECM (female) (55) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJ2, and connect T-adapters to each
4 (wire breakage or defective con- female side.
tact of connector) Between ECM (female) (55) and INJ2 (female) (2) Resistance Max. 2 z
Between ECM (female) (52) and INJ2 (female) (1) Resistance Max. 2 z
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJ2, and connect T-adapters to female
5
(contact with ground circuit) side of either of them.
Between ECM (female) (55) or INJ2 (female) (2)
Resistance Min. 100 kz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJ2 and connect T-adapters to female
side of ECM.
a Check by using multimeter in continuity mode.
6 Short circuit in wiring harness
Between ECM (female) (55) and each pin other No continuity (no sound
than (55) is heard.)
Between ECM (female) (52) and each pin other No continuity (no sound
than (52) is heard.)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no failure is found by above checks, engine controller is defective. (Since this
8 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

40-158 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA332] Inj #4(L#4) Open/Short Error

Circuit diagram related to injector #4 40-159

HB205-1, HB215LC-1 40-159

(01)
Troubleshooting by failure code
Failure code [CA342] Calibration Code Incompatibility

Failure code [CA342] Calibration Code Incompatibility 40-160

User code Failure code Calibration code incompatible

Failure
(Engine controller system)
E10 CA342
Detail of failure q Matching error occurs in engine controller data.
Action of con-
q None in particular
troller
Problem on
q Engine may run normally, or engine is stopped and cannot be restarted.
machine
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q Power supply voltage of engine controller can be checked with moniitoring funtion.
mation
(Code: 03203 (V))

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Defective power supply voltage

2 Perform troubleshooting for failure code [CA441].
line

40-160 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA351] Injectors Drive Circuit Error

Failure code [CA351] Injectors Drive Circuit Error 40-161

User code Failure code Injectors drive circuit error

Failure
(Engine controller system)
E10 CA351
Detail of failure q There is error in drive power circuit of injector.
Action of con-
q Runs engine with engine output limited.
troller
q Exhaust smoke becomes black.
Problem on q Combustion becomes irregular.
machine q Engine output lowers.
q Engine cannot be started.
q Method of reproducing failure code: Start engine.
Related infor-
q Power supply voltage of engine controller can be checked with moniitoring funtion.
mation
(Code: 03203 (V))

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Defective power supply voltage

2 Perform troubleshooting for failure code [CA441].
system

HB205-1, HB215LC-1 40-161

(01)
Troubleshooting by failure code
Failure code [CA352] Sens Supply 1 Volt Low Error

Failure code [CA352] Sens Supply 1 Volt Low Error 40-162

User code Failure code Sensor power supply 1 voltage low error
Failure
(Engine controller system)
E15 CA352
Detail of failure q Low voltage appears in sensor power supply 1 circuit.
Action of con-
q Takes ambient pressure to be at fixed value and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After each troubleshooting, turn starting switch to OFF position.
If this failure code is not displayed when a sensor is disconnected, sensor or
engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed as well. This is because of disconnection
of connector. Ignore all failure codes other than [CA352].
Sensor or harness Connector
Ambient pressure sensor AIR
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to male side.
3 Defective engine controller 3. Turn starting switch to ON position with connector ECM disconnected.
Between ECM (male) (33) and (38) Voltage 4.75 5.25 V

40-162 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA352] Sens Supply 1 Volt Low Error

Circuit diagram related to sensor power supply 1 40-163

HB205-1, HB215LC-1 40-163

(01)
Troubleshooting by failure code
Failure code [CA386] Sens Supply 1 Volt High Error

Failure code [CA386] Sens Supply 1 Volt High Error 40-164

User code Failure code Sensor power supply 1 high error

Failure
(Engine controller system)
E15 CA386
Detail of failure q High voltage appears in sensor power supply 1 circuit.
Action of con-
q Takes ambient pressure to be at fixed value and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA352]

40-164 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA386] Sens Supply 1 Volt High Error

HB205-1, HB215LC-1 40-165

(01)
Troubleshooting by failure code
Failure code [CA428] Water in Fuel Sensor High Error

Failure code [CA428] Water in Fuel Sensor High Error 40-16

User code Failure code Water-in-fuel sensor high error

Failure
(Engine controller system)
E15 CA428
Detail of failure q High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
Action of con-
q None in particular
troller
Problem on
q Water separator monitor is not displayed correctly.
machine
q Signal (ON/OFF) from water-in-fuel sensor can be checked with monitoring function.
Related infor-
(Code: 18800)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
Defective water-in-fuel sensor
2 a If water is in water separator, drain it.
installed to fuel pre-filter
Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapters to female side.
3
ness
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
5 Short circuit in wiring harness
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector P47, and connect T-adapters to female side.
Between P47 (female) (1) and (2) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
Between ECM (female) (14) and (47)
Resistance Min. 100 kz
(Resistance of water-in-fuel sensor)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and P47, and connect T-adapters to each
female side.
Between ECM (female) (14) and P47 (female) (1) Resistance Max. 10 z
Between ECM (female) (47) and P47 (female) (2) Resistance Max. 10 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and P47, and connect T-adapters to female
side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (14) and each pin other No continuity (no sound
than (14) is heard.)
If no failure is found by above checks, engine controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-166 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA428] Water in Fuel Sensor High Error

Circuit diagram related to water-in-fuel sensor 40-167

HB205-1, HB215LC-1 40-167

(01)
Troubleshooting by failure code
Failure code [CA429] Water in Fuel Sensor Low Error

Failure code [CA429] Water in Fuel Sensor Low Error 40-168

User code Failure code Water-in-fuel sensor low error

Failure
(Engine controller system)
E15 CA429
Detail of failure q Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
Action of con-
q None in particular
troller
Problem on
q Water separator monitor is not displayed correctly.
machine
q Signal (ON/OFF) from water-in-fuel sensor can be checked with monitoring function.
Related infor-
(Code: 18800)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector P47, and connect T-adapters to female side.
Defective water-in-fuel sensor a If water is in water separator, drain it.
2
installed to fuel pre-filter Between P47 (female) (1) and (2) Resistance Min. 100 kz
Between P47 (female) (1) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapters to female side.
Short circuit or ground fault in wir-
3 Between ECM (female) (14) and (47)
ing harness Resistance Min. 100 kz
(Resistance of water-in-fuel sensor)
Between ECM (female) (14) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and P47, and connect T-adapters to female
side of ECM.
4 Short circuit in wiring harness
a Check by using multimeter in continuity mode.
Between ECM (female) (14) and each pin other No continuity (no sound
than (14) is heard.)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and P47, and connect T-adapters to either
5
(contact with ground circuit) female side.
Between ECM (female) (14) or P47 (female) (1) and
Resistance Min. 100 kz
ground
If no failure is found by above checks, engine controller is defective. (Since this
6 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

40-168 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA429] Water in Fuel Sensor Low Error

Circuit diagram related to water-in-fuel sensor 40-169

HB205-1, HB215LC-1 40-169

(01)
Troubleshooting by failure code
Failure code [CA435] Eng Oil Press Sw Error

Failure code [CA435] Eng Oil Press Sw Error 40-170

User code Failure code Engine oil pressure switch error

Failure
(Engine controller system)
E15 CA435
Detail of failure q Abnormality is detected in signal circuit of engine oil pressure switch.
Action of con-
q None in particular
troller
Problem on q Engine protection function based on engine oil pressure does not work.
machine q Engine oil pressure monitor is not displayed correctly.
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is stopped),
Related infor- but is in OPEN (OFF) when high (when engine is running).
mation q To display this failure code, engine controller checks if engine oil pressure switch is in CLOSED
(ON), that is, if signal voltage is zero or not only when engine is stopped.
q When engine is running, failure of engine oil pressure switch is shown by failure code [B@BAZG].

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
Defective engine oil pressure 2. Disconnect connector O.P.S and connect T-adapters to male side.
2
switch
Between O.P.S (male) (1) and ground Resistance Max. 10 z
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapters to female side.
3
ness
Between ECM (female) (17) and ground Resistance Max. 10 z
If no failure is found by above checks, engine controller is defective. (Since this
4 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to engine oil pressure switch 40-170

40-170 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA435] Eng Oil Press Sw Error

HB205-1, HB215LC-1 40-171

(01)
Troubleshooting by failure code
Failure code [CA441] Battery Voltage Low Error

Failure code [CA441] Battery Voltage Low Error 40-172

User code Failure code Battery voltage low error

Failure
(Engine controller system)
E10 CA441
Detail of failure q Low voltage appears in controller power supply circuit.
Action of con-
q None in particular
troller
Problem on q Engine stops.
machine q Engine starting performance becomes deteriorated.
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q Power supply voltage of engine controller can be checked with moniitoring funtion.
mation
(Code: 03203 (V))

Cause Procedure, measuring location, criteria and remarks

Loose or corroded battery cable
1 Battery cable terminal may be loose or corroded. Check it directly.
terminal
Loose terminal or partial open cir- 1. Turn starting switch to OFF position.
2
cuit at terminal Check terminals of alternator, battery relay, ground terminal (T12), etc.
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
3 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Perform troubleshooting with starting switch at OFF position and at engine
4 Lowered battery voltage cranking.
Between battery terminals (+) and (-). Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector E12.
5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
27.5 29.5
Between E12 (1) and ground Voltage
V
If no failure is found by above checks, engine controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Insert T-adapters into connector CE03.
3. Connect battery ground cable.
6 Defective engine controller
4. Measure voltage with starting switch at ON position and when starting
engine.
Between CE03 (3) and
Starting switch: ON Voltage 20 30 V
(1)
Between CE03 (3) and
Starting switch: START Voltage Min. 12 V
(1)

40-172 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA441] Battery Voltage Low Error

Circuit diagram related to engine controller power supply 40-173

HB205-1, HB215LC-1 40-173

(01)
Troubleshooting by failure code
Failure code [CA442] Battery Voltage High Error

Failure code [CA442] Battery Voltage High Error 40-174

User code Failure code Battery voltage high error

Failure
(Engine controller system)
E10 CA442
Detail of failure q High voltage (36 V or higher) appears in controller power supply circuit.
Action of con-
q None in particular
troller
Problem on q Engine continues to run normally, but it may stop during running or may not be able to start if it is
machine stopped.
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q Power supply voltage of engine controller can be checked with moniitoring funtion.
mation
(Code: 03203 (V))

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA441].

40-174 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA449] Rail Press Very High Error

Failure code [CA449] Rail Press Very High Error 40-175

User code Failure code Common rail pressure sensor very high error
Failure
(Engine controller system)
E11 CA449
Detail of failure q High pressure error (2) occurs in common rail circuit.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine sound becomes large when no or light load is applied.
machine q Engine output lowers.
q Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Air may be in low-pressure circuit. Check it directly according to following pro-

cedure.
2 Air in low-pressure circuit 1. Remove fuel pressure pickup port plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
3. Check fuel and air from pressure pickup plug for leakage level.
a For check of pressure in fuel return circuit, see Testing and adjusting, "Test-
ing fuel pressure".
3 Defect in fuel return circuit parts Max. 0.02 MPa
Fuel return circuit pres- Engine at low idle or
sure cranking {Max. 0.19 kg/cm2}
Defective common rail pressure
4 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system
a For check of leakage from pressure limiter, see "Checking fuel return rate
and leakage" in Testing and adjusting.
5 Defective pressure limiter
Leakage from
Engine at low idle 0 cc (no leakage)
pressure limiter
6 Defective supply pump If no failure is found by above checks, supply pump may be defective.

HB205-1, HB215LC-1 40-175

(01)
Troubleshooting by failure code
Failure code [CA451] Rail Press Sensor High Error

Failure code [CA451] Rail Press Sensor High Error 40-176

User code Failure code Common rail pressure sensor high error
Failure
(Engine controller system)
E11 CA451
Detail of failure q High voltage appears in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine speed or output lowers.
machine q Engine does not start.
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor volt)
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q This failure code appears if common rail pressure sensor connector is disconnected.
mation
q Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for
checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 ment" in "Checks before troubleshooting" of "General information on trouble-
tor
Defective common rail pressure
2
sensor power supply system
3 Short circuit in wiring harness
Hot short circuit in wiring harness 3.
4
(contact with 24 V circuit)
5 Open circuit in wiring harness
Defective common rail pressure
6 sensor (improper input voltage to 2. Insert T-adapters to connector ECM.
engine controller)
7 Defective engine controller
See descriptions of wirings harness and connectors in "c: Electrical equip-
shooting", and check them directly.
If failure code [CA227] or [CA187] is also displayed, perform troubleshooting
for it first.
1. Turn starting switch to OFF position.
2. Disconnect connectors CAM, RAIL, BOOST, amd ECM.
3. Connect T-adapters to female side of ECM.
Between ECM (female) (25) and (37) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector RAIL and insert T-adapters into connector ECM.
Turn starting switch to ON position (with connector RAIL disconnected).
a ECM (25) pin is connected to 5 V power supply through resistor in engine
controller.
Between ECM (25) and (47) Voltage Approx. 5 V
If no failure is found by above checks, there may be open circuit in wiring har-
ness. (*)
a If no failure is found by checks on causes 1 to 5 and check result of cause
6 is abnormal, sensor is defective.
1. Turn starting switch to OFF position.
3. Turn starting switch to ON position.
Sensor out-
Between ECM (25) and (47) Voltage 0.2 4.6 V
put
If no failure is found by above checks, engine controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General in-
formation on troubleshooting".

40-176 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA451] Rail Press Sensor High Error

Circuit diagram related to common rail pressure sensor 40-17

HB205-1, HB215LC-1 40-177

(01)
Troubleshooting by failure code
Failure code [CA452] Rail Press Sensor Low Error

Failure code [CA452] Rail Press Sensor Low Error 40-178

User code Failure code Common rail pressure sensor low error
Failure
(Engine controller system)
E11 CA452
Detail of failure q Low voltage appears in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine speed or output lowers.
machine q Engine does not start
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor volt)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q If sensor connector is disconnected even in normal condition, failure code [CA451] for "High Error"
is displayed.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective common rail pressure If failure code [CA187] (ground fault in sensor power supply system) or
2
sensor power supply system [CA227] is displayed, perform troubleshooting for it first.
a Check that failure code [CA187] (Ground fault in sensor power supply sys-
tem) is not displayed.
Defective common rail pressure 1. Turn starting switch to OFF position.
3 2. Disconnect connector RAIL.
sensor
3. Turn starting switch to ON position.
If failure code [CA452] changes to [CA451] , sensor is defective.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and RAIL and connect T-adapters to female
4 side of ECM.
(contact with ground circuit)
Between ECM (female) (25) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and RAIL and connect T-adapters to female
5 Short circuit in wiring harness side of ECM.
Between ECM (female) (25) and (47) Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this
6 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

40-178 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA452] Rail Press Sensor Low Error

Circuit diagram related to common rail pressure sensor 40-179

HB205-1, HB215LC-1 40-179

(01)
Troubleshooting by failure code
Failure code [CA488] Chg Air Temp High Torque Derate

Failure code [CA488] Chg Air Temp High Torque Derate 40-180

User code Failure code Boost temperature high error

Failure
(Engine controller system)
E11 CA488
q Temperature signal from boost pressure & temperature sensor exceeds upper limit of temperature
Detail of failure
control.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on
q Engine output lowers.
machine
q Boost temperature can be checked with monitoring function.
Related infor-
(Code: 18500 Boost temperature)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Aftercooler cooling performance may degrade. Directly check it for following
points:
Lowered cooling performance of
1 q Looseness and breakage of fan belt
aftercooler
q Insufficient cooling air
q Clogging of aftercooler fins
Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related
2
let temperature parts directly.
Defective boost temperature sen-
3 Perform troubleshooting for failure codes [CA153] and [CA154].
sor

40-180 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA553] Rail Press High Error

Failure code [CA553] Rail Press High Error 40-181

User code Failure code Common rail pressure high error

Failure
(Engine controller system)
E15 CA553
Detail of failure q High pressure error (1) is detected in common rail circuit.
Action of con-
q None in particular
troller
Problem on q Engine sound becomes large when no or light load is applied.
machine q Engine output lowers.
q Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Connection of ground terminal may be defective. Check following terminals

directly.
Defective connection of ground q Ground terminal of machine (() terminal of battery)
2
terminal q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor
Defective O-ring of supply pump
3 O-ring of supply pump actuator may be damaged. Check it directly.
actuator
Defective common rail pressure
4 Perform troubleshooting for failure code [CA451] and [CA452]
sensor system

HB205-1, HB215LC-1 40-181

(01)
Troubleshooting by failure code
Failure code [CA559] Supply Pump Press Low Error 1

Failure code [CA559] Supply Pump Press Low Error 1 40-182

User code Failure code Supply pump pressure low error 1

Failure
(Engine controller system)
E15 CA559
Detail of failure q Low pressure error (1) is detected in common rail circuit.
Action of con-
q None in particular
troller
q Engine does not start at all or does not start easily.
Problem on
q Exhaust gas becomes black.
machine
q Engine output lowers.
q Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Use of improper fuel Check fuel used directly as it may be improper one.
Fuel may leak to outside. Check it directly (Check visually while running engine
2 Fuel leakage to outside
at low idle).
a For more information on troubleshooting, see Note 1.
a For check of fuel pressure in low-pressure circuit, see Testing and adjust-
ing, "Testing fuel pressure".
Negative pressure at fuel
At high idle Max. -50.7 MPa
supply pump inlet (outlet
(if engine can be started) {Max. -380 mmHg}
3 Defect in low-pressure circuit parts side of fuel pre-filter)
During cranking 0.3 1.1 MPa
(if engine cannot be
Inlet pressure of fuel started) {3.1 11.3 kg/cm2}
main filter 0.5 1.3 MPa
At low idle
(if engine can be started) {5.1 13.3 kg/cm2}
a For check of leakage from pressure limiter, see Testing and adjusting,
Checking fuel return rate and leakage.
4 Defective pressure limiter
Leakage from
At low idle 0 cc (no leakage)
pressure limiter
a For check of return rate from injector, see Testing and adjusting, Checking
fuel return rate and leakage.
Defective injector During cranking
5 (including high-pressure piping in (if engine cannot be Max. 90 cc/min
cylinder head) Return rate from injector started)
At low idle
Max. 120 cc/min
(if engine can be started)
a For check of discharge from supply pump and return rate from supply pump,
see Testing and adjusting, Measuring fuel discharge, return and leakage.
Engine speed:
Min. 75 cc/30 sec.
Discharge from supply 125 rpm
6 Defective supply pump
pump Engine speed:
Min. 90 cc/30 sec.
150 rpm
Return rate from supply At low idle:
Max. 400 cc/25 sec.
pump 750 rpm
Defective common rail pressure
7 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system

40-182 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA559] Supply Pump Press Low Error 1

Note 1: Check the low-pressure line parts for the following.

1) Fuel level
2) Clogging of fuel tank breather
3) Leakage from or clogging of low-pressure fuel piping
4) Clogging of fuel pre-filter
5) Clogging of fuel main filter
6) Replace the fuel filter when the problem is not removed even if it is found to be not clogged.

HB205-1, HB215LC-1 40-183

(01)
Troubleshooting by failure code
Failure code [CA689] Eng Ne Speed Sensor Error

Failure code [CA689] Eng Ne Speed Sensor Error 40-184

User code Failure code Engine Ne speed sensor error

Failure
(Engine controller system)
E15 CA689
Detail of failure q Signal from engine Ne speed sensor is abnormal.
Action of con-
q Continues to control engine by using signal from engine Bkup speed sensor.
troller
q Engine hunts.
Problem on
q Engine starting performance becomes deteriorated.
machine
q Engine output lowers.
q Method of reproducing failure code: Start engine.
q Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
sensor cannot be determined to be normal by measuring its resistance with multimeter.
Related infor-
q Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be measured by
mation
using multimeter.
q Speed sensor senses passing slotted hole in speed sensing wheel that is installed on inside of
crankshaft vibration damper and rotated by crankshaft.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective Ne speed sensor power
2 If failure code [CA238] is also displayed, perform troubleshooting for it first.
supply system
Breakage or improper installation
Engine Ne speed sensor may be broken or may have improper installation
3 (looseness) of engine Ne speed
(looseness). Check it directly.
sensor
1. Turn starting switch to OFF position.
Defective power input to Ne speed 2. Disconnect connector CRANK and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
sensor
Between CRANK (female) (1) and (2) Power input Voltage 4.75 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CRANK.
a If no failure is found by check on cause 4, this
check is not required. Resis-
Max. 10 z
Open circuit in wiring harness Between ECM (female) (16) and CRANK tance
5 (wire breakage or defective con- (female) (1)
tact of connector) a If no failure is found by check on cause 4, this
check is not required. Resis-
Max. 10 z
Between ECM (female) (48) and CRANK tance
(female) (2)
Between ECM (female) (27) and CRANK (female) Resis-
Max. 10 z
(3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CRANK.
Between ECM (female) (16) and (27), or between Resis-
6 Short circuit in wiring harness Min. 100 kz
CRANK (female) (1) and (3) tance
Between ECM (female) (27) and (48), or between Resis-
Min. 100 kz
CRANK (female) (2) and (3) tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and CRANK.
7
(contact with ground circuit) Between ECM (female) (27) or CRANK (female) (3) Resis-
Min. 100 kz
and ground tance

40-184 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA689] Eng Ne Speed Sensor Error

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector CRANK.
8 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between CRANK (female) (3) and ground Voltage Max. 1 V
Damage or loose mounting of
9 Check speed sensing wheel directly.
speed sensing wheel
If no failure is found by above checks, Ne speed sensor is defective. (Since
10 Defective Ne speed sensor
this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, engine controller is defective. (Since
11 Defective engine controller
this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to engine Ne speed sensor 40-185

HB205-1, HB215LC-1 40-185

(01)
Troubleshooting by failure code
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Failure code [CA731] Eng Bkup Speed Sens Phase Error 40-186

User code Failure code Engine Bkup speed sensor phase error
Failure
(Engine controller system)
E15 CA731
q Phase error is detected between signals from engine Ne speed sensor and engine Bkup speed
Detail of failure
sensor.
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
q Engine does not start at all or does not start easily.
Problem on
q Idle speed is unstable.
machine
q Exhaust gas becomes black.
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Breakage of engine Ne speed
1 Engine Ne speed sensor may be broken. Check it directly.
sensor
Breakage of engine Bkup speed
2 Engine Bkup speed sensor may be broken. Check it directly.
sensor
Deformation or breakage of speed
3 Check speed sensing wheel (1) as it may be deformed or damaged.
sensing wheel on crankshaft
Speed sensing ring on camshaft may be installed defectively or broken. Check
it according to the following procedure.
Defective installation or breakage 1. Set No. 1 cylinder to compression TDC (align with mark).
4
of speed sensing ring on camshaft 2. Remove Bkup speed sensor.
3. If you can see double-slot part (with one crest) (B) on speed sensing ring
through sensor mounting hole (H), speed sensing ring is installed correctly.
Defective timing of crankshaft and
5 Timing of crankshaft and camshaft may be defective. Check it directly.
camshaft
Connection of ground terminal may be defective. Check following terminals
directly.
Defective connection of ground q Ground terminal of machine ((-) terminal of battery)
6
terminal q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor

40-186 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA757] All Continuous Data Lost Error

Failure code [CA757] All Continuous Data Lost Error 40-187

User code Failure code All continuous data lost error

Failure
(Engine controller system)
E10 CA757
Detail of failure q All data in engine controller are lost.
Action of con-
q None in particular
troller
Problem on q Engine may stop and may not be started again.
machine q Monitoring function of machine monitor (engine controller system) may not work normally.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

2 Perform troubleshooting for failure code [CA441].

HB205-1, HB215LC-1 40-187

(01)
Troubleshooting by failure code
Failure code [CA778] Eng Bkup Speed Sensor Error

Failure code [CA778] Eng Bkup Speed Sensor Error 40-18

User code Failure code Engine Bkup speed sensor error

Failure
(Engine controller system)
E15 CA778
Detail of failure q Singal from engine Bkup speed (cam) sensor is abnormal.
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
Problem on q Engine starting performance becomes deteriorated.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
q Since inside of speed sensor is not coil but Hall sensor and electronic circuit, speed sensor cannot
Related infor- be determined to be normal by measuring its resistance with multimeter.
mation q Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured by
using multimeter.
q Speed sensor scans rotating slot of speed sensing ring mounted on camshaft.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective sensor power supply 2
2 If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
system
Damage or incorrect (loose) instal-
Engine Bkup speed (CAM) sensor may be damaged or incorrectly (loosely)
3 lation of engine Bkup speed
installed. Check it directly.
(CAM) sensor
1. Turn starting switch to OFF position.
2. Disconnect connector CAM, and connect T-adapters to female side.
Defective power input to engine
4 3. Turn starting switch to ON position.
Bkup speed sensor
Power sup-
Between CAM (female) (1) and (2) Voltage 4.75 5.25 V
ply
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM, and connect T-adapters to each
female side.
Open circuit in wiring harness Resis-
Between ECM (female) (37) and CAM (female) (1) Max. 10 z
5 (wire breakage or defective con- tance
tact of connector) Resis-
Between ECM (female) (47) and CAM (female) (2) Max. 10 z
tance
Resis-
Between ECM (female) (26) and CAM (female) (3) Max. 10 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM, and connect T-adapters to either
female side.
6 Short circuit in wiring harness Between ECM (female) (26) and (37), or between Resis-
Min. 100 kz
CAM (female) (1) and (3) tance
Between ECM (female) (26) and (47), or between Resis-
Min. 100 kz
CAM (female) (2) and (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM, and connect T-adapters to either
Ground fault in wiring harness
7 female side.
(contact with ground circuit)
Between ECM (female) (26) or CAM (female) (3) Resis-
Min. 100 kz
and ground tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector CAM, and connect T-adapters to female side.
8 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between CAM (female) (3) and ground Voltage Max. 1 V

40-188 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA778] Eng Bkup Speed Sensor Error

Cause Procedure, measuring location, criteria and remarks

9 Loose speed sensing ring
Defective engine Bkup speed
10
(CAM) sensor
11 Defective engine controller
Remove engine Bkup speed (CAM) sensor, and check ring directly through
hole (H).
a If speed sensing ring (B) is loosely installed, follow instructions given in the
"Reference" column.
If no failure is found by above checks, engine Bkup speed (CAM) sensor is
defective. (Since this is an internal defect, troubleshooting cannot be per-
formed.)
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to engine Bkup speed sensor 40-189

HB205-1, HB215LC-1 40-189

(01)
Troubleshooting by failure code
Failure code [CA778] Eng Bkup Speed Sensor Error

Reference for troubleshooting of CA778 (107 se- 5. Check mounting bolt (4) of camshaft ring (5) for
ries engine) looseness.
Checking camshaft ring for loose installation 3 Mounting bolt (4):
Remove the front cover and check the camshaft ring 10 2 Nm
for looseness. (DP): Dowel pin
a See "Removal and installation of front seal" in
Disassembly and assembly.
a Keep the front seal, liquid gasket LG-7 and front
seal tool (795-799-6400) on hand.
Removal 40-190
1. Remove the fan and fan belt. For details, see
"Removal and installation of front seal" in Disas-
sembly and assembly.
2. Remove damper assembly (1).

Installation 40-190
a See the figures in "Removal" for installation.
1. Install front cover (2).
2 Front cover: Liquid gasket LG-7
a Refer to the engine shop manual for tighten-
ing order and tightening torque of the mount-
ing bolts.
2. Referring to Disassembly and Assembly,
1) Install the CAM sensor.
3. Remove front cover (2). 2) Install front seal (3).
a Remove the CAM sensor before removing 3) Install the damper assembly with the dowel
the front cover. (To avoid interference be- pin (DP).
tween the sensor and camshaft ring when re- 4) Install fan belt, and install the fan.
moving the cover.) 5) Install the cooling system assembly.
4. Remove front seal (3).
(RING): Ring

40-190 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA1633] KOMNET Datalink Timeout Error

Failure code [CA1633] KOMNET Datalink Timeout Error 40-191

User code Failure code KOMNET datalink timeout error
Failure
(Engine controller system)
E0E CA1633
q Engine controller detects communication error in KOMNET communication circuit between engine
Detail of failure
controller and pump controller or machine monitor.
Action of con- q Allows engine to run in default mode or keeps control conditions at the time of failure detection.
troller q If cause of failure disappears, machine becomes normal by itself.
q Machine may not operate normally because informations which are exchanged through KOMNET
Problem on
communication are not transmitted properly.
machine
(Failure symptom depends on failed section.)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [DA2RMC].

HB205-1, HB215LC-1 40-191

(01)
Troubleshooting by failure code
Failure code [CA2185] Throt Sens Sup Volt High Error

Failure code [CA2185] Throt Sens Sup Volt High Error 40-192

User code Failure code Throttle sensor power supply voltage high error
Failure
(Engine controller system)
E14 CA2185
Detail of failure q High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
Action of con-
q Sets throttle position by using signal other than throttle sensor signal and allows engine to run.
troller
Problem on
q Engine speed cannot be controlled by fuel control dial.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor (fuel con-
2 If this failure code is not displayed, throttle sensor is defective.
trol dial)
a Other failure codes are displayed, too. This is because connector is discon-
nected. Ignore failure codes other than [CA2185].
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02, CE03 and P20, and connect T-adapters to
each female side of CE02 and CE03.
3 Short circuit in wiring harness Between CE02 (female) (22) and each pin other Resis-
Min. 1 Mz
than (22) tance
Resis-
Between CE02 (female) (22) and CE03 (female) (3) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector P20 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between P20 (female) (1) and ground Voltage 4.75 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connector CE02, and connect T-adapters to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness disconnected.
Between CE02 (male) (22) and (23) Voltage 4.75 5.25 V

Circuit diagram related to throttle sensor 40-192

40-192 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA2186] Throt Sens Sup Volt Low Error

Failure code [CA2186] Throt Sens Sup Volt Low Error 40-193

User code Failure code Throttle sensor power supply voltage low error
Failure
(Engine controller system)
E14 CA2186
Detail of failure q Low voltage appears in throttle sensor power supply circuit.
Action of con-
q Sets throttle position by using signal other than throttle sensor signal and allows engine to run.
troller
Problem on
q Engine speed cannot be controlled by fuel control dial.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Checks before troubleshooting" in "General information on troubleshoot-
tor
Defective throttle sensor (fuel con-
2 If this failure code is not displayed, throttle sensor is defective.
trol dial)
Ground fault in harness
3 female side.
(contact with ground circuit)
4 Short circuit in wiring harness
5 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector P20, and turn starting switch to ON position.
a Other failure code is displayed too. This is because connector is disconnect-
ed. Ignore failure codes other than [CA2186].
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapters to either
Between CE02 (female) (22) or P20 (female) (1) Resis-
Min. 1 Mz
and ground tance
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapters to female
side of CE02.
3. Turn starting switch to ON position.
Between CE02 (female) (22) and each pin other Resis-
Min. 1 Mz
than (22) tance
1. Turn starting switch to OFF position.
2. Disconnect connector CE02, and connect T-adapters to male side.
3. Turn starting switch to ON position with wiring harness disconnected.
Between CE02 (male) (22) and (23) Voltage 4.75 5.25 V

Circuit diagram related to throttle sensor 40-193

HB205-1, HB215LC-1 40-193

(01)
Troubleshooting by failure code
Failure code [CA2249] Rail Press Very Low Error

Failure code [CA2249] Rail Press Very Low Error 40-194

User code Failure code Common rail pressure very low error
Failure
(Engine controller system)
E11 CA2311
Detail of failure q Low pressure appears in common rail circuit.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine starting performance becomes deteriorated.
Problem on
q Exhaust gas becomes black.
machine
q Engine output lowers.
q Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA559] .

40-194 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA2311] IMV Solenoid Error

Failure code [CA2311] IMV Solenoid Error 40-195

User code Failure code IMV solenoid error
Failure
(Engine controller system)
E11 CA2311
Detail of failure q Resistance of supply pump actuator circuit is abnormally high or low.
Action of con-
q None in particular
troller
Problem on
q Engine output lowers.
machine
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure codes [CA271] and [CA272].

HB205-1, HB215LC-1 40-195

(01)
Troubleshooting by failure code
Failure code [CA2555] Grid Htr Relay Open Circuit Error

Failure code [CA2555] Grid Htr Relay Open Circuit Error 40-196

User code Failure code Intake air heater relay open circuit
Failure
(Engine controller system)
E15 CA2555
Detail of failure q Open circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
q None in particular
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
q Temperature sensed by boost temperature sensor can be checked with monitoring function.
(Code: 18500)
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor- is below -4 C)
mation q Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheater relay R18.
q For troubleshooting related to heater relay and secondary side of preheater relay R18, see E-2 in
E-mode.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect relay R18, and connect T-adapters to male side.
Between R18 (male) (1) and (2) Resistance 200 400 z
2 Defective preheater relay R18 1. Turn starting switch to OFF position.
2. Replace relay R18 with another one.
3. Turn starting switch to ON position.
If this failure code disappears, original preheater relay R18 is defective.
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector CE02, and connect T-adapters to female side.
3
ness Between CE02 (female) (40) and (42)
Resistance 200 400 z
a Preheater relay R18 coil resistance
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector CE02 and relay R18, and connect T-adapters to each
4 Open circuit in wiring harness female side.
Between CE02 (female) (40) and R18 (female) (1) Resistance Max. 10 z
Between R18 (female) (2) and CE02 (42) Resistance Max. 10 z
1. Turn starting switch to OFF position.
2. Disconnect connector CE02 and relay R18, and connect T-adapters to
female side of CE02.
5 Short circuit in wiring harness a Check by using multimeter in continuity mode.
Between CE02 (female) (40) and each pin other No continuity
than (40) (No sound is heard)
If no failure is found by above checks, engine controller is defective. (Since this
6 Defective engine controller
is an internal defect, troubleshooting cannot be performed.)

40-196 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA2555] Grid Htr Relay Open Circuit Error

Circuit diagram related to intake air heater relay 40-197

HB205-1, HB215LC-1 40-197

(01)
Troubleshooting by failure code
Failure code [CA2556] Grid Htr Relay Short Circuit Error

Failure code [CA2556] Grid Htr Relay Short Circuit Error 40-198

User code Failure code Intake air heater relay short circuit
Failure
(Engine controller system)
E15 CA2556
Detail of failure q Short circuit is detected in drive circuit (primary circuit) of preheater relay.
Action of con-
q None in particular
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
q Temperature sensed by boost temperature sensor can be checked with monitoring function.
(Code: 18500 )
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor- is below -4 C)
mation q Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheater relay R18.
q For troubleshooting related to heater relay and secondary side of preheater relay R18, see E-2 in
E-mode.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect relay R18, and connect T-adapters to male side.

Between R18 (male) (1) and (2) Resistance 200 400 z

2 Defective preheater relay R18
3 Ground fault in wiring harness
4 Short circuit in wiring harness
5 Defective engine controller
1. Turn starting switch to OFF position.
2. Replace relay R18 with another one.
3. Turn starting switch to ON position.
If this failure code disappears, original preheater relay R18 is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector CE02 and relay R18, and connect T-adapters to
either female side.
Between CE02 (female) (40) or R18 (female) (1)
Resistance Min. 100 kz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector CE02 and relay R18, and connect T-adapters to
female side of CE02.
a Check by using multimeter in continuity mode.
Between CE02 (female) (40) and each pin other No continuity
than (40) (No sound is heard)
If no failure is found by above checks, engine controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-198 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [CA2556] Grid Htr Relay Short Circuit Error

Circuit diagram related to intake air heater relay 40-19

HB205-1, HB215LC-1 40-199

(01)
Troubleshooting by failure code
Failure code [D19JKZ] Personal Code Relay Abnormality

Failure code [D19JKZ] Personal Code Relay Abnormality 40-20

User code Failure code Personal Code Relay Abnormality

Failure
(KOMTRAX system in machine monitor)
E01 D19JKZ
Detail of failure q Open circuit error or short circuit error is detected in primary (coil) circuit of personal code relay.
q None in particular (when open circuit is detected).
Action of q Shuts of power supply to personal code relay (when short circuit is detected).
machine moni- q If cause of failure disappears, machine becomes normal by itself (when open circuit is detected).
tor q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position (when short circuit is detected).
Problem on
machine
q This failure code is displayed only when engine lock function is enabled.
q Method of reproducing failure code: Turn starting switch to ON position (open circuit). Failure code
Related infor-
cannot be reproduced (short circuit).
mation
q Troubleshooting for this failure code covers circuit starting from No. 3 of fuse F01, through primary
(coil) circuit of personal code relay R07, to machine monitor.

Cause Procedure, measuring location, criteria and remarks

1 Blown fuse No. 3 of fuse box F01
2 Defective personal code relay R07 1. Turn starting switch to OFF position.
2. Replace relay R07 with another one.
3. Turn starting switch to ON position.
Open circuit or short circuit or
3
ground fault in wiring harness
4 Open circuit in wiring harness
5 Ground fault in wiring harness
6 Short circuit in wiring harness
If fuse is blown, circuit probably has ground fault.
1. Turn starting switch to OFF position.
2. Disconnect relay R07, and connect T-adapters to male side.
Between R07 (male) (1) and (2) Resistance 100 500 z
If this failure code disappears, original personal code relay R07 is defective.
1. Turn starting switch to OFF position.
2. Remove fuse No. 3 of fuse box F01.
3. Disconnect connector CM01 and connect T-adapters to female side.
Between F01-3 and CM01 (female) (6) Resistance 100 500 z
Between F01-3 or CM01 (female) (6) and ground Resistance Min. 1 Mz
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse No. 3 of fuse box F01.
3. Disconnect connector CM01 and relay R07, and connect T-adapters to
each female side.
Between F01-3 and R07 (female) (1) Resistance Max. 1 z
Between R07 (female) (2) and CM01 (female) (6) Resistance Max. 1 z
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse No. 3 of fuse box F01.
3. Disconnect connector CM01 and relay R07, and connect T-adapters to
either female side.
Between F01-3 or R07 (female) (1) and ground Resistance Min. 1 Mz
Between R07 (female) (2) and ground, or between
Resistance Min. 1 Mz
CM01 (female) (6) and ground
1. Turn starting switch to OFF position.
2. Remove fuse No. 3 of fuse box F01.
3. Disconnect connectors CM01 and relay R07, and connect T-adapters to
female side of connector CM01.
a Check by using multimeter in continuity mode.
Between CM01 (female) (6) and each pin other No continuity
than pin (6) (No sound is heard)

40-200 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [D19JKZ] Personal Code Relay Abnormality

Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, machine monitor (KOMTRAX portion) is
Defective machine monitor
7 defective. (Since this is an internal defect, troubleshooting cannot be per-
(KOMTRAX section)
formed.)

HB205-1, HB215LC-1 40-201

(01)
Troubleshooting by failure code
Failure code [D19JKZ] Personal Code Relay Abnormality

Circuit diagram related to personal code relay 40-202

40-202 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [D862KA] GPS Antenna Open Circuit

Failure code [D862KA] GPS Antenna Open Circuit 40-203

User code Failure code GPS antenna open circuit
Failure
(KOMTRAX system in machine monitor)
D862KA
Detail of failure q Open circuit is detected in GPS antenna circuit.
Action of
q None in particular
machine moni-
q If cause of failure disappears, machine becomes normal by itself.
tor
Problem on
q GPS positioning cannot work.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective GPS antenna or Probable causes are defective GPS antenna, open circuit or short circuit in antenna
1
antenna cable cable, and defective connection of antenna cable connector (GPS).

Structural illustration 40-203

HB205-1, HB215LC-1 40-203

(01)
Troubleshooting by failure code
Failure code [DA22KK] Pump Solenoid Power Low Error

Failure code [DA22KK] Pump Solenoid Power Low Error 40-204

User code Failure code Pump solenoid power supply voltage drop (input)
Failure
(Pump controller system)
E0E DA22KK
Detail of failure q Solenoid power supply voltage of controller is below 20 V.
q Stops generation of failure codes (open circuit and short circuit) for all solenoid systems while this
Action of con-
failure code is active.
troller
q If cause of failure disappears, machine becomes normal by itself.
Problem on
q No solenoid valve is energized properly, so machine does not work properly.
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective fusible link F04 or fuse
1 If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 5.)
No. 2 of fuse box F01
1. Turn starting switch to OFF position.
2 Improper battery voltage 2. After measuring voltage, measure it again when starting engine.
Between battery (+) and ground Voltage 20 30 V
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect connector C02 and connect T-adapters to female side.
3 Defective harness 3. Connect battery ground cable and turn starting switch to ON position.
Between each of (116), (118) and (121) of C02 and
Voltage 20 30 V
ground
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Remove fusible link F04 and fuse No. 2 of fuse box F01.
3. Disconnect connector C02 and connect T-adapters to female side.
4 Open circuit in wiring harness
Between each of (116), (118) and (121) of C02
Resistance Max. 1 z
(female) and F01-2
Between F01-1A and F04 (male) (2) Resistance Max. 1 z
Between F04 (male) (1) and terminal R03 Resistance Max. 1 z

a If no failure is found by checks on cause 3, this check is not required.

Ground fault in wiring harness
5
(contact with ground circuit)
6 Defective pump controller
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Remove fusible link F04 and fuse No. 2 of fuse box F01.
3. Disconnect connector C02 and connect T-adapters to female side.
Between ground and each of (116), (118) and (121)
Resistance Min. 1 Mz
of C02 (female) or F01-2
Between F01-1A or F04 (male) (2) and ground Resistance Min. 1 Mz
Between F04 (male) (1) or terminal R03 and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-204 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DA22KK] Pump Solenoid Power Low Error

Circuit diagram related to solenoid power supply 40-205

HB205-1, HB215LC-1 40-205

(01)
Troubleshooting by failure code
Failure code [DA25KP] 5V Sensor1 Power Abnormality

Failure code [DA25KP] 5V Sensor1 Power Abnormality 40-206

User code Failure code 5 V sensor power supply output 1 circuit abnormal.
Failure
(Pump controller system)
DA25KP
Detail of failure q Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
q Stops output from 5V sensor power supply output 1.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
q Automatic travel speed selector function does not work (pump pressure sensor system).
Problem on
q Auto-decelerator keeps working and is not canceled or fine control performance of work equipment
machine
is lowered (PPC pressure sensor system).
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective pressure sensor
1
(short circuit in internal wiring)
Hot short circuit in wiring harness
2 (e.g. P07).
(contact with 24 V circuit)
Ground fault in wiring harness
3 3. Connect T-adapters to female side of connector C01.
(contact with ground circuit)
4 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect following sensors one by one, and turn starting switch to ON
position for each troubleshooting.
a If this failure code disappears, disconnected sensor is defective.
3. After each troubleshooting, turn starting switch to OFF position.
Sensor Connector
Bucket CURL PPC pressure sensor P01
Bucket DUMP PPC pressure sensor P05
Arm IN pressure sensor P04
Boom RAISE PPC pressure sensor P06
Swing RIGHT PPC pressure sensor P07
Swing LEFT PPC pressure sensor P03
F pump pressure sensor P25
R pump pressure sensor P26
a To measure voltage before controller stops output.
1. Turn starting switch to OFF position.
2. Disconnect connectors P01, P03 to P07, and P25 to P26.
3. Connect T-adapters to female side of either of disconnected connectors
4. Turn starting switch to ON position (with connectors P01, P03 to P07, and
P25 to P26 disconnected).
Between P07 (female) (3) and ground Voltage 4.5 5.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors C01, P01, P03 to P07, P09, P10, and P25 to P26.
Between C01 (female) (9) and ground Resistance Min. 1 Mz
If no failure is found by above checks, the pump controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)

40-206 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DA25KP] 5V Sensor1 Power Abnormality

Circuit diagram related to 5 V sensor power supply 1 circuit 40-207

HB205-1, HB215LC-1 40-207

(01)
Troubleshooting by failure code
Failure code [DA26KP] 5V Sensor2 Power Abnormality

Failure code [DA26KP] 5V Sensor2 Power Abnormality 40-208

User code Failure code 5V sensor power supply 2 output circuit abnormal
Failure
(Pump controller system)
DA26KP
Detail of failure q Voltage of 5 V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
Action of con- q Stops power supply from 5 V sensor power supply output 2.
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned

Problem on
q All sensor functions do not work properly (arm crane specification machine).
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1 Hot short circuit in wiring harness 1. Turn starting switch to OFF position.
(contact with 24 V circuit) 2. Connect T-adapters to male side of connector A08.
3. Turn starting switch to ON position.

Between A08 (male) (7) and ground Voltage 4.5 5.5 V

1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector C01.
2 3. Connect T-adapters to female side of connector C01.
(contact with ground circuit)
Between C01 (female) (8) and ground Resistance Min. 1 Mz
If no failure is found by above checks, the pump controller is defective. (Since
3 Defective pump controller
this is an internal defect, troubleshooting cannot be performed.)
*: Connector A08 exists on arm crane specification machines (for Japan only).

40-208 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DA26KP] 5V Sensor2 Power Abnormality

Circuit diagram related to 5 V sensor power supply 2 40-209

HB205-1, HB215LC-1 40-209

(01)
Troubleshooting by failure code
Failure code [DA29KQ] Model Selection Abnormality

Failure code [DA29KQ] Model Selection Abnormality 40-210

User code Failure code Model selection abnormality

Failure
(Pump controller system)
DA29KQ
Detail of failure q Model code signal for model which is not registered in controller is input.
q Controls machine, taking it as default model (HB205).
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q No problems since pump controller recognizes as "HB205".
machine
q Input of model selection signal can be checked with monitoring function.
Related infor-
(Code: 02201 Switch Input 2)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector S30 and connect T-adapters to female side.
Between S30 (female) (1) and (8) Resistance Min. 1 Mz
Defective model selection connec- Between S30 (female) (2) and (8) Resistance Min. 1 Mz
1
tor (internal open or short circuit)
Between S30 (female) (4) and (8) Resistance Min. 1 Mz
Between S30 (female) (3) and (8) Resistance Max. 1 z
Between S30 (female) (7) and (8) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapters to female side.
2 Open circuit in wiring harness
Between C01 (female) (39) and ground Resistance Max. 1 z
Between C01 (female) (77) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapters to female side.

3 Short circuit in wiring harness Between C01 (female) (39) and C01 (21) Resistance Min. 1 Mz
Between C01 (female) (39) and C01 (40) Resistance Min. 1 Mz
Between C01 (female) (39) and C01 (58) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapters to female side.
Ground fault in wiring harness Between C01 (female) (40) and ground Resistance Min. 1 Mz
4
(contact with ground circuit)
Between C01 (female) (58) and ground Resistance Min. 1 Mz
Between C01 (female) (21) and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this
5 Defective pump controller
is an internal defect, troubleshooting cannot be performed.)

40-210 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DA29KQ] Model Selection Abnormality

Circuit diagram related to model selection 40-21

HB205-1, HB215LC-1 40-211

(01)
Troubleshooting by failure code
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

Failure code [DA2RMC] CAN Discon (Pump Con Detected) 40-212

User code Failure code CAN communication disable (pump controller detected)
Failure
(Pump controller system)
E0E DA2RMC

q Pump controller fails in CAN communication with inverter (hybrid controller) or engine controller.
Detail of failure
1) CAN communication line or ACC line of starting switch is defective.

q Limits pump absorption torque to a certain level.

Action of con- q Continues to control machine by using information of CAN communication just before detection of
troller error.
q If cause of failure disappears, machine becomes normal by itself.
q Engine output lowers. (Pump absorption torque decreases.)
q If work load increases, engine may stall.
Problem on
q Information may not be transmitted normally through CAN communication lines and machine may
machine
not operate normally.
(Failure symptom depends on failed section.)
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is recognized by each controller when ACC signal of starting switch
is received.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code
[DA2RMC] is displayed on machine monitor, CAN communication between pump controller and
machine monitor is normal. That is, there can not be short circuit, ground fault or hot short circuit in
CAN communication line.
Related infor- q Since air conditioner is also controlled via CAN communication, check whether you can operate air
mation conditioner (such as power on/off switching and air flow rate control) on "Air conditioner" screen.)
(air conditioner can be controlled even if failure code [DA2RMC] is displayed.)
q [If failure codes [DAFRMC] and [GA14KR] are also displayed, engine controller may be defective.
q If failure code [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller may be defective.
q Since each controller and machine monitor are connected to battery directly, they receive continu-
ous power even while starting switch is at OFF position.
q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using
multimeter.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Remove fuses F01-19 (30 A fuse) and F01-20 (5 A fuse).
1 Defective fuse F01-19 or 20
a If fuse is blown, controller probably has short circuit.

a If fuse is not blown, this check is not required.

Defective engine controller
2
(internal short circuit)
Improper power supply to engine
3 3. Turn starting switch to ON position.
controller
Defective CAN terminating resistor
4
(internal open or short circuit)
1. Turn starting switch to OFF position.
2. Disconnect connector CE03, and connect T-adapters to male side.
a If measured resistance is below 10 z, engine controller is defective (inter-
nal short circuit).
Between CE03 (male) (3) and (1) Resistance Min. 10 z
a Check ground terminal T12 for looseness and rust.
1. Turn starting switch to OFF position.
2. Disconnect connector CE03, and connect T-adapters to female side.
a If fuse F01-19 is broken, replace it with new one.
Between CE03 (female) (3) and (1) Voltage 20 30 V
a If failure is found, perform troubleshooting for Detail of failure 2) "Engine
controller power supply circuit is abnormal."
1. Turn starting switch to OFF position.
2. Disconnect connectors HK02 and CM02, and connect T-adapters to each
male side.
Between HK02 (male) (A) and (B) Resistance 120 12 z
Between CM02 (male) (8) and (10) Resistance 120 12 z

40-212 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

Cause Procedure, measuring location, criteria and remarks

Open or short circuit in wiring har-
5
ness
Open circuit in wiring harness
6 (wire breakage or defective con-
tact of connector)
q CAN communication line
a There is 120 z CAN terminating resistor inside machine monitor, too. Since
120 z resistors are connected in parallel, if combined resistance measured
at connector of controller other than machine monitor is 60 z, there is no
open circuit in harness.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect one of connectors CE02, C01, N10, HK02, CM02, and HC02,
and connect T-adapters to female side of connector disconnected.
a If short circuit occurs (if resistance between terminals is 1 z or less), dis-
connect all of connectors CE02, C01, N10, HK02, CM02, and HC02. Then,
check whether failure is short circuit between wiring harnesses or within the
controller.
Approx.
Between CE02 (female) (46) and (47) Resistance
60 z
Approx.
Between C01 (female) (45) and (64) Resistance
60 z
Approx.
Between N10 (female) (1) and (2) Resistance
60 z
Approx.
Between HC02 (female) (1) and (11) Resistance
60 z
Approx.
Between HK02 (female) (A) and (B) Resistance
120 z
Approx.
Between CM02 (female) (9) and (10) Resistance
120 z
a If no failure is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect connectors CE02, C01, N10, HK02, CM02, and HC02, and
connect T-adapters to each female side.
Between C01 (female) (45) and each of CM02
Resistance Max. 1 z
(female) (9) and (8).
Between C01 (female) (64) and CM02 (female) (10) Resistance Max. 1 z
Between C01 (female)( 45) and CE02 (female) (46) Resistance Max. 1 z
Between C01 (female) (64) and CE02 (female) (47) Resistance Max. 1 z
Between C01 (female) (45) and HC02 (female) (1) Resistance Max. 1 z
Between C01 (female) (64) and HC02 (female) (11) Resistance Max. 1 z
Between C01 (female) (45) and N10 (female) (1) Resistance Max. 1 z
Between C01 (female) (64) and N10 (female) (2) Resistance Max. 1 z
Between CE02 (female) (46) and HK02 (female) (A) Resistance Max. 1 z
Between CE02 (female) (47) and HK02 (female) (B) Resistance Max. 1 z
q ACC signal from starting switch
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Insert T-adapters into connectors CE02, C01, CM01, and HC01.
3. Connect battery ground cable and turn starting switch to ON position.
Between CE02 (39) and ground Voltage 20 30 V
Between C01 (2) and each of C01 (24), (43) and
Voltage 20 30 V
(79)
Between CM01 (14) and (3) Voltage 20 30 V
Between each of HC01 (6) and (12) and (17) Voltage 20 30 V

HB205-1, HB215LC-1 40-213

(01)
Troubleshooting by failure code
Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Cause
Open circuit in wiring harness
6 (wire breakage or defective con-
tact of connector)
7 Defective engine controller
Defective power supply to inverter
8 Perform troubleshooting for failure code [DW45KK], cause 1 to 6.
(hybrid controller)
Defective inverter (hybrid control-
9 played on machine monitor, inverter (hybrid controller) is defective. (Since this
ler)
10 Defective pump controller
40-214
Procedure, measuring location, criteria and remarks
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect connectors CE02, C01, CM01, and HC01, and connect
T-adapters to each female side.
Between starting switch (ACC) and each of C01
Resistance Max. 1 z
(female) (24), (43) and (79).
Between starting switch (ACC) and CM01 (female)
Resistance Max. 1 z
(14)
Between starting switch (ACC) and CE02 (female)
Resistance Max. 1 z
(39)
Between starting switch (ACC) and each of HC01
Resistance Max. 1 z
(female) (6) and (12)
If no failure is found by above checks and if failure codes [DAFRMC] and
[GA14KR] are also displayed on machine monitor, engine controller is defec-
tive.
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks and if failure code [DAFRMC] is also dis-
is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, the pump controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
HB205-1, HB215LC-1
(01)
 Troubleshooting by failure code
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

Circuit diagram related to CAN communication line 40-215

HB205-1, HB215LC-1 40-215

(01)
Troubleshooting by failure code
Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Detail of failure 2) Engine controller power supply circuit is abnormal.
Cause
1 Loose or corroded battery terminal Battery terminal may be loosened or corroded. Check it directly.
2 Defective fuse F01-19
Defective wiring harness connec-
3 ment"of "Checks before troubleshooting" in "General information on trouble-
tor
4 Lowered battery voltage
Defective relays (R23 and R24) for
5
engine controller power supply
6 Defective diode D10 and D11
Open circuit in wiring harness
7 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
8
(contact with ground circuit)
40-216
Procedure, measuring location, criteria and remarks
Remove fuse F01-19 (30 A fuse).
a If fuse is blown, controller probably has short circuit.
See descriptions of wiring harness and connectors in "c: Electrical equip-
shooting", and check them directly.
1. Turn starting switch to OFF position.
2. Perform troubleshooting with starting switch at OFF position and at engine
cranking.
Between battery (2 pieces) terminal (+) and (-) Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Exchange relays (R23 and R24 one by one) for engine controller power
supply with other relays.
3. Turn starting switch to ON position.
If this failure code disappeas, original relay is defective.
1. Turn starting switch to OFF position.
2. Remove diode arrays D10 and D11 and connect T-adapters to each male
side.
a Measure by using multimeter in diode range.
Between D10 (male) (2) (+) and (1) (-) Continuity
Between D10 (male) (1) (+) and (2) (-) No continuity
Between D11 (male) (2) (+) and (1) (-) Continuity
Between D11 (male) (1) (+) and (2) (-) No continuity
1. Turn starting switch to OFF position.
2. Remove fuse F01-19 (30 A fuse).
3. Disconnect connectors R23, R24, CE02, CE03, D10 and D11, and connect
T-adapters to each female side.
Between F01-19 and each of R23 (female) (3) and
Resistance Max. 1 z
R24 (female) (3)
Between CE03 (female) (3) and each of R23
Resistance Max. 1 z
(female) (5) and R24 (female) (5)
Between CE03 (female) (1) and ground (T12)
Resistance Max. 1 z
a Corroded or loosened ground terminal (T12)
Between CE02 (female) (33) and each of R23
Resistance Max. 1 z
(female) ( 2) and R24 (female) (2)
Between each of R23 (female) (1) and R24 (female)
(1) and each of D10 (female) (1) and D11 (female) Resistance Max. 1 z
(1)
Between battery relay R04 and each of R23
Resistance Max. 1 z
(female) (3) and R24 (female) (3)
Between CE02 (female) (49) and D11 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position and disconnect ground cable from
battery.
2. Remove fuse F01-19 (30 A fuse).
3. Disconnect connectors R23, R24, CE02 and CE03, and connect
T-adapters to either female side.
Between ground and any of F01-19 ,R23 (female)
Resistance Min. 1 Mz
(3) or R24 (female) (3)
Between ground and any of R23 (female) (5), R24
Resistance Min. 1 Mz
(female) (5) or CE03 (female) (3)
HB205-1, HB215LC-1
(01)
 Troubleshooting by failure code
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position and disconnect ground cable from
battery.
2. Disconnect connectors CE02 and CE03 and connect T-adapters to each
female side.
9 Short circuit in wiring harness Between CE03 (female) (3) and (1) Resistance Min. 1 Mz
Between CE03 (female) (3) and CE02 (female)
Resistance Min. 1 Mz
(each pin)
Between CE03 (female) (1) and CE02 (female)
Resistance Min. 1 Mz
(each pin)

Circuit diagram related to engine controller power supply 40-217

HB205-1, HB215LC-1 40-217

(01)
Troubleshooting by failure code
Failure code [DAF8KB] Camera Power Supply Short Circuit

Failure code [DAF8KB] Camera Power Supply Short Circuit 40-218

User code Failure code Camera power supply short circuit
Failure
(Machine monitor system)
DAF8KB
q Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.0 V or above
Detail of failure
10 V.
Action of q Stops output of power supply voltage (Rating: 8 V) to camera.
machine moni- q Even if cause of failure disappears, machine does not become normal until starting switch is turned
tor to OFF position.
Problem on
q Camera image is not displayed on monitor screen.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective camera (internal short
1
circuit)
2 Defective machine monitor
Ground fault in wiring harness
3 3. Connect T-adapters to female side of connector CM05.
(contact with ground circuit)
Hot short circuit in wiring harness 4. Turn starting switch to ON position.
4
(contact with 24 V circuit)
1. Turn starting switch to OFF position.
2. Disconnect camera connector(s), and turn starting switch to ON position.
Disconnect camera connectors and perform failure code reproducing proce-
dure. If failure code disappears, camera has internal defect.
1. Turn starting switch to OFF position.
2. Disconnect connector CM05.
3. Connect T-adapters to male side of connector CM05.
4. Turn starting switch to ON position.
Between CM05 (male) (1) and ground Voltage 6 10 V
1. Turn starting switch to OFF position.
2. Disconnect connector CM05 and camera connector(s).
Between CM05 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect camera connector(s).
3. Insert T-adapters into connector CM05.
(Disconnect camera connector(s) and check that camera is not defective in
advance.)
Between CM05 (1) and (7) Voltage Max. 10 V

40-218 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DAF8KB] Camera Power Supply Short Circuit

Circuit diagram related to camera power supply 40-219

HB205-1, HB215LC-1 40-219

(01)
Troubleshooting by failure code
Failure code [DAFGMC] GPS Module Error

Failure code [DAFGMC] GPS Module Error 40-2 0

User code Failure code GPS module defective
Failure
(KOMTRAX system in machine monitor)
DAFGMC
q Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication mo-
Detail of failure
dem in 50 seconds after KOMTRAX started.
Action of
q None in particular
machine moni-
q If cause of failure disappears, machine becomes normal by itself.
tor
Problem on
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position (at least 50 seconds after
mation starting switch is turned to ON position).

Cause Procedure, measuring location, criteria and remarks

GPS module of machine monitor may be defective. (Since this is an internal defect,
1 Defective machine monitor
troubleshooting cannot be performed.)

40-220 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Failure code [DAFRMC] CAN Discon (Monitor Detected) 40-2 1

User code Failure code CAN communication disabled (monitor detected)

Failure
(Machine monitor system)
E0E DAFRMC
q Machine monitor fails in CAN communication with pump controller, inverter (hybrid controller), or
Detail of failure engine controller.
1) CAN communication line or ACC line of starting switch
Action of
machine moni- q If cause of failure disappears, machine becomes normal by itself.
tor
q Engine output lowers. (Pump absorption torque decreases.)
q If work load increases, engine may stall.
Problem on
q Information may not be transmitted normally through CAN communication lines and machine may
machine
not operate normally.
(Failure symptom depends on failed section.)
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is recognized by each controller when ACC signal of starting switch
is received.
q Since air conditioner is also controlled via CAN communication, check whether air conditioner can
be operated (turned ON/OFF and air flow can be adjusted) on air conditioner screen. (Air condition-
er can be operated even while failure code is displayed on monitor screen.)
Related infor- If air conditioner can be operated, there is no possibility of ground fault or short circuit or hot short
mation circuit in harness (CAN communication line)
q [If failure codes [DA2RMC] and [GA14KR] are also displayed, engine controller may be defective.
q If failure code [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller may be defective.
q Since each controller and machine monitor are connected to battery directly, they receive continu-
ous power even while starting switch is at OFF position.
q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using
multimeter.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
1 Defective fuse F01-19 or 20 2. Remove fuses F01-19 (30 A fuse) and F01-20 (5 A fuse).
a If fuse is blown, controller probably has short circuit.
a If fuse is not blown, this check is not required.
1. Turn starting switch to OFF position.
Defective engine controller 2. Disconnect connector CE03, and connect T-adapters to male side.
2 a If measured resistance is below 10 z, engine controller is defective (internal
(internal short circuit)
short circuit).
Between CE03 (male) (3) and (1) Resistance Min. 10 z
a Check ground terminal T12 for looseness and rust.
1. Turn starting switch to OFF position.
2. Disconnect connector CE03, and connect T-adapters to female side.
Improper power supply to a If fuse F01-19 is broken, replace it with new one.
3 3. Turn starting switch to ON position.
engine controller
Between CE03 (female) (3) and (1) Voltage 20 30 V
a If failure is found, perform troubleshooting for failure code [DA2RMC] (Detail
of failure 2) "Engine controller power supply circuit is abnormal").
1. Turn starting switch to OFF position.
2. Disconnect connectors HK02 and CM02, and connect T-adapters to each
Defective CAN terminating resis- male side.
4
tor (internal open or short circuit) Between HK02 (male) (A) and (B) Resistance 120 12 z
Between CM02 (male) (8) and (10) Resistance 120 12 z

HB205-1, HB215LC-1 40-221

(01)
Troubleshooting by failure code
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Cause Procedure, measuring location, criteria and remarks

q CAN communication line
a CAN terminating resistor of 120 z is also installed inside machine monitor.
Since 120 z resistors are connected in parallel, if combined resistance mea-
sured at connector of controller other than machine monitor is 60 z, CAN
communication line has no open circuit.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect one of connectors of CE02, C01, N10, CM02, HK02, and HC02,
and connect T-adapters to female side of connector disconnected.
a If short circuit occurs (if resistance between terminals is 1 z or less), discon-
nect all of connectors CE02, C01, N10, CM02, HK02, and HC02. Then, check
Open or short circuit in wiring
5 whether failure is short circuit between wiring harnesses or within the control-
harness ler.
Between CE02 (female) (46) and (47) Resistance Approx. 60 z
Between C01 (female) (45) and (64) Resistance Approx. 60 z
Between N10 (female) (1) and (2) Resistance Approx. 60 z
Between HC02 (female) (1) and (11) Resistance Approx. 60 z
Between HK02 (female) (A) and (B) Resistance Approx. 120 z
Between CM02 (female) (9) and (10) Resistance Approx. 120 z
a If no failure is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect connectors CE02, C01, N10, HK02, CM02, and HC02, and
connect T-adapters to each female side.
Between C01 (female) (45) and each of CM02
Resistance Max. 1 z
(female) (9) and (8).
Between C01 (female) (64) and CM02 (female)
Resistance Max. 1 z
(10)
Between C01 (female)( 45) and CE02 (female)
Resistance Max. 1 z
(46)
Between C01 (female) (64) and CE02 (female)
Resistance Max. 1 z
(47)
Between C01 (female) (45) and HC02 (female)
Resistance Max. 1 z
(1)
Between C01 (female) (64) and HC02 (female)
Resistance Max. 1 z
Open circuit in wiring harness (11)
6 (wire breakage or defective con- Between C01 (female) (45) and N10 (female) (1) Resistance Max. 1 z
tact of connector) Between C01 (female) (64) and N10 (female) (2) Resistance Max. 1 z
Between CE02 (female) (46) and HK02 (female)
Resistance Max. 1 z
(A)
Between CE02 (female) (47) and HK02 (female)
Resistance Max. 1 z
(B)
q ACC signal from starting switch
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Insert T-adapters into connectors CE02, C01, CM01, and HC01.
3. Connect battery ground cable and turn starting switch to ON position.
Between CE02 (39) and ground Voltage 20 30 V
Between C01 (2) and each of C01 (24), (43) and
Voltage 20 30 V
(79)
Between CM01 (14) and (3) Voltage 20 30 V
Between each of HC01 (6) and (12) and (17) Voltage 20 30 V

40-222 HB205-1, HB215LC-1

(01)

Cause
Open circuit in wiring harness
6 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
7 connect T-adapters to female side of connector disconnected.
(contact with ground circuit)
Short circuit or hot short circuit 3. Connect battery ground cable.
8 (contact with 24 V circuit) in har- 4. Turn starting switch to ON position.
ness
9 Defective engine controller
Defective power supply to
10
inverter (hybrid controller)
Defective inverter (hybrid con- played on machine monitor while [GA14KR] is not displayed, inverter (hybrid
11
troller)
Improper power supply to pump Perform troubleshooting for Detail of failure 2) "Pump controller power supply cir-
12
controller
13 Defective pump controller
HB205-1, HB215LC-1
(01)
Troubleshooting by failure code
Failure code [DAFRMC] CAN Discon (Monitor Detected)
Procedure, measuring location, criteria and remarks
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect connectors CE02, C01, CM01, and HC01, and connect
T-adapters to each female side.
Between starting switch (ACC) and each of C01
Resistance Max. 1 z
(female) (24), (43) and (79).
Between starting switch (ACC) and CM01
Resistance Max. 1 z
(female) (14)
Between starting switch (ACC) and CE02
Resistance Max. 1 z
(female) (39)
Between starting switch (ACC) and each of HC01
Resistance Max. 1 z
(female) (6) and (12)
a If failure code [DA2RMC] is displayed on machine monitor, or you can operate
air conditioner on air conditioner screen, this check is not required.
a If check result of cause 5 is normal (no open circuit), measure resistance at
one connector. Disconnect one of connectors of CE02, C01, and CM02 and
Between ground and C01 (female) (45), CM02
Resistance Min. 1 Mz
(female) (8), (9) or CE02 (female) (46)
Between ground and C01 (64), CM02 (10) or
Resistance Min. 1 Mz
CE02 (47)
a If failure code [DA2RMC] is displayed on machine monitor, or you can operate
air conditioner on air conditioner screen, this check is not required.
a If check result of cause 5 is normal (no open circuit), measure at any one
place.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Insert T-adapters into connector CE02, C01 or CM02.
a CAN_H and CAN_L lines are considered to be normal if their voltage are be-
tween 1 to 4 V because their normal voltage is 2.5 1 V during communica-
tion.
Between ground and C01 (45), CM02 (8), (9) or
Voltage 14V
CE02 (46)
Between ground and C01 (64), CM02 (10) or
Voltage 14V
CE02 (47)
If no failure is found by above checks and if failure codes [DA2RMC] and
[GA14KR] are also displayed, engine controller is defective. (Since this is an
internal defect, troubleshooting cannot be performed.)
Perform troubleshooting for failure code [DW45KK], cause 1 to 6.
If no failure is found by above checks and if failure code [DA2RMC] is also dis-
controller) is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
cuit is abnormal."
If no failure is found by above checks and if failure code [GA14KR] is also dis-
played on machine monitor while [DA2RMC] is not displayed, pump controller is
defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
40-223
Troubleshooting by failure code
Failure code [DAFRMC] CAN Discon (Monitor Detected)
Cause
Defective engine controller,
14 pump controller, inverter, or air
conditioner unit
15 Defective machine monitor
40-224
Procedure, measuring location, criteria and remarks
If no failure is found by above checks and if air conditioner cannot be operated,
locate defective controller as follows.
q Step 1
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect engine controller (connector CE02), pump controller (connector
C01), and inverter (connector HC02).
3. Connect battery ground cable and turn starting switch to ON position.
4. Operate air conditioner.
a If air conditioner can be operated, go to step 2.
NO Defective air conditioner unit
Can air conditioner be operated? Removed controller is defec-
YES
tive
q Step 2
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect one of engine controller (connector CE02), pump controller
(connector C01), and inverter (connector HC02).
3. Connect battery ground cable, turn starting switch to ON position and perform
troubleshooting.
4. Return to 1. and perform troubleshooting on next controller.
Removed controller is defec-
Can air conditioner be operated? YES
tive
If no failure is found by above checks, machine monitor is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
HB205-1, HB215LC-1
(01)
 Troubleshooting by failure code
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Circuit diagram related to CAN communication 40-2 5

HB205-1, HB215LC-1 40-225

(01)
Troubleshooting by failure code
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Detail of failure 2) Pump controller power supply circuit is abnormal.

Cause Procedure, measuring location, criteria and remarks

Defective fusible link F05 or No. 17
1 If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 5.)
of fuse box F01
2 Lowered battery voltage
3 Defective harness
1. Turn starting switch to OFF position.
2. After measuring voltage, measure it again when starting engine.
Between battery (+) and ground Voltage 20 30 V
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect connector C01 and connect T-adapters to female side.
3. Connect battery ground cable and turn starting switch to ON position.
Between each of C01 (1) and (4) and ground Voltage 20 30 V

a If no failure is found by check on cause 3, this check is not required.

1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Remove fusible link F05 and fuse No. 17 of fuse box F01.
3. Disconnect connector C01 and connect T-adapters to female side.
4 Open circuit in wiring harness
Between F01 No. 17 and each of C01 (female)
Resistance Max. 1 z
(116), (118), and (121)
Between F01-16D and F05 (male) (2) Resistance Max. 1 z
Between F05 (male) (1) and terminal R04 Resistance Max. 1 z

a If no failure is found by check on cause 3, this check is not required.

1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Remove fusible link F05 and fuse No. 17 of fuse box F01.
3. Disconnect connector C01 and connect T-adapters to female side.
Ground fault in wiring harness
5
(contact with ground circuit) Between ground and any of C01 (female) (1), (4) or
Resistance Min. 1 Mz
F01-17
Between F01-16 or F05 (male) (2) and ground Resistance Min. 1 Mz
Between F05 (male) (1) or terminal R04 and ground Resistance Min. 1 Mz

40-226 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Circuit diagram related to pump controller power supply 40-2 7

HB205-1, HB215LC-1 40-227

(01)
Troubleshooting by failure code
Failure code [DGH2KB] Hyd Oil Sensor Short

Failure code [DGH2KB] Hyd Oil Sensor Short 40-2 8

User code Failure code Hydraulic oil temperature sensor short circuit
Failure
(Pump controller system)
DGH2KB
Detail of failure q Signal voltage of hydraulic oil temperature sensor circuit is below 1 V, so ground fault is detected.
Action of con-
q If cause of failure disappears, machine becomes normal by itself.
troller
Problem on q While hydraulic oil temperature rises normally, indicator of hydraulic oil temperature gauge does
machine not move from top of white range (bottom of green range).
q Signal voltage from hydraulic oil temperature sensor can be checked with monitoring function.
Related infor-
(Code: 04402: Hydraulic oil temperature sensor voltage)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P22 and connect T-adapters to male side.
10C Resistance Approx. 90 kz
Defective hydraulic oil
temperature sensor Between P22 (male) (1) and (2) 30C Resistance Approx. 35 kz
(internal open or short a Temperature-Resistance charac-
1
teristics of oil temperature sensor 80C Resistance Approx. 6.5 kz
circuit)
100C Resistance Approx. 3.5 kz
Between P22 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector P22 and connect T-adapters to female side.
Open circuit, short cir- 3. Turn starting switch to ON position.
cuit, ground fault or hot a If voltage is 0 V, wiring harness has open circuit, ground fault, or short circuit, and if
2 voltage is 24 V, wiring harness has hot short circuit.
short circuit in wiring
harness a Voltage of about 5 V is applied to temperature sensor signal lines through resistor in
pump controller.
Between P22 (female) (1) and (2) Voltage Approx. 5 V
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapters to female side.
a Use Temperature-Resistance characteristics table for troubleshooting on cause 1.
Short circuit or ground a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is below 1 z,
3
fault in wiring harness wiring harness has short circuit.
Between C01 (female) (29) and (46) Resistance 3.5 90 kz
Between C01 (female) (29) and ground Resistance Min. 1 Mz
a If no failure is found by checks cause 2, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
4 harness (contact with 2. Disconnect connectors C01 and P22, and connect T-adapters to either female side.
ground circuit) Between C01 (female) (29) and ground, or between
Resistance Min. 1 Mz
P22 (female) (2) and ground
Defective pump con- If no failure is found by above checks, pump controller is defective. (Since this is an inter-
5
troller nal defect, troubleshooting cannot be performed.)

40-228 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DGH2KB] Hyd Oil Sensor Short

Circuit diagram related to hydraulic oil temperature sensor 40-2 9

HB205-1, HB215LC-1 40-229

(01)
Troubleshooting by failure code
Failure code [DHPAMA] Pump Press Sensor Abnormality

Failure code [DHPAMA] Pump Press Sensor Abnormality 40-230

User code Failure code Front pump pressure sensor malfunction

Failure
(Pump controller system)
DHPAMA
Detail of failure q Signal voltage of front pump pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls pump taking front pump pressure to be 2.9 MPa {30 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic travel speed selector function does not work.
machine q
Straight travel performance or steering performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Front pump pressure can be checked with monitoring function.
(Code: 01100 F pump pressure).
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective 5V sensor power supply 3.
1
1 system
Defective front pump pressure
2
sensor (internal defect)
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
If failure code [DA25KP] is also displayed, carry out troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector P25, and connect T-adapters to female side.
Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to troubleshooting for cause
3.
Power sup-
Between P25 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector P25.
3. Turn starting switch to ON position.
Sensor out-
Between P25 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause is defective sensor, ground fault or hot
short circuit of harness. Check as below.
1. Turn starting switch to OFF position.
2. Replace connector P25 with connector P26 of R pump PPC pressure
sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, front pump pressure sensor
is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P25, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (18) and P25 (female) (1)
Between C01 (female) (49) and P25 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P25 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P25, and connect T-adapters to either
Between C01 (female) (49) or P25 (female) (2) and
Resistance Min. 1 Mz
ground

40-230 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHPAMA] Pump Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring harness
5
(Contact with 5 V or 24 V circuit)
6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector P25.
3. Connect T-adapters to female side of connector P25.
4. Turn starting switch to ON position.
Between P25 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to front pump pressure sensor 40-231

HB205-1, HB215LC-1 40-231

(01)
Troubleshooting by failure code
Failure code [DHPBMA] R Pump Press Sensor Abnormality

Failure code [DHPBMA] R Pump Press Sensor Abnormality 40-232

User code Failure code Rear pump pressure sensor malfunction

Failure
(Pump controller system)
DHPBMA
Detail of failure q Signal voltage of rear pump pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls pump taking rear pump pressure to be 2.9 MPa {30 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic travel speed selector function does not work.
machine q
Straight travel performance or steering performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Rear pump pressure can be checked with monitoring function.
(Code: 01101 R pump pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P26, and connect T-adapters to female side.
1 3. Turn starting switch to ON position.
1 system
Defective rear pump pressure sen-
2
sor (internal defect)
Open circuit in wiring harness
3 (wire breakage or defective con- Between C01 (female) (18) and P26 (female) (1)
tact of connector)
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
a If power supply voltage is abnormal, proceed to troubleshooting for cause
3.
Power sup-
Between P26 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Connect T-adapters to connector P26.
3. Turn starting switch to ON position.
Sensor out-
Between P26 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause is defective sensor, ground fault or hot
short circuit of harness. Check as below.
1. Turn starting switch to OFF position.
2. Replace connector P26 with connector P25 of front pump PPC pressure
sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, rear pump pressure sensor
is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P26, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (68) and P26 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P26 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P26, and connect T-adapters to either
Between C01 (female) (68) or P26 (female) (2) and
Resistance Min. 1 Mz
ground

40-232 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHPBMA] R Pump Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring harness
5
(Contact with 5 V/24 V circuit)
6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector P26.
3. Connect T-adapters to female side of connector P26.
4. Turn starting switch to ON position.
Between P26 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to rear pump pressure sensor 40-23

HB205-1, HB215LC-1 40-233

(01)
Troubleshooting by failure code
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality

Failure code [DHS3MA] Arm IN PPC Sen. Abnormality 40-234

User code Failure code Arm IN PPC sensor system malfunction

Failure
(Pump controller system)
DHS3MA
Detail of failure q Signal voltage of arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking arm IN PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Arm IN performance lowers.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200 Arm IN PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P04 and connect T-adapters to female side.
1 3. Turn starting switch to ON position.
1 system
a If power supply voltage is abnormal, proceed to troubleshooting for cause
cause 3.
Power sup-
Between P04 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector P04
3. Turn starting switch to ON position.
Sensor out-
Between P04 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective arm IN PPC pressure is difficult to judge whether cause is defective sensor, ground fault or hot
2 short circuit of harness. Check as below.
sensor (internal defect)
1. Turn starting switch to OFF position.
2. Replace connector P04 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, arm IN PPC pressure sensor
is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P04, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between C01 (female) (18) and P04 (female) (1)
tact of connector)
Between C01 (female) (17) and P04 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P04 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P04, and connect T-adapters to either
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
Between C01 (female) (17) or P04 (female) (2) and
Resistance Min. 1 Mz
ground

40-234 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality

Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring harness
5
(contact with 24 V circuit)
6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector P04.
3. Connect T-adapters to female side of connector P04.
4. Turn starting switch to ON position.
Between P04 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to arm IN PPC pressure sensor 40-235

HB205-1, HB215LC-1 40-235

(01)
Troubleshooting by failure code
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality

Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality 40-236

User code Failure code Bucket CURL PPC pressure sensor system malfunction
Failure
(Pump controller system)
DHS4MA
Detail of failure q Signal voltage of bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- Controls machine taking bucket CURL PPC pressure to be 0 MPa {0 kg/cm2}.
q
troller q
If cause of failure disappears, machine becomes normal by itself.
q Automatic deceleration cannot be canceled.
Problem on
q Bucket CURL performance lowers.
machine
q Low speed matching function is disabled.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Bucket CURL PPC pressure can be checked with monitoring function.
(Code: 07300 Bucket CURL PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P01 and connect T-adapters to female side.
1 3. Turn starting switch to ON position.
1 system
a If power supply voltage is abnormal, proceed to troubleshooting for cause
3.
Power sup-
Between P01 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector P01.
3. Turn starting switch to ON position.
Sensor out-
Between P01 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective bucket CURL PPC pres- is difficult to judge whether cause is defective sensor, ground fault or hot
2 short circuit of harness. Check as below.
sure sensor (internal defect)
1. Turn starting switch to OFF position.
2. Replace connector P01 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, bucket CURL PPC pressure
sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P01, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between C01 (female) (18) and P01 (female) (1)
tact of connector)
Between C01 (female) (73) and P01 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P01 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P01, and connect T-adapters to either
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
Between C01(female) (73) and ground, or between
Resistance Min. 1 Mz
P01 (female) (2) and ground

40-236 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring harness
5
(contact with 24 V circuit)
6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector P01.
3. Connect T-adapters to female side of connector P01.
4. Turn starting switch to ON position.
Between P01 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to bucket CURL PPC pressure sensor 40-237

HB205-1, HB215LC-1 40-237

(01)
Troubleshooting by failure code
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality

Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality 40-238

User code Failure code Boom RAISE PPC pressure sensor system malfunction
Failure
(Pump controller system)
DHS8MA
Detail of failure q Signal voltage of boom RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- Controls machine taking boom RAISE PPC pressure to be 0 MPa {0 kg/cm2}.
q
troller q If cause of failure disappears, machine becomes normal by itself.
q Automatic deceleration cannot be canceled.
Problem on
q Boom RAISE performance lowers.
machine
q Low speed matching function is disabled.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Boom RAISE PPC pressure can be checked with monitoring function.
(Code: 07400 Boom RAISE PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1.
Turn starting switch to OFF position.
Defective 5V sensor power 2.
Disconnect connector P06 and connect T-adapters to female side.
1 3.
Turn starting switch to ON position.
supply 1 system
a
If power supply voltage is abnormal, proceed to troubleshooting for cause 3.
Power sup-
Between P06 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters in connector P06.
3. Turn starting switch to ON position.
Sensor out-
Between P06 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it is dif-
Defective boom RAISE PPC ficult to judge whether cause is defective sensor, ground fault or hot short circuit
2 pressure sensor (internal of harness. Check as below.
defect) 1. Turn starting switch to OFF position.
2. Replace connector P06 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record" screen of
electrical system on machine monitor.
4. If E mark is not displayed for this failure code, boom RAISE PPC pressure sensor
is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P06, and connect T-adapters to each female
side.
Open circuit in wiring har- a If power supply voltage measured in check on cause
ness (wire breakage or 1 is normal, this check is not required. Resistance Max. 1 z
3
defective contact of connec- Between C01 (female) (18) and P06 (female) (1)
tor) Between C01 (female) (53) and P06 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on cause
1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P06 (female) (3)
1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Disconnect connectors C01 and P06, and connect T-adapters to either female
4 ness (contact with ground side.
circuit) Between C01 (female) (53) and ground, or between
Resistance Min. 1 Mz
P06 (female) (2) and ground

40-238 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring har- 2. Disconnect connector P06.
5 ness (contact with 24 V cir- 3. Connect T-adapters to female side of connector P06.
cuit) 4. Turn starting switch to ON position.
Between P06 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an
6 Defective pump controller
internal defect, troubleshooting cannot be performed.)

Circuit diagram related to boom RAISE PPC pressure sensor 40-239

HB205-1, HB215LC-1 40-239

(01)
Troubleshooting by failure code
Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open or short circuit

Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open
or short circuit 40-240

User code Failure code Swing RIGHT PPC pressure sensor open or short circuit
Failure
(Pump controller system)
E09 DHSAKZ
Detail of failure q Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
q Limits swing speed, etc.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Swing RIGHT PPC pressure can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P07, and connect T-adapters to female side.
1 3. Turn starting switch to ON position.
1 system
a If power supply voltage is abnormal, proceed to troubleshooting for cause
3.
Power sup-
Between P07 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Connect T-adapters to connector P07.
3. Turn starting switch to ON position.
Sensor out-
Between P07 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective swing RIGHT PPC pres- is difficult to judge whether cause is defective sensor, ground fault or hot
2 short circuit of harness. Check as below.
sure sensor (internal defect)
1. Turn starting switch to OFF position.
2. Replace connector P07 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, swing RIGHT PPC pressure
sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P07, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between C01 (female) (18) and P07 (female) (1)
tact of connector)
Between C01 (female) (72) and P07 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P07 (female) (3)

40-240 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open or short circuit

Cause Procedure, measuring location, criteria and remarks

Ground fault in wiring harness
4 female side.
(contact with ground circuit)
Hot short circuit in wiring harness
5
(contact with 5 V/24 V circuit)
6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P07, and connect T-adapters to either
Between ground and C01 (female) (72) or P07
Resistance Min. 1 Mz
(female) (2)
1. Turn starting switch to OFF position.
2. Disconnect connector P07.
3. Connect T-adapters to female side of connector P07.
4. Turn starting switch to ON position.
Between P07 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to swing RIGHT PPC pressure sensor 40-241

HB205-1, HB215LC-1 40-241

(01)
Troubleshooting by failure code
Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open or short circuit

Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open
or short circuit 40-242

User code Failure code Swing LEFT PPC pressure sensor open or short circuit
Failure
(Pump controller system)
E09 DHSBKZ
Detail of failure q Signal voltage of swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
q Limits swing speed, etc.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P03 and connect T-adapters to female side.
1 3. Turn starting switch to ON position.
1 system
a If power supply voltage is abnormal, proceed to troubleshooting for cause
3.
Power sup-
Between P03 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector P03.
3. Turn starting switch to ON position.
Sensor out-
Between P03 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective swing LEFT PPC pres- is difficult to judge whether cause is defective sensor, ground fault or hot
2 short circuit of harness. Check as below.
sure sensor (internal defect)
1. Turn starting switch to OFF position.
2. Replace connector P03 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E-mark for this failure code is not displayed, swing LEFT PPC pressure
sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P03, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between C01 (female) (18) and P03 (female) (1)
tact of connector)
Between C01 (female) (16) and P03 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P03 (female) (3)

40-242 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open or short circuit

Cause Procedure, measuring location, criteria and remarks

Ground fault in wiring harness
4 female side.
(contact with ground circuit)
Hot short circuit in wiring harness
5
(Contact with 5 V/24 V circuit)
6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P03, and connect T-adapters to either
Between ground and C01 (female) (16) or P03
Resistance Min. 1 Mz
(female) (2)
1. Turn starting switch to OFF position.
2. Disconnect connector P03.
3. Connect T-adapters to female side of connector P03.
4. Turn starting switch to ON position.
Between P03 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to swing LEFT PPC pressure sensor 40-243

HB205-1, HB215LC-1 40-243

(01)
Troubleshooting by failure code
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality

Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality 40-24

User code Failure code Swing RIGHT PPC pressure sensor malfunction
Failure
(Pump controller system)
DHSAMA
Detail of failure q Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking swing RIGHT PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Poor operatability of right swing operation
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Swing RIGHT PPC pressure can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P07, and connect T-adapters to female side.
1 3. Turn starting switch to ON position.
1 system
a If power supply voltage is abnormal, proceed to troubleshooting for cause
3.
Power sup-
Between P07 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Connect T-adapters to connector P07.
3. Turn starting switch to ON position.
Sensor out-
Between P07 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective swing RIGHT PPC pres- is difficult to judge whether cause is defective sensor, ground fault or hot
2 short circuit of harness. Check as below.
sure sensor (internal defect)
1. Turn starting switch to OFF position.
2. Replace connector P07 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, swing RIGHT PPC pressure
sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P07, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between C01 (female) (18) and P07 (female) (1)
tact of connector)
Between C01 (female) (72) and P07 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P07 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P07, and connect T-adapters to either
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
Between ground and C01 (female) (72) or P07
Resistance Min. 1 Mz
(female) (2)

40-244 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality

Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring harness
5
(Contact with 5 V/24 V circuit)
6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector P07.
3. Connect T-adapters to female side of connector P07.
4. Turn starting switch to ON position.
Between P07 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to swing RIGHT PPC pressure sensor 40-245

HB205-1, HB215LC-1 40-245

(01)
Troubleshooting by failure code
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality

Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality 40-246

User code Failure code Swing LEFT PPC pressure sensor malfunction
Failure
(Pump controller system)
DHSBMA
Detail of failure q Signal voltage of swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking swing LEFT PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Poor operatability of left swing operation
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P03 and connect T-adapters to female side.
1 3. Turn starting switch to ON position.
1 system
a If power supply voltage is abnormal, proceed to troubleshooting for cause
3.
Power sup-
Between P03 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector P03.
3. Turn starting switch to ON position.
Sensor out-
Between P03 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective swing LEFT PPC pres- is difficult to judge whether cause is defective sensor, ground fault or hot
2 short circuit of harness. Check as below.
sure sensor (internal defect)
1. Turn starting switch to OFF position.
2. Replace connector P03 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E-mark for this failure code is not displayed, swing LEFT PPC pressure
sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P03, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between C01 (female) (18) and P03 (female) (1)
tact of connector)
Between C01 (female) (16) and P03 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P03 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P03, and connect T-adapters to either
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
Between ground and C01 (female) (16) or P03
Resistance Min. 1 Mz
(female) (2)

40-246 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality

Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring harness
5
(Contact with 5 V/24 V circuit)
6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector P03.
3. Connect T-adapters to female side of connector P03.
4. Turn starting switch to ON position.
Between P03 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to swing LEFT PPC pressure sensor 40-247

HB205-1, HB215LC-1 40-247

(01)
Troubleshooting by failure code
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality

Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 40-248

User code Failure code Bucket DUMP PPC pressure sensor malfunction
Failure
(Pump controller system)
DHSDMA
Detail of failure q Signal voltage of bucket DUMP PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- Controls machine taking bucket DUMP PPC pressure to be 0 MPa {0 kg/cm2}.
q
troller q
If cause of failure disappears, machine becomes normal by itself.
q Automatic deceleration cannot be canceled.
Problem on
q Bucket DUMP performance lowers.
machine
q Low speed matching function is disabled.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Bucket DUMP PPC pressure can be checked with monitoring function.
(Code: 07301 Bucket DUMP PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P05 and connect T-adapters to female side.
1 3. Turn starting switch to ON position.
1 system
a If power supply voltage is abnormal, proceed to troubleshooting for cause
3.
Power sup-
Between P05 (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector P05.
3. Turn starting switch to ON position.
Sensor out-
Between P05 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective bucket DUMP PPC pres- is difficult to judge whether cause is defective sensor, ground fault or hot
2 short circuit of harness. Check as below.
sure sensor (internal defect)
1. Turn starting switch to OFF position.
2. Replace connector P05 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, bucket DUMP PPC pressure
sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P05, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between C01 (female) (18) and P05 (female) (1)
tact of connector)
Between C01 (female) (34) and P05 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P05 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P05, and connect T-adapters to either
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
Between ground and C01 (female) (34) or P05
Resistance Min. 1 Mz
(female) (2)

40-248 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring harness
5
(contact with 24 V circuit)
6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector P05.
3. Connect T-adapters to female side of connector P05.
4. Turn starting switch to ON position.
Between P05 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to bucket DUMP PPC pressure sensor 40-249

HB205-1, HB215LC-1 40-249

(01)
Troubleshooting by failure code
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit

Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open
or short circuit 40-250

User code Failure code HYB arm IN PPC pressure sensor open or short circuit
Failure
(Hybrid controller system)
E09 DHV3KZ
Detail of failure q Signal voltage of HYB arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.

Action of con- q Controls machine taking arm IN PPC pressure to be 0 MPa {0 kg/cm2}.
q Low speed matching function does not work.
troller
q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Low speed matching function is disabled.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q HYB arm IN PPC pressure sensor voltage can be checked with monitoring function.
Related infor-
(Code: 07202 Arm IN PPC pressure sensor 2 voltage)
mation
q Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200 Arm IN PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [GA13MC] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective power supply system for 2. Disconnect connector HP05 and connect T-adapters to female side.
1
5 V sensor
Defective HYB arm IN PPC pres-
2 short circuit of harness. Check as below.
sure sensor (internal failure)
Open circuit in wiring harness
3 (wire breakage or defective con- Between HC02 (female) (38) and HP05 (female) (1)
tact of connector)
3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to troubleshooting for cause 3.
Power sup-
Between HP05 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector HP05.
3. Turn starting switch to ON position.
Sensor out-
Between HP05 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause is defective sensor, ground fault or hot
1. Turn starting switch to OFF position.
2. Replace connector HP05 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, HYB system arm IN PPC
pressure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP05, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between HC02 (female) (10) and HP05 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between HC02 (female) (7) and HP05 (female) (3)

40-250 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP05, and connect T-adapters to either
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
Between HC02 (female) (10) or HP05 (female)
Resistance Min. 1 Mz
(2) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector HP05.
Hot short circuit in wiring harness 3. Connect T-adapters to female side of connector HP05.
5
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Between HP05 (female) (2) and ground Voltage Max. 1 V
Defective inverter (hybrid control- If no failure is found by above checks, inverter (hybrid controller) is defective.
6
ler) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to HYB arm IN PPC pressure sensor 40-251

HB205-1, HB215LC-1 40-251

(01)
Troubleshooting by failure code
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir

Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir 40-252

User code Failure code HYB boom LOWER PPC pressure sensor open or short circuit
Failure
(Hybrid controller system)
E09 DHV9KZ
Detail of failure q Signal voltage of HYB boom LOWER PPC pressure sensor circuit is below 0.3 V or above 4.5 V.

Action of con- q Controls machine taking boom LOWER PPC pressure to be 0 MPa {0 kg/cm2}.
q Disables low speed matching function.
troller
q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Low speed matching function is disabled.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related infor- q Lever stroke sensed by HYB boom LOWER PPC pressure sensor can be checked with monitoring
mation function.
(Code: 42104 Boom lever stroke)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [GA13MC] is also displayed, perform troubleshooting for it first.

Defective 5V sensor power sup-
1
ply 1 system
Defective HYB boom LOWER
2 PPC pressure sensor (internal fail-
ure)
Open circuit in wiring harness
3 (wire breakage or defective con- Between HC02 (female) (38) and HP07 (female) (1)
tact of connector)
1.
Turn starting switch to OFF position.
2.
Disconnect connector HP07 and connect T-adapters to female side.
3.
Turn starting switch to ON position.
a
If power supply voltage is abnormal, proceed to troubleshooting for cause 3.
Power sup-
Between HP07 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector HP07.
3. Turn starting switch to ON position.
Sensor out-
Between HP07 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause is defective sensor, ground fault or hot
short circuit of harness. Check as follows.
1. Turn starting switch to OFF position.
2. Replace connector HP07 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, HYB boom LOWER PPC
pressure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP07, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between HC02 (female) (20) and HP07 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between HC02 (female) (7) and HP07 (female) (3)

40-252 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP07, and connect T-adapters to either
Ground fault in wiring harness female side.
4
(contact with ground circuit)
Between HC02 (female) (20) or HP07 (female)
Resistance Min. 1 Mz
(2) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector HP07.
Hot short circuit in wiring harness 3. Connect T-adapters to female side of connector HP07.
5
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Between HP07 (female) (2) and ground Voltage Max. 1 V
Defective inverter (hybrid control- If no failure is found by above checks, inverter (hybrid controller) is defective.
6
ler) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to HYB boom LOWER PPC pressure sensor 40-253

HB205-1, HB215LC-1 40-253

(01)
Troubleshooting by failure code
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir

Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir 40-254

User code Failure code HYB swing RIGHT PPC pressure sensor open or short circuit
Failure
(Hybrid controller system)
E09 DHVAKZ
Detail of failure q Signal voltage of HYB swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
q Controls machine movement and limits swing speed, etc. according to swing RIGHT PPC pressure
Action of con- obtained by pump controller.
troller q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related infor- q Signal voltage from HYB swing RIGHT PPC pressure sensor can be checked with monitoring func-
mation tion.
(Code: 09007 Swing RIGHT PPC pressure sensor 2 voltage)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [GA13MC] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector HP06 and connect T-adapters to female side.
Defective power supply system for 3. Turn starting switch to ON position.
1
5 V sensor a If power supply voltage is abnormal, perform troubleshooting for failure
code [GA13MC].
Power sup-
Between HP06 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector HP06.
3. Turn starting switch to ON position.
Sensor out-
Between HP06 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause is defective sensor, ground fault or hot
Defective HYB swing RIGHT PPC
2 short circuit of harness. Check as below.
pressure sensor (internal failure)
1. Turn starting switch to OFF position.
2. Replace connector HP06 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, HYB swing RIGHT PPC pres-
sure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP06, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between HC02 (female) (38) and HP06 (female) (1)
tact of connector)
Between HC02 (female) (9) and HP06 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between HC02 (female) (7) and HP06 (female) (3)

40-254 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP06, and connect T-adapters to either
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
Between HC02 (female) (9) or HP06 (female)
Resistance Min. 1 Mz
(2) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector HP06.
Hot short circuit in wiring harness 3. Connect T-adapters to female side of connector HP06.
5
(contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
Between HP06 (female) (2) and ground Voltage Max. 1 V
Defective inverter (hybrid control- If no failure is found by above checks, inverter (hybrid controller) is defective.
6
ler) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to HYB swing RIGHT PPC pressure sensor 40-25

HB205-1, HB215LC-1 40-255

(01)
Troubleshooting by failure code
Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor signal abnormality

Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor
signal abnormality 40-256

User code Failure code HYB swing RIGHT PPC pressure sensor signal abnormal
Failure
(Hybrid controller system)
E09 DHVAL8
q Whie motor-generator is running, difference between measured values from HYB swing RIGHT
Detail of failure PPC pressure sensor and pump controller swing RIGHT PPC pressure sensor exceeds 0.49 MPa
{5.0 kg/cm2}.
q Controls machine using value from pump controller or HYB swing RIGHT PPC pressure sensors
whichever are smaller.
Action of con-
q Limits swing speed, etc.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q HYB swing RIGHT PPC pressure can be checked with monitoring function.
Related infor-
(Code: 09008 Swing Right PPC Pressure #2)
mation
q Pressure sensed by swing RIGHT PPC pressure sensor can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure codes [DHVAKZ], [DHSAKZ], [GA14KR], and [GA60MC].

40-256 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor malfunction

Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor
malfunction 40-257

User code Failure code HYB swing RIGHT PPC pressure sensor malfunction
Failure
(Hybrid controller system)
E09 DHVAMA
q Two failures from among HYB swing RIGHT PPC pressure sensor open or short circuit [DHVAKZ],
Detail of failure HYB swing RIGHT PPC pressure sensor signal abnormal [DHVAL8], KOMNET datalink timeout
error, or pump controller swing RIGHT PPC pressure sensor malfunction occur.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Hoist matching function does not work.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing is disabled.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q HYB swing RIGHT PPC pressure sensor voltage can be checked with monitoring function.
Related infor-
(Code: 09007 Swing RIGHT PPC pressure sensor 2 voltage)
mation
q Pressure sensed by swing RIGHT PPC pressure sensor can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure codes [DHVAKZ], [DHSAKZ], and [GA14KR].

HB205-1, HB215LC-1 40-257

(01)
Troubleshooting by failure code
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir

Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir 40-258

User code Failure code HYB in swing LEFT PPC pressure sensor open or short circuit
Failure
(Hybrid controller system)
E09 DHVBKZ
Detail of failure q Signal voltage of HYB swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
q Controls machine movement and limits swing speed, etc. according to swing LEFT PPC pressure
Action of con- obtained by pump controller.
troller q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related infor-
q HYB swing LEFT PPC pressure sensor voltage can be checked with monitoring function.
mation
(Code: 09006 Swing LEFT PPC pressure sensor 2 voltage)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective power supply system for 3.
1
5 V sensor
Defective HYB swing LEFT PPC
2 short circuit of harness. Check as below.
pressure sensor (internal failure)
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
If failure code [GA13MC] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector HP04 and connect T-adapters to female side.
Turn starting switch to ON position.
a If power supply voltage is abnormal, perform troubleshooting for failure
code [GA13MC].
Power sup-
Between HP04 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector HP04.
3. Turn starting switch to ON position.
Sensor out-
Between HP04 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause is defective sensor, ground fault or hot
1. Turn starting switch to OFF position.
2. Replace connector HP04 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, HYB swing LEFT PPC pres-
sure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP04, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between HC02 (female) (38) and HP04 (female) (1)
Between HC02 (female) (19) and HP04 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between HC02 (female) (7) and HP04 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP04, and connect T-adapters to either
Between HC02 (female) (19) or HP04 (female) (2)
Resistance Min. 1 Mz
and ground

40-258 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector HP04.
Hot short circuit in wiring harness 3. Connect T-adapters to female side of connector HP04.
5
(Contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
Between HP04 (female) (2) and ground Voltage Max. 1 V
Defective inverter (hybrid control- If no failure is found by above checks, inverter (hybrid controller) is defective.
6
ler) (Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to swing LEFT PPC pressure sensor 40-259

HB205-1, HB215LC-1 40-259

(01)
Troubleshooting by failure code
Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor signal abnormality

Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor
signal abnormality 40-260

User code Failure code HYB swing LEFT PPC pressure sensor signal abnormal
Failure
(Hybrid controller system)
E09 DHVBL8
q Whie motor-generator is running, difference between measured values from HYB swing LEFT PPC
Detail of failure pressure sensor and pump controller swing LEFT PPC pressure sensor exceeds 0.49 MPa
{5.0 kg/cm2}.
q Controls machine using value from pump controller or HYB swing LEFT PPC pressure sensors
whichever are smaller.
Action of con-
q Limits swing speed, etc.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q Pressure sensed by HYB swing LEFT PPC pressure can be checked with monitoring function.
Related infor-
(Code: 09008 Swing LEFT PPC Pressure #2)
mation
q Pressure sensed by swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure codes [DHVBKZ], [DHSBKZ], [GA14KR], and [GA60MC].

40-260 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor malfunction

Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor
malfunction 40-261

User code Failure code HYB swing LEFT PPC pressure sensor malfunction
Failure
(Hybrid controller system)
E09 DHVBMA
q Two failures from among HYB system swing LEFT PPC pressure sensor open or short circuit [DH-
Detail of failure VBKZ], HYB swing LEFT PPC pressure sensor signal abnormal [DHVBL8], KOMNET datalink tim-
eout error, or pump controller swing LEFT PPC pressure malfunction occur.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Hoist matching function does not work.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing is disabled.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q HYB swing LEFT PPC pressure sensor voltage can be checked with monitoring function.
Related infor-
(Code: 09006 Swing LEFT PPC pressure sensor 2 voltage)
mation
q Pressure sensed by swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure codes [DHVBKZ], [DHSBKZ], and [GA14KR].

HB205-1, HB215LC-1 40-261

(01)
Troubleshooting by failure code
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir

Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir 40-262

User code Failure code HYB arm OUT PPC pressure sensor open or short circuit
Failure
(Hybrid controller system)
E09 DHVCKZ
Detail of failure q Signal voltage of HYB arm OUT PPC pressure sensor circuit is below 0.3 V or above 4.5 V.

Action of con- q Controls machine taking arm OUT PPC pressure to be 0 MPa {0 kg/cm2}.
q Disables low speed matching function.
troller
q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Low speed matching function is disabled.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related infor-
q HYB arm OUT PPC pressure sensor voltage can be checked with monitoring function.
mation
(Code: 07602 Arm OUT PPC pressure sensor voltage 2)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [GA13MC] is also displayed, perform troubleshooting for it first.

1.
Turn starting switch to OFF position.
Defective 5V sensor power sup- 2.
Disconnect connector HP03 and connect T-adapters to female side.
1
ply 1 system 3.
Turn starting switch to ON position.
a
If power supply voltage is abnormal, proceed to troubleshooting for cause 3.
Power sup-
Between HP03 (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector HP03.
3. Turn starting switch to ON position.
Sensor out-
Between HP03 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective arm OUT PPC pressure is difficult to judge whether cause is defective sensor, ground fault or hot
2 short circuit of harness. Check as below.
sensor (internal failure)
1. Turn starting switch to OFF position.
2. Replace connector HP03 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, arm OUT PPC pressure
sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP03, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between HC02 (female) (38) and HP03 (female) (1)
tact of connector)
Between HC02 (female) (29) and HP03 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between HC02 (female) (7) and HP03 (female) (3)

40-262 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP03, and connect T-adapters to either
Ground fault in wiring harness female side.
4
(contact with ground circuit)
Between HC02 (female) (29) or HP03
Resistance Min. 1 Mz
(female) (2) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector HP03.
Hot short circuit in wiring harness 3. Connect T-adapters to female side of connector HP03.
5
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Between HP03 (female) (2) and ground Voltage Max. 1 V
Defective inverter (hybrid control- If no failure is found by above checks, inverter (hybrid controller) is defective.
6
ler) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to HYB arm OUT PPC pressure sensor 40-263

HB205-1, HB215LC-1 40-263

(01)
Troubleshooting by failure code
Failure code [DW43KA] Travel Speed Sol Open Circuit

Failure code [DW43KA] Travel Speed Sol Open Circuit 40-264

User code Failure code Travel speed selector solenoid system open circuit
Failure
(Pump controller system)
DW43KA
q When command to drive travel speed selector solenoid is ON, no current flows and open circuit is
Detail of failure
detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel speed is still
machine "Lo".)
q Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring
function. (If controller sends solenoid ON command, monitoring screen shows ON even if solenoid
Related infor-
is not switched to ON due to open circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.

Cause Procedure, measuring location, criteria and remarks

Defective travel speed selector
1
solenoid (Internal open circuit)
Open circuit in wiring harness
2 (wire breakage or defective con-
tact of connector)
3 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V04, and connect T-adapters to male side.
Between V04 (male) (1) and (2) Resistance 20 60 z
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Between C02 (female) (87) and each of (115) , (117)
Resistance 20 60 z
and (120)
a If no failure is found by above checks , this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V04, and connect T-adapters to each
female side.
Between C02 (female) (87) and V04 (female) (1) Resistance Max. 1 z
Between V02 (female) (2) and each of C02 (female)
Resistance Max. 1 z
(115), (117) and (120)
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-264 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW43KA] Travel Speed Sol Open Circuit

Circuit diagram related to travel speed selector solenoid 40-265

HB205-1, HB215LC-1 40-265

(01)
Troubleshooting by failure code
Failure code [DW43KB] Travel Speed Sol Short Circuit

Failure code [DW43KB] Travel Speed Sol Short Circuit 40-26

User code Failure code Travel speed selector solenoid short circuit
Failure
(Pump controller system)
DW43KB
q When command to drive travel speed selector solenoid is ON, abnormal current flows and short
Detail of failure
circuit is detected.
q Shuts off power supply to travel speed selector solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on q "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel speed is still
machine "Lo".)
q Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring
function. (If controller sends solenoid ON command, monitoring screen shows ON even if solenoid
Related infor-
is not switched to ON due to short circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.

Cause Procedure, measuring location, criteria and remarks

Defective travel speed selector
1 solenoid (Internal short circuit,
ground fault)
2 Short circuit in wiring harness
Ground fault in wiring harness
3
(contact with ground circuit)
4 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V04, and connect T-adapters to male side.
Between V04 (male) (1) and (2) Resistance 20 60 z
Between V04 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Between C02 (female) (87) and each of (115), (117)
Resistance 20 60 z
and (120)
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V04, and connect T-adapters to either
female side.
Between C02 (female) (87) or V04 (female) (1) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-266 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW43KB] Travel Speed Sol Short Circuit

Circuit diagram related to travel speed selector solenoid 40-267

HB205-1, HB215LC-1 40-267

(01)
Troubleshooting by failure code
Failure code [DW45KA] Swing holding brake solenoid valve open circuit

Failure code [DW45KA] Swing holding brake solenoid valve open circuit40-268

User code Failure code Swing holding brake solenoid valve open circuit
Failure
(Hybrid controller system)
E09 DW45KA
q When command to drive swing holding brake solenoid is ON (to release swing holding brake), no
Detail of failure
current flows (swing holding brake is not released).
Action of con- q None in particular (Since no current flows, solenoid does is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Upper structure does not swing (swing holding brake is not released).
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing holding
brake cancel switch to RELEASE position. (However, swing holding brake is not released when the
starting switch is in OFF position. Swing holding brake remains applied.)
q Be sure to set both of swing lock switch and swing holding brake cancel switch to OFF position dur-
ing troubleshooting.
Related infor-
q Brake is released when current flows through swing holding brake solenoid.
mation
q Command (ON/OFF) to swing holding brake solenoid can be checked with monitoring function.
(Code: 09700 Hybrid controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position.
q Swing holding brake solenoid circuit is powered from pin (8) of inverter (hybrid controller) connector
HC01 or F01 of fuse box F01.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective swing holding brake 2. Disconnect connector V03, and connect T-adapters to male side.
1
solenoid
Between V03 (male) (1) and (2) Resistance 20 60 z
1. Turn starting switch to OFF position.
2. Remove diode arrays D01 and D03, and connect T-adapters to their male
side.
a Check by using multimeter in diode range.
2 Defective diode array D01 or D03 Between D01 (male) (3) (+) and (7) (-) No continuity
Between D01 (male) (7) (+) and (3) (-) Continuity
Between D03 (male) (3) (+) and (7) (-) No continuity
Between D03 (male) (7) (+) and (3) (-) Continuity
1. Turn starting switch to OFF position.
2. Disconnect connector S04.
Defective swing lock switch
3
(internal open circuit) Between S04 (male) (3) Switch: OFF Resistance Max. 1 z
and (4) Switch: ON Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector HS01.
Defective emergency stop switch
4
(internal open circuit) Between HS01 (round Switch: OFF Resistance Max. 1 z
terminal) (21) and (22) Switch: ON Resistance Min. 1 Mz

40-268 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW45KA] Swing holding brake solenoid valve open circuit

Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
Defective inverter (hybrid control- If no failure is found by above checks, inverter (hybrid controller) is defective.
6
ler)
1. Turn starting switch to OFF position.
2. Remove diode D01.
3. Disconnect connector HC01 and connect T-adapters to each female side.
a Swing lock switch OFF, emergency stop switch OFF
Between HC01 (female) (8) and D01 (female) (7) Resistance Max. 1 z
Between D01 (female) (3) and HC01 (female) (13),
Resistance 20 60 z
(19)
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors D01, HC01, and V03, and connect T-adapters to
each female side.
Between D01 (female) (3) and S04 (female) (3) Resistance Max. 1 z
Between S04 (female) (4) and HS01 (22) Resistance Max. 1 z
Between HS01 (21) and V03 (female) (1) Resistance Max. 1 z
Between V03 (female) (2) and each of HC01
Resistance Max. 1 z
(female) (13) and (19)
(Since this is an internal defect, troubleshooting cannot be performed.)

HB205-1, HB215LC-1 40-269

(01)
Troubleshooting by failure code
Failure code [DW45KA] Swing holding brake solenoid valve open circuit

Circuit diagram related to swing holding brake solenoid 40-270

40-270 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW45KB] Swing holding brake solenoid valve short circuit

Failure code [DW45KB] Swing holding brake solenoid valve short circuit40-271

User code Failure code Swing holding brake solenoid valve short circuit
Failure
(Hybrid controller system)
E09 DW45KB
q When command to drive swing holding brake solenoid is ON (to release swing holding brake), ab-
Detail of failure
normal current flows.
q Shuts off power supply swing holding brake solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Upper structure does not swing (swing holding brake is not released).
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing holding
brake cancel switch to RELEASE position. (However, swing holding brake is not released when
starting switch is in OFF position. Swing holding brake remains applied.)
q Be sure to set both of swing lock switch and emergency stop switch to OFF position during trouble-
shooting.
Related infor- q Brake is released when current flows through swing holding brake solenoid.
mation q Controller command (ON/OFF) to swing holding brake solenoid can be checked with monitoring
function.
(Code: 09700 Hybrid controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position.
q Swing holding brake solenoid circuit is powered from pin (8) of inverter (hybrid controller) connector
HC01 or F01 of fuse box F01.

Cause Procedure, measuring location, criteria and remarks

Blown fuse No. 1 (right top fuse) of Even if fuse is blown, perform troubleshooting according to following steps to
1
fuse box F01 identify cause.
1. Turn starting switch to OFF position.
2. Disconnect connector V03, and connect T-adapters to male side.
Defective swing holding brake
2
solenoid Between V03 (male) (1) and (2) Resistance 20 60 z
Between V03 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Remove diode arrays D01 and D03, and connect T-adapters to each male
side.
a Check by using multimeter in diode range.
3 Defective diode array D01 or D03 Between D01 (male) (3) (+) and (7) (-) No continuity
Between D01 (male) (7) (+) and (3) (-) Continuity
Between D03 (male) (3) (+) and (7) (-) No continuity
Between D03 (male) (7) (+) and (3) (-) Continuity
a swing brake cancel switch: Normal
1. Turn starting switch to OFF position.
2. Remove fuse No. 1 (upper right, 10 A) of fuse box F01.
Ground fault in wiring harness 3. Disconnect connectors HC01, D01, D03, and V03.
4
(contact with ground circuit) 4. Connect T-adapters to female sides of connectors HC01 and D01.
Between HC01 (female) (8) and ground Resistance Min. 1 Mz
Between D01 (female) (3) and ground Resistance Min. 1 Mz

HB205-1, HB215LC-1 40-271

(01)
Troubleshooting by failure code
Failure code [DW45KB] Swing holding brake solenoid valve short circuit

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector HC01 and connect T-adapters to female side.
5 Short circuit in wiring harness
Between HC01 (female) (8) and each of (13) and
Resistance 20 60 z
(19)
Defective inverter (hybrid control- If no failure is found by above checks, inverter (hybrid controller) is defective.
6
ler) (Since this is an internal defect, troubleshooting cannot be performed.)

40-272 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW45KB] Swing holding brake solenoid valve short circuit

Circuit diagram related to swing holding brake solenoid 40-273

HB205-1, HB215LC-1 40-273

(01)
Troubleshooting by failure code
Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop

Failure code [DW45KK] Swing holding brake solenoid valve power

voltage drop 40-274

User code Failure code Swing holding brake solenoid valve power voltage drop
Failure
(Hybrid controller system)
E09 DW45KK
q Drop in power supply voltage is detected at swing holding brake solenoid drive power circuit in hy-
Detail of failure
brid controller.
Action of con- q None in particular. (Since no current flows, solenoid is not energized.)
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Upper structure does not swing (swing holding brake is not released).
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing holding
brake cancel switch to RELEASE position. (However, swing holding brake is not released when
Related infor- starting switch is in OFF position.)
mation q Command (ON/OFF) to swing holding brake solenoid can be checked with monitoring function.
(Code: 09700 Hybrid controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Looseness or corrosion of battery
1 Battery terminal may be loose or corroded. Check it directly.
terminal
Battery (1 piece) Starting switch: OFF Voltage Min. 12 V
2 Lowered battery voltage Between (+) and () ter-
minals Starting switch: START Voltage Min. 6.2 V

3 Blown fuse No.2 If fuse is blown, circuit probably has grounding fault. (See Cause 6.)

4 Blown fuse No. 17. If fuse is blown, circuit probably has grounding fault. (See Cause 6.)

Defective wiring harness connec-
5 q Looseness of connector, breakage of lock, or breakage of seal
tor
Open circuit in wiring harness
6 (wire breakage or defective con-
tact of connector)
Defective inverter (hybrid control- If no falure is found by above checks, inverter (hybrid controller) is defective.
7
ler)
Connections in circuit from fuses No. 2 and 17, through machine harness, to
hybrid conrtoller may be defective. Check connections directly.
q Corrosion, bend, breakage, pushed-in, or expantion of pin
q Moisture or dirt in connector or defective insulation
a If no failure is found by above checks, this check is not required.
1. Prepare with starting switch OFF, then perform troubleshooting without
turning starting switch to ON position.
Between F01-17 and each of HC01 (female) (5) and
Resistance Max. 1 z
(11)
Between F01-2 and each of HC01 (female) (1) and
Resistance Max. 1 z
(7)
Between H15A (male) (5) and each of HC01
Resistance Max. 1 z
(female) (6) and (12)
(Since this is an internal defect, troubleshooting cannot be performed.)

40-274 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop

Circuit diagram related to hybrid controller (inverter) 40-275

HB205-1, HB215LC-1 40-275

(01)
Troubleshooting by failure code
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir

Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir 40-276

User code Failure code Swing holding brake solenoid valve hot short circuit
Failure
(Hybrid controller system)
E09 DW45KY
q When command to drive swing holding brake solenoid is OFF, controller output voltage to solenoid
Detail of failure
is above standard value.
q Shuts off power supply to swing holding brake solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Swing holding brake does not work if current flows abnormally to swing holding brake solenoid.
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing holding
brake cancel switch to RELEASE position. (However, swing holding brake is not released when
starting switch is in OFF position. Swing holding brake remains applied.)
q Be sure to set both of swing lock switch and emergency stop switch to OFF position during trouble-
shooting.
q Brake is released when current flows through swing holding brake solenoid.
Related infor-
(Lower work equipment to ground. Swing holding brake may not work.)
mation
q Controller command (ON/OFF) to swing holding brake solenoid can be checked with monitoring
function.
(Code: 09700 Hybrid controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position.
q Swing holding brake solenoid circuit is powered from pin (8) of inverter (hybrid controller) connector
HC01 or F01 of fuse box F01.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors HC01, D01, and V03, and connect T-adapters to
either female side.
3. Turn starting switch to ON position.
Hot short circuit in wiring harness
1 a Ignore failure codes displayed on machine monitor.
(contact with 24 V circuit)
Between HC01 (female) (8) or D01 (female) (7) and
Voltage Max. 1 V
ground
Between D01 (female) (3) or V03 (female) (1) and
Voltage Max. 1 V
ground
Defective inverter (hybrid system If no failure is found by above checks, inverter (hybrid controller) is defective.
2
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-276 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir

Circuit diagram related to swing holding brake solenoid 40-27

HB205-1, HB215LC-1 40-277

(01)
Troubleshooting by failure code
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit

Failure code [DW4WKA] Cancel Bucket Dump Open Circuit 40-278

User code Failure code Bucket DUMP prohibit EPC solenoid open circuit
Failure
(Pump controller system)
E50 DW4WKA
q When command to drive bucket DUMP prohibit EPC solenoid is OFF, controller output voltage to
Detail of failure
solenoid is above standard value and open circuit is detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Bucket DUMP does not work.
machine
q This failure code is subject to be displayed only when arm crane mode (L) is selected for arm crane
Related infor- specification machine.
mation q Method of reproducing failure code: Turn starting switch to ON position and select arm crane mode
(L).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective bucket DUMP prohibit
2. Disconnect connector Y08 and connect T-adapters to male side.
1 EPC solenoid (internal open cir-
Resis-
cuit) Between Y08 (male) (1) and (2) 20 60 z
tance
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ness Between C02 (female) (94) and (115) Resis-
20 60 z
(Resistance of EPC solenoid coil) tance
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and Y08 and connect T-adapters to each
Open circuit in wiring harness
female side.
3 (open circuit or defective contact
Resis-
of connector) Between C02 (female) (94) and Y08 (female) (1) Max. 1 z
tance
Resis-
Between C02 (female) (115) and Y08 (female) (2) Max. 1 z
tance
4 Defective pump controller If no failure is found by above checks, pump controller is defective.

40-278 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit

Circuit diagram related to bucket DUMP prohibit EPC solenoid 40-279

HB205-1, HB215LC-1 40-279

(01)
Troubleshooting by failure code
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit

Failure code [DW4WKB] Cancel Bucket Dump Short Circuit 40-280

User code Failure code Bucket DUMP prohibit EPC solenoid short circuit
Failure
(Pump controller system)
DW4WKB
q When command to drive bucket DUMP prohibit EPC solenoid is ON, abnormal current flows in cir-
Detail of failure
cuit and short circuit is detected.
q Shuts off power supply to bucket DUMP prohibit EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Bucket DUMP does not work.
machine
q This failure code is detected only when mode other than arm crane mode (L) is selected for arm
Related infor- crane specification machine.
mation q Method of reproducing failure code: Turn starting switch to ON position and select arm crane mode
(L).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector Y08 and connect T-adapters to male side.
Defective bucket DUMP prohibit
1 EPC solenoid (internal short circuit Between Y08 (male) (1) and (2) Resis-
20 60 z
or ground fault) tance
Resis-
Between Y08 (male) (2) and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ness Between C02 (female) (94) and (115) Resis-
20 60 z
(Resistance of EPC solenoid coil) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and Y08, and connect T-adapters to either
Ground fault in wiring harness
3 female side.
(contact with ground circuit)
Between C02 (female) (94) or Y08 (female) (1) and Resis-
Min. 1 Mz
ground tance
4 Defective pump controller If no failure is found by above checks, pump controller is defective.

40-280 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit

Circuit diagram related to bucket DUMP prohibit EPC solenoid 40-281

HB205-1, HB215LC-1 40-281

(01)
Troubleshooting by failure code
Failure code [DW91KA] Travel Junction Sol. Disc.

Failure code [DW91KA] Travel Junction Sol. Disc. 40-282

User code Failure code Travel junction solenoid open circuit

Failure
(Pump controller system)
DW91KA
q When command to drive travel junction solenoid is OFF, controller output current to solenoid is be-
Detail of failure
low standard value.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Machine is not steered easily during travel.
machine
q Controller's command (ON/OFF) to travel junction valve solenoid can be checked with monitoring
function. (If controller sends solenoid ON command, monitoring screen displays ON even if sole-
Related infor-
noid is not switched to ON due to open circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine and steer machine with right and left travel levers.

Cause Procedure, measuring location, criteria and remarks

Defective travel interconnection
1
solenoid (internal open circuit)
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ness
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
4 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V02, and connect T-adapters to male side.
Between V02 (male) (1) and (2) Resistance 20 60 z
1. Turn starting switch to OFF position.
Between C02 (female) (110) and each of (115),
Resistance 20 60 z
(117) and (120)
a If no failure is found by checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V02, and connect T-adapters to each
female side.
Between C02 (female) (110) and V02 (female) (1) Resistance Max. 1 z
Between V02 (female) (2) and each of C02 (female)
Resistance Max. 1 z
(115), (117) and (120)
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-282 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW91KA] Travel Junction Sol. Disc.

Circuit diagram related to travel junction solenoid 40-283

HB205-1, HB215LC-1 40-283

(01)
Troubleshooting by failure code
Failure code [DW91KB] Travel Junction Sol. S/C

Failure code [DW91KB] Travel Junction Sol. S/C 40-284

User code Failure code Travel junction solenoid short circuit

Failure
(Pump controller system)
DW91KB
q When command to drive travel interconnection solenoid is ON, abnormal current flows through cir-
Detail of failure
cuit and short circuit is detected.
q Shuts off power supply to travel junction solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Machine is not steered easily during travel.
machine
q Controller's command (ON/OFF) to travel junction solenoid can be checked with monitoring func-
tion. (If controller sends solenoid ON command, monitoring screen displays ON even if solenoid is
Related infor-
not switched to ON due to short circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine and steer machine with right and left travel levers.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective travel interconnection 2. Disconnect connector V02, and connect T-adapters to male side.
1 solenoid (internal short circuit or
Between V02 (male) (1) and (2) Resistance 20 60 z
ground fault)
Between V02 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Short circuit or ground fault in wir-
2 Between C02 (female) (110) and each of (115),
ing harness Resistance 20 60 z
(117) and (120)
Between C02 (female) (110) and ground Resistance Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C02 and V02, and connect T-adapters to either
3
(contact with ground circuit) female side.
Between C02 (female) (110) or V02 (female) (1) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
4 Defective pump controller
is an internal defect, troubleshooting cannot be performed.)

40-284 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DW91KB] Travel Junction Sol. S/C

Circuit diagram related to travel junction solenoid 40-285

HB205-1, HB215LC-1 40-285

(01)
Troubleshooting by failure code
Failure code [DWA2KA] Attachment Sol Open Circuit

Failure code [DWA2KA] Attachment Sol Open Circuit 40-286

User code Failure code Attachment single/double selector solenoid open circuit
Failure
(Pump controller system)
DWA2KA
q When command to drive attachment return selector solenoid is ON, no current flows and open cir-
Detail of failure
cuit is detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Attachment hydraulic circuit does not change to single-acting circuit.
machine
q Controller's command (ON/OFF) to attachment return selector solenoid can be checked with mon-
itoring function. (If controller sends solenoid ON command, monitoring screen displays ON even if
Related infor- solenoid is not switched to ON due to open circuit.)
mation (Code: 02301 Solenoid 2)
q Method of reproducing failure code: Turn starting switch ON and set machine in mode other than
breaker mode (B).

Cause Procedure, measuring location, criteria and remarks

Defective attachment return selec- 2. Disconnect connector V06, and connect T-adapters to male side.
1
tor solenoid (internal open circuit)
Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ing harness
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
4 Defective pump controller
1. Turn starting switch to OFF position.
Between V06 (male) (1) and (2) Resistance 20 60 z
1. Turn starting switch to OFF position.
Between C02 (female) (86) and ground
Resistance 20 60 z
a Use frame as ground.
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V06, and connect T-adapters to each
female side.
a Looseness or rust on ground terminal T09.
Between C02 (female) (86) and V06 (female) (1) Resistance Max. 1 z
Between V06 (female) (2) and ground Resistance Max. 1 z
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-286 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DWA2KA] Attachment Sol Open Circuit

Circuit diagram related to ATT single/double selector solenoid 40-287

HB205-1, HB215LC-1 40-287

(01)
Troubleshooting by failure code
Failure code [DWA2KB] Attachment Sol Short Circuit

Failure code [DWA2KB] Attachment Sol Short Circuit 40-28

User code Failure code Attachment single/double selector solenoid short circuit
Failure
(Pump controller system)
DWA2KB
q When command to drive attachment return selector solenoid is ON, abnormal current flows through
Detail of failure
circuit and short circuit is detected.
q Shuts off power supply to attachment return selector solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Attachment hydraulic circuit does not change to single-acting circuit.
machine
q Controller's command (ON/OFF) to attachment return selector solenoid can be checked with mon-
itoring function. (If controller sends solenoid ON command, monitoring screen displays ON even if
Related infor-
solenoid is not switched to ON due to short circuit.)
mation
(Code: 02301 Solenoid 2)
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).

Cause Procedure, measuring location, criteria and remarks

Defective attachment return selec- 2. Disconnect connector V06, and connect T-adapters to male side.
1 tor solenoid (internal short circuit
or ground fault)
Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ing harness
Ground fault in wiring harness
3
(contact with ground circuit)
4 Defective pump controller
1. Turn starting switch to OFF position.
Between V06 (male) (1) and (2) Resistance 20 60 z
Between V06 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Between C02 (female) (86) and ground
Resistance 20 60 z
a Use frame as ground.
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V06, and connect T-adapters to either
female side.
Between C02 (female) (86) or V06 (female) (1) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-288 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DWA2KB] Attachment Sol Short Circuit

Circuit diagram related to ATT single/double selector solenoid 40-289

HB205-1, HB215LC-1 40-289

(01)
Troubleshooting by failure code
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit

Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 40-290

User code Failure code 2-stage relief solenoid system open circuit
Failure
(Pump controller system)
DWK0KA
q When stop command to drive 2-stage relief solenoid is OFF, controller output voltage to solenoid
Detail of failure
is above standard value and open circuit is detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q Travel power is low (main relief valve is not set to high-pressure setting)
machine q One-touch power max. function does not work.
q Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring func-
tion. (If controller sends solenoid ON command, monitoring screen displays ON even if solenoid is
not switched to ON due to open circuit.)
Related infor- (Code: 02300 Solenoid 1)
mation q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.
q Controller detects open circuit only when command to drive solenoid is OFF.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective 2-stage relief solenoid 2. Disconnect connector V02, and connect T-adapters to male side.
1
(internal open circuit)
Between V02 (male) (1) and (2) Resistance 20 60 z
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is
2
ness below 1 z, wiring harness has short circuit.
Between C02 (female) (109) and each of
Resistance 20 60 z
(115), (117) and (120)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V02, and connect T-adapters to each
Open circuit in wiring harness
female side.
3 (wire breakage or defective con-
Between C02 (female) (109) and V02
tact of connector) Resistance Max. 1 z
(female) (1)
Between V02 (female) (2) and each of C02
Resistance Max. 1 z
(female) (115), (117) and (120)
If no failure is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-290 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit

Circuit diagram related to 2-stage relief solenoid 40-291

HB205-1, HB215LC-1 40-291

(01)
Troubleshooting by failure code
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit

Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 40-292

User code Failure code 2-stage relief solenoid system short circuit
Failure
(Pump controller system)
DWK0KB
q When command to drive 2-stage relief solenoid circuit is ON, abnormal current flows through circuit
Detail of failure
and short circuit is detected.
q Shuts off power supply to 2-stage relief solenoid circuit.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on q Travel power is low (main relief valve is not set to high-pressure setting)
machine q One-touch power maximizing function does not work.
q Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring func-
tion. (If controller sends solenoid ON command, monitoring screen displays ON even if solenoid is
not switched to ON due to short circuit.)
Related infor-
(Code: 02300 Solenoid 1)
mation
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective 2-stage relief solenoid
1 (internal short circuit or ground
fault)
Ground fault in wiring harness
2 side of V02.
(contact with ground circuit)
3 Short circuit in wiring harness
4 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V02, and connect T-adapters to male side.
Between V02 (male) (1) and (2) Resistance 20 60 z
Between V02 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V02, and connect T-adapters to female
Between C02 (female) (109) or V02 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V02, and connect T-adapters to female
side of V02.
Between V02 (male) (1) and (2) Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-292 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit

Circuit diagram related to 2-stage relief solenoid 40-293

HB205-1, HB215LC-1 40-293

(01)
Troubleshooting by failure code
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit

Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit 40-294

User code Failure code F-PC-EPC solenoid system open circuit

Failure
(Pump controller system)
E02 DXA8KA
Detail of failure q When driving F-PC-EPC solenoid, no current flows and open circuit is detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q If pump load increases, engine speed decreases sharply and engine may stall.
machine
q When solenoid and wiring harness are normal, engine can be prevented from stalling by setting
emergency pump drive switch to ON position.
Related infor-
q Drive current to F-PC-EPC solenoid can be checked with monitoring function.
mation
(Code: 01300 PC-EPC solenoid current (F))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective F-PC-EPC solenoid
1
(internal open circuit)
Defective emergency pump drive Between S25 (male) (3)
2 switch
(internal open circuit)
Open or short circuit in wiring har-
3 a Check that emergency pump drive switch is at normal position (lower side).
ness
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
5 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V11, and connect T-adapters to male side.
Between V11 (male) (1) and (2) Resistance 3 14 z
1. Turn starting switch to OFF position.
2. Disconnect connector S25 and connect T-adapters to female side.
Switch position: Normal Resistance Max. 1 z
and (2) Switch position: Emer-
Resistance Min. 1 Mz
gency
Switch position: Normal Resistance Max. 1 z
Between S25 (male) (6)
and (5) Switch position: Emer-
Resistance Min. 1 Mz
gency
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Between C02 (female) (96) and each of (115), (117)
Resistance 3 14 z
and (120)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02, S25 and V11, and connect T-adapters to each
female side.
Between C02 (female) (96) and S25 (female) (3) Resistance Max. 1 z
Between S25 (female) (2) and V11 (female) (1) Resistance Max. 1 z
Between S25 (female) (6) and each of C02 (female)
Resistance Max. 1 z
(115), (117) and (120)
Between S25 (female) (5) and V11 (female) (2) Resistance Max. 1 z
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-294 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit

Circuit diagram related to F-PC-EPC solenoid 40-295

HB205-1, HB215LC-1 40-295

(01)
Troubleshooting by failure code
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit

Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 40-296

User code Failure code F-PC-EPC solenoid system short circuit

Failure
(Pump controller system)
E02 DXA8KB
q When driving F-PC-EPC solenoid, abnormal current flows through circuit and short circuit is detect-
Detail of failure
ed.
q Shuts off power supply to F-PC-EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q If pump load increases, engine speed decreases sharply and engine may stall.
machine
q When solenoid and wiring harness are normal, engine can be prevented from stalling by setting
emergency pump drive switch to ON position.
Related infor-
q Drive current to F-PC-EPC solenoid can be checked with monitoring function.
mation
(Code: 01300 PC-EPC solenoid current (F))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective F-PC-EPC solenoid
1 (internal short circuit or ground
fault)
Defective emergency pump drive
2 switch (internal short circuit or
ground fault)
Short circuit or ground fault in wir- a Check that emergency pump drive switch is at normal position (lower side).
3 Between C02 (female) (96) and each of (115), (117)
ing harness
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V11, and connect T-adapters to male side.
Between V11 (male) (1) and (2) Resistance 3 14 z
Between V11 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector S25 and connect T-adapters to female side.
Between each of S25 (male) (2) and
Resistance Min. 1 Mz
(3) and (5) Switch posi-
Between each of S25 (male) (2) and tion: Normal
Resistance Min. 1 Mz
(3) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Resistance 3 14 z
and (120)
Between C02 (female) (96) and ground Resistance Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02, S25 and V11, and connect T-adapters to either
female side.
Between C02 (female) (96) or S25 (female) (3) and
Resistance Min. 1 Mz
ground
Between S25 (female) (2) or V11 (female) (1) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

40-296 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit

Circuit diagram related to F-PC-EPC solenoid 40-297

HB205-1, HB215LC-1 40-297

(01)
Troubleshooting by failure code
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit

Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit 40-298

User code Failure code R-PC-EPC solenoid system open circuit

Failure
(Pump controller system)
E02 DXA9KA
Detail of failure q When driving R-PC-EPC solenoid, no current flows and open circuit is detedted.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q If pump load increases, engine speed decreases sharply and engine may stall.
machine
q When solenoid and wiring harness are normal, engine can be prevented from stalling by setting
emergency pump drive switch to ON position.
Related infor-
q Drive current to R-PC-EPC solenoid can be checked with monitoring function.
mation
(Code: 01302 PC-EPC solenoid current (R))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective R-PC-EPC solenoid
1
(internal open circuit)
Defective emergency pump drive Between S25 (male) (9)
2 switch
(internal open circuit)
Open or short circuit in wiring har-
3 a Check that emergency pump drive switch is at normal position (lower side).
ness
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
5 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V12, and connect T-adapters to male side.
Between V12 (male) (1) and (2) Resistance 3 14 z
1. Turn starting switch to OFF position.
2. Disconnect connector S25 and connect T-adapters to female side.
Switch position: Normal Resistance Max. 1 z
and (8) Switch position: Emer-
Resistance Min. 1 Mz
gency
Switch position: Normal Resistance Max. 1 z
Between S25 (male) (11)
and (12) Switch position: Emer-
Resistance Min. 1 Mz
gency
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Between C02 (female) (104) and each of (115),
Resistance 3 14 z
(117) and (120)
a If no failure is found in check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02, S25 and V12, and connect T-adapters to each
female side.
Between C02 (female) (104) and S25 (female) (9) Resistance Max. 1 z
Between S25 (female) (8) and V12 (female) (1) Resistance Max. 1 z
Between each of C02 (female) (115), (117) and
Resistance Max. 1 z
(120) and S25 (female) (12)
Between S25 (female) (11) and V12 (female) (2) Resistance Max. 1 z
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-298 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit

Circuit diagram related to R-PC-EPC solenoid 40-29

HB205-1, HB215LC-1 40-299

(01)
Troubleshooting by failure code
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit

Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 40-30

User code Failure code R-PC-EPC solenoid system short circuit

Failure
(Pump controller system)
E02 DXA9KB
Detail of failure q When driving R-PC-EPC solenoid, abnormal current flows and short circuit is detected.
q Shuts off power supply to R-PC-EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q If pump load increases, engine speed decreases sharply and engine may stall.
machine
q When solenoid and wiring harness are normal, engine can be prevented from stalling by setting
emergency pump drive switch to ON position.
Related infor-
q Drive current to R-PC-EPC solenoid can be checked with monitoring function.
mation
(Code: 01302 PC-EPC solenoid current (R))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective R-PC-EPC solenoid
1 (internal short circuit or ground
fault)
Defective emergency pump drive
2 switch (internal short circuit or
ground fault)
Short circuit or ground fault in wir- a Check that emergency pump drive switch is at normal position (lower side).
3 Between C02 (female) (104) and each of (115),
ing harness
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V12, and connect T-adapters to male side.
Between V12 (male) (1) and (2) Resistance 3 14 z
Between V12 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector S25 and connect T-adapters to female side.
Between each of S25 (male) (8) and
Resistance Min. 1 Mz
(9) and (11) Switch posi-
Between each of S25 (male) (8) and tion: Normal
Resistance Min. 1 Mz
(9) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Resistance 3 14 z
(117) and (120)
Between C02 (female) (104) and ground Resistance Min. 1 Mz
a If no failure is found in check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02, S25 and V12, and connect T-adapters to either
female side.
Between C02 (female) (104) or S25 (female) (9)
Resistance Min. 1 Mz
and ground
Between S25 (female) (8) or V12 (female) (2) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-300 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit

Circuit diagram related to R-PC-EPC solenoid 40-301

HB205-1, HB215LC-1 40-301

(01)
Troubleshooting by failure code
Failure code [DXE0KA] LS-EPC Sol Open Circuit

Failure code [DXE0KA] LS-EPC Sol Open Circuit 40-302

User code Failure code LS-EPC solenoid system open circuit

Failure
(Pump controller system)
DXE0KA
Detail of failure q When driving LS-EPC solenoid, no current flows and open circuit is detected .
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q Machine travels fast in Lo travel speed setting.
machine q Work equipment moves fast in fine control mode (L).
q Drive current to LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective LS-EPC solenoid
1
(internal open circuit )
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ness
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
4 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V19, and connect T-adapters to male side.
Between V19 (male) (1) and (2) Resistance 3 14 z
1. Turn starting switch to OFF position.
Between C02 (female) (88) and each of (115), (117)
Resistance 3 14 z
and (120)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V19, and connect T-adapters to each
female side.
Between C02 (female) (88) and V19 (female) (1) Resistance Max. 1 z
Between V19 (female) (2) and each of C02 (female)
Resistance Max. 1 z
(115), (117) and (120)
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-302 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXE0KA] LS-EPC Sol Open Circuit

Circuit diagram related to LS-EPC solenoid 40-303

HB205-1, HB215LC-1 40-303

(01)
Troubleshooting by failure code
Failure code [DXE0KB] LS-EPC Sol Short Circuit

Failure code [DXE0KB] LS-EPC Sol Short Circuit 40-304

User code Failure code LS-EPC solenoid system short circuit

Failure
(Pump controller system)
DXE0KB
Detail of failure q When driving LS-EPC solenoid, abnormal current flows and short circuit is detected .
q Shuts off power supply to LS-EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on q Machine travels fast in Lo travel speed setting.
machine q Work equipment moves fast in fine control mode (L).
q Drive current to LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective LS-EPC solenoid 2. Disconnect connector V19 and connect T-adapters to male side.
1 (internal short circuit or ground
Between V19 (male) (1) and (2) Resistance 3 14 z
fault)
Between V19 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Short circuit or ground fault in wir-
2 Between C02 (female) (88) and each of (115), (117)
ing harness Resistance 3 14 z
and (120)
Between C02 (female) (88) and ground Resistance Min. 1 Mz
a If no failure is found by check cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C02 and V19, and connect T-adapters to either
3
(contact with ground circuit) female side.
Between C02 (female) (88) or V19 (female) (1) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
4 Defective pump controller
is an internal defect, troubleshooting cannot be performed.)

40-304 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXE0KB] LS-EPC Sol Short Circuit

Circuit diagram related to LS-EPC solenoid 40-305

HB205-1, HB215LC-1 40-305

(01)
Troubleshooting by failure code
Failure code [DXE4KA] Service Current EPC Disc.

Failure code [DXE4KA] Service Current EPC Disc. 40-306

User code Failure code Attachment flow rate adjustment EPC open circuit
Failure
(Pump controller system)
DXE4KA
q When driving attachment flow rate adjustment EPC solenoid, no current flows and open circuit is
Detail of failure
detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Attachment does not move.
machine
q Drive current of attachment flow rate adjustment EPC solenoid can be checked with monitoring
Related infor- function.
mation (Code: 01700 Service solenoid current)
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).

Cause Procedure, measuring location, criteria and remarks

Defective attachment flow rate 1. Turn starting switch to OFF position.

1 adjustment EPC solenoid
(Internal open circuit)
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ness
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
4 Defective pump controller
2. Disconnect connector V30, and connect T-adapters to male side.
Between V30 (male) (1) and (2) Resistance 3 14 z
1. Turn starting switch to OFF position.
Between C02 (female) (97) and each of (115), (117)
Resistance 3 14 z
and (120)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V30, and connect T-adapters to each
female side.
Between C02 (female) (97) and V30 (female) (1) Resistance Max. 1 z
Between V30 (female) (2) and each of C02 (female)
Resistance Max. 1 z
(115), (117) and (120)
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-306 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXE4KA] Service Current EPC Disc.

Circuit diagram related to attachment flow rate adjustment EPC 40-307

HB205-1, HB215LC-1 40-307

(01)
Troubleshooting by failure code
Failure code [DXE4KB] Service Current EPC S/C

Failure code [DXE4KB] Service Current EPC S/C 40-308

User code Failure code Attachment flow rate adjustment EPC short circuit
Failure
(Pump controller system)
DXE4KB
q When driving attachment flow rate adjustment EPC solenoid, abnormal current flows and short cir-
Detail of failure
cuit is detected .
q Shuts off power supply to attachment flow rate adjustment EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Attachment does not move.
machine
q Drive current of attachment flow rate adjustment EPC solenoid can be checked with monitoring
Related infor- function.
mation (Code: 01700 Service solenoid current)
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment flow rate
2. Disconnect connector V30, and connect T-adapters to male side.
adjustment EPC solenoid
1
(internal short circuit or ground Between V30 (male) (1) and (2) Resistance 3 14 z
fault)
Between V30 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Short circuit or ground fault in wir-
2 Between C02 (female) (97) and each of (115), (117)
ing harness Resistance 3 14 z
and (120)
Between C02 (female) (97) and ground Resistance Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C02 and V30, and connect T-adapters to either
3
(contact with ground circuit) female side.
Between C02 (female) (97) or V30 (female) (1) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
4 Defective pump controller
is an internal defect, troubleshooting cannot be performed.)

40-308 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXE4KB] Service Current EPC S/C

Circuit diagram related to attachment flow rate adjustment EPC 40-309

HB205-1, HB215LC-1 40-309

(01)
Troubleshooting by failure code
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit

Failure code [DXE5KA] Merge-divider Main Sol Open Circuit 40-310

User code Failure code Merge-divider main solenoid open circuit

Failure
(Pump controller system)
DXE5KA
Detail of failure q When driving merge-divider (main) EPC solenoid, no current flows and open circuit is detected .
q Shuts off power supply to merge-divider (main) EPC solenoid. (Since no current flows, merge-di-
Action of con- vider LS solenoid is not energized, either.)
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Single operation speed of work equipment and swing is high in fine control mode (L).
machine q Machine cannot be steered easily during travel.
q Drive current to merge-divider main EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 Merge-divider (main) solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective merge-divider main 1. Turn starting switch to OFF position.

1 EPC solenoid (internal open cir-
cuit)
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ness
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
4 Defective pump controller
2. Disconnect connector V23, and connect T-adapters to male side.
Between V23 (male) (1) and (2) Resistance 3 14 z
1. Turn starting switch to OFF position.
Between C02 (female) (112) and each of (115),
Resistance 3 14 z
(117) and (120)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V23, and connect T-adapters to each
female side.
Between C02 (female) (112) and V23 (female) (1) Resistance Max. 1 z
Between V23 (female) (2) and each of C02 (female)
Resistance Max. 1 z
(115), (117) and (120)
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-310 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit

Circuit diagram related to pump merge-divider main solenoid 40-31

HB205-1, HB215LC-1 40-311

(01)
Troubleshooting by failure code
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit

Failure code [DXE5KB] Merge-divider Main Sol Short Circuit 40-312

User code Failure code Merge-divider main solenoid short circuit

Failure
(Pump controller system)
DXE5KB
q When driving merge-divider (main) EPC solenoid, abnormal current flows and short circuit is de-
Detail of failure
tected.
q Shuts off power supply to merge-divider (main) EPC solenoid. (Since no current flows, merge-di-
Action of con- vider LS solenoid is not energized, either.)
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Single operation speed of work equipment and swing is high in fine control mode (L).
machine q Machine cannot be steered easily during travel.
q Drive current to merge-divider main EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 Merge-divider (main) solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective merge-divider main
1 EPC solenoid (internal short circuit
or ground fault)
Short circuit or ground fault in wir-
2 Between C02 (female) (112) and each of (115),
ing harness
Ground fault in wiring harness
3
(contact with ground circuit)
4 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V23, and connect T-adapters to male side.
Between V23 (male) (1) and (2) Resistance 3 14 z
Between V23 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Resistance 3 14 z
(117) and (120)
Between C02 (female) (112) and ground Resistance Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V23, and connect T-adapters to either
female side.
Between C02 (female) (112) or V23 (female) (1) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-312 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit

Circuit diagram related to pump merge-divider main solenoid 40-313

HB205-1, HB215LC-1 40-313

(01)
Troubleshooting by failure code
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit

Failure code [DXE6KA] Merge-divider LS Sol Open Circuit 40-314

User code Failure code Merge-divider LS solenoid open circuit

Failure
(Pump controller system)
DXE6KA
Detail of failure q When driving merge-divider (LS) EPC solenoid, no current flows and open circuit is detected.
q Shuts off power supply to merge-divider (LS) EPC solenoid (since no current flows, merge-divider
Action of con- LS solenoid is not energized, either).
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Single operation speed of work equipment and swing is high in fine control mode (L).
machine q Machine cannot be steered easily during travel.
q Drive current to merge-divider LS EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08001 Merge-divider (LS) solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective merge-divider LS EPC
1
solenoid (internal open circuit)
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side.
2
ness
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
4 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V24, and connect T-adapters to male side.
Between V24 (male) (1) and (2) Resistance 3 14 z
1. Turn starting switch to OFF position.
Between C02 (female) (89) and each of (115), (117)
Resistance 3 14 z
and (120)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V24, and connect T-adapters to each
female side.
Between C02 (female) (89) and V24 (female) (1) Resistance Max. 1 z
Between V24 (female) (2) and each of C02 (female)
Resistance Max. 1 z
(115), (117) and (120)
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-314 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit

Circuit diagram related to pump merge-divider LS solenoid 40-315

HB205-1, HB215LC-1 40-315

(01)
Troubleshooting by failure code
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit

Failure code [DXE6KB] Merge-divider LS Sol Short Circuit 40-316

User code Failure code Merge-divider LS solenoid short circuit

Failure
(Pump controller system)
DXE6KB
q When driving merge-divider (LS) EPC solenoid, abnormal current flows and short circuit is detect-
Detail of failure
ed.
q Shuts off power supply to merge-divider (LS) EPC solenoid (since no current flows, merge-divider
Action of con- LS solenoid is not energized,either).
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Single operation speed of work equipment and swing is high in fine control mode (L).
machine q Machine cannot be steered easily during travel.
q Drive current to merge-divider LS EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08001 Merge-divider (LS) solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective merge-divider LS EPC 2. Disconnect connector V24, and connect T-adapters to male side.
1 solenoid (internal short circuit or
Between V24 (male) (1) and (2) Resistance 3 14 z
ground fault)
Between V24 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapters to female side.
Short circuit or ground fault in wir-
2 Between C02 (female) (89) and each of (115), (117)
ing harness Resistance 3 14 z
and (120)
Between C02 (female) (89) and ground Resistance Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C02 and V24, and connect T-adapters to either
3
(contact with ground circuit) female side.
Between C02 (female) (89) or V24 (female) (1) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
4 Defective pump controller
is an internal defect, troubleshooting cannot be performed.)

40-316 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit

Circuit diagram related to merge-divider LS solenoid 40-317

HB205-1, HB215LC-1 40-317

(01)
Troubleshooting by failure code
Failure code [DY20KA] Wiper Working Abnormality

Failure code [DY20KA] Wiper Working Abnormality 40-318

User code Failure code Wiper working error

Failure
(Pump controller system)
DY20KA
Detail of failure q When windshield wiper works, W signal that indicates wiper motor working area ends is not input.
Action of con- q Shuts off power supply to wiper motor.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Wiper motor does not work.
machine
q
Signal input (ON/OFF) of W contact that indicates wiper working area end can be checked with
monitoring function.
(Code: 02204 Switch input 5)
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
a Single wiper specification does not have lower wiper of double wiper specification (upper wiper is
called wiper).
q Method of reproducing failure code: Turn starting switch to ON position and and set wiper switch
to INT or ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector M05 and connect T-adapters to female side.
Wiper position: work- Resis-
Max. 1 z
Defective wiper motor ing area upper end tance
1 Between M05 (female) (6) and (5) Wiper position: other
(internal open circuit) Resis-
than working area Min. 1 Mz
tance
upper end
Wiper position: Resis-
Between M05 (female) (1) and (3) Max. 20 z
whole range tance
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and C02 and connect T-adapters to each
female side.
Wiper position: work- Resis-
Max. 1 z
Open or short circuit in wiring har- ing area upper end tance
2 Between C01 (female) (56) and
ness Wiper position: other
ground Resis-
than working area Min. 1 Mz
tance
upper end
Between C02 (female) (114) and Wiper position: Resis-
Max. 20 z
(119) whole range tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connector CP01 and CP02 and to
male side of M05.
Open circuit in wiring harness Resis-
Between C01 (female) (56) and M05 (male) (6) Max. 1 z
3 (wire breakage or defective con- tance
tact of connector) Resis-
Between M05 (male) (5) and ground (T05) Max. 1 z
tance
Resis-
Between C02 (female) (114) and M05 (male) (1) Max. 1 z
tance
Resis-
Between C02 (female) (119) and M05 (male) (3) Max. 1 z
tance
If no failure is found by above checks, pump controller is defective. (Since this
4 Defective pump controller
is an internal defect, troubleshooting cannot be performed.)

40-318 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DY20KA] Wiper Working Abnormality

Circuit diagram related to wiper 40-319

HB205-1, HB215LC-1 40-319

(01)
Troubleshooting by failure code
Failure code [DY20MA] Wiper Parking Abnormality

Failure code [DY20MA] Wiper Parking Abnormality 40-320

User code Failure code Wiper resting error

Failure
(Pump controller system)
DY20MA
Detail of failure q When windshield wiper rests, P signal for rest area is not input.
Action of con- q Stops output for resting to wiper motor.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Wiper motor does not rest.
machine
q Condition of P contact signal of wiper resting area can be checked with monitoring function.
(Code: 02204 Switch input 5)
Related infor- q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
mation sured at pump controller connector.
q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to
INT/ON to OFF position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector M05 and connect T-adapters to female side.
Wiper position: rest Resis-
Defective wiper motor Max. 1 z
1 area tance
(internal open circuit) Between M05 (female) (4) and (5)
Wiper position: Resis-
Min. 1 Mz
working area tance
Wiper position: Resis-
Between M05 (female) (1) and (3) Max. 20 z
whole range tance
1. Turn starting switch to OFF position.
2. Disconnect diode arrays C01 and C02 and connect T-adapters to each
female side.
Wiper position: rest Resis-
Open or short circuit in wiring har- Max. 1 z
2 Between C01 (female) (75) and area tance
ness
ground Wiper position: Resis-
Min. 1 Mz
working area tance
Between C02 (female) (114) and Wiper position: Resis-
Max. 20 z
(119) whole range tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01, C02, and M05.
3. Connect T-adapters to female sides of connector C01 and C02 and to male
side of M05.
Open circuit in wiring harness Resis-
Between C01 (female) (75) and M05 (male) (4) Max. 1 z
3 (wire breakage or defective con- tance
tact of connector) Resis-
Between M05 (male) (5) and ground (T01) Max. 1 z
tance
Resis-
Between C02 (female) (114) and M05 (male) (1) Max. 1 z
tance
Resis-
Between C02 (female) (119) and M05 (male) (3) Max. 1 z
tance
If no failure is found by above checks, pump controller is defective. (Since this
4 Defective pump controller
is an internal defect, troubleshooting cannot be performed.)

40-320 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DY20MA] Wiper Parking Abnormality

Circuit diagram related to wiper 40-321

HB205-1, HB215LC-1 40-321

(01)
Troubleshooting by failure code
Failure code [DY2CKA] Washer drive discon

Failure code [DY2CKA] Washer drive discon 40-32

User code Failure code Window washer drive system open circuit
Failure
(Pump controller system)
DY2CKA
q When command to drive window washer drive is OFF, no voltage appears at output pin (pin No. 3)
Detail of failure
of controller and open circuit is detected.
Action of con- q None in particular (washer motor does not work because no current flows).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Window washer does not operate.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Blown fuse No. 4 of fuse box F01 If fuse is blown, circuit probably has ground fault, etc. (See Cause 6.)

1. Turn starting switch to OFF position.

Defective washer motor
2 (internal open circuit or ground
fault)
Defective diode array D02 (inter-
3
nal short circuit)
Open circuit or short circuit in wir- 3.
4
ing harness
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
6
(contact with ground circuit)
7 Defective pump controller
2. Disconnect connector M06 and connect T-adapters to male side.
Resis-
Between M06 (male) (1) and (2) 5 20 z
tance
Between M06 (male) (1) and ground, or between M06 Resis-
Min. 1 Mz
(male) (2) and ground tance
1. Turn starting switch to OFF position.
2. Disconnect connector D02 and connect T-adapters to male side.
a Measure by using multimeter in diode range.
Between D02 (male) (7) (+) and (3) (-) Continuity
Between D02 (male) (3) (+) and (7) (-) No continuity
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapters to female side.
Turn starting switch to ON position.
a Ignore failure code displayed on machine monitor.
Between C01 (female) (3) and ground Voltage 20 30 V
a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect fuse No. 4 of fuse box F01.
3. Disconnect connectors M06 and C01 and connect T-adapters to each
female side.
Resis-
Between F01-4 and M06 (female) (2) Max. 1 z
tance
Resis-
Between C01 (female) (3) and M06 (female) (1) Max. 1 z
tance
a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect fuse No. 4 of fuse box F01.
3. Disconnect connectors M06, C01, and D02, and connect T-adapters to
either female side.
Between ground and any of F01-4, M06 (female) (2) or Resis-
D02 (female) (3) Min. 1 Mz
tance
Between C01 (female) (3) or M06 (female) (1) or D02 Resis-
(female) (7) and ground Min. 1 Mz
tance
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-322 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DY2CKA] Washer drive discon

Circuit diagram related to window washer motor 40-323

HB205-1, HB215LC-1 40-323

(01)
Troubleshooting by failure code
Failure code [DY2CKB] Washer drive short

Failure code [DY2CKB] Washer drive short 40-324

User code Failure code Window washer drive system short circuit
Failure
(Pump controller system)
DY2CKB

Detail of failure q When driving window washer motor, abnormal current flows and short circuit is detected.

q Shuts of power supply to washer motor.

Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Window washer does not operate.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and turn washer switch to
mation ON position.

Cause Procedure, measuring location, criteria and remarks

1 Blown fuse No. 4 of fuse box F01
Defective washer motor
2 (internal open circuit or ground
fault)
Defective diode array D02 (inter-
3
nal short circuit)
Hot short circuit in wiring harness 3. Disconnect fuse No. 4 of fuse box F01.
4
(contact with 24 V circuit)
5 Defective pump controller
If fuse is blown, circuit probably has ground fault, etc. (See failure code
[DY2CKA].)
1. Turn starting switch to OFF position.
2. Disconnect connector M06 and connect T-adapters to male side.
Between M06 (male) (1) and (2) Resistance 5 20 z
Between M06 (male) (1) and ground, or between
Resistance Min. 1 Mz
M06 (male) (2) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector D02 and connect T-adapters to male side.
a Check the continuity in diode range.
Between D02 (male) (7) (+) and (3) (-) Continuity
Between D02 (male) (3) (+) and (7) (-) No continuity
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and M06 and connect T-adapters to female
side of C01.
4. Turn starting switch to ON position.
a Ignore failure code displayed on machine monitor.
Between C01 (female) (3) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-324 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DY2CKB] Washer drive short

Circuit diagram related to window washer motor 40-325

HB205-1, HB215LC-1 40-325

(01)
Troubleshooting by failure code
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit

Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 40-326

User code Failure code Wiper motor drive normal rotation system short circult
Failure
(Pump controller system)
DY2DKB
q When normal rotation command to power wiper motor drive is ON, abnormal current flows through
Detail of failure
circuit and short circuit is detected.
q Shuts off power supply to normal rotation system of wiper motor drive.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Windshield wiper does not operate.
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor- sured at pump controller connector.
mation q Method of reproducing failure code: Turn starting switch to ON position and and set wiper switch
to INT or ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiper motor
1 (internal short circuit or ground
fault)
2 Short circuit in wiring harness
Ground fault in wiring harness
3 wiring harness side.
(contact with ground circuit)
4 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector M05 and connect T-adapters to female side.
Between M05 (female) (3) and (1) Continuity
Between M05 (female) (3) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and M05 and connect T-adapters to either
wiring harness side.
Between C02 (female) (119) and (114), or between
Resistance Min. 1 Mz
M05 (male) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and M05 and connect T-adapters to either
Between C02 (female) (119) or M05 (male) (3) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector M05.
3. Turn starting switch to ON position.
4. Turn wiper switch ON and OFF for troubleshooting.
Wiper
Voltage Max. 3 V
switch: OFF
Between M05 (3) and (5)
Wiper Pulse below 3 V io
Voltage
switch: ON above 20 V

40-326 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit

Circuit diagram related to wiper 40-327

HB205-1, HB215LC-1 40-327

(01)
Troubleshooting by failure code
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit

Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 40-328

User code Failure code Wiper motor drive reverse rotation system short circuit
Failure
(Pump controller system)
DY2EKB
q When reverse rotation command to wiper motor drive is ON, abnormal current flows through circuit
Detail of failure
and short circuit is detected.
q Shuts off power supply to reverse rotation system of wiper motor drive.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Windshield wiper does not operate.
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor- sured at pump controller connector.
mation q Method of reproducing failure code: Turn starting switch to ON position and and set wiper switch
to INT or ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiper motor
1 (internal short circuit or ground
fault)
2 Short circuit in wiring harness
Ground fault in wiring harness
3 wiring harness side.
(contact with ground circuit)
4 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector M05 and connect T-adapters to female side.
Between M05 (female) (1) and (3) Continuity
Between M05 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and M05 and connect T-adapters to either
wiring harness side.
Between C02 (female) (119) and (114), or between
Resistance Min. 1 Mz
M05 (male) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and M05 and connect T-adapters to either
Between C02 (female) (114) or M05 (male) (1) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector M05.
3. Turn starting switch to ON position.
4. Turn wiper switch ON and OFF for troubleshooting.
Wiper
Voltage Max. 3 V
switch: OFF
Between M05 (1) and (5)
Wiper Pulse below 3 V io
Voltage
switch: ON above 20 V

40-328 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit

Circuit diagram related to wiper 40-329

HB205-1, HB215LC-1 40-329

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Troubleshooting by failure code [GA****] (code display) 40-3 0

Precaution in hybrid device troubleshooting, and common trouble-
shooting procedures for high voltage devices 40-3 0

Precautions related to hybrid devices 40-3 0

k When testing or adjusting hybrid devices, ensure that you fully understand the following.

1.Never disassemble the hybrid devices.

2.Never disassemble the hybrid devices.
3.The hybrid devices and high-voltage wirings (wound with orange conduits) must be replaced by the unit.
4.When handling hybrid devices, be sure to discharge the capacitor completely first.
(For details, see Special functions of machine monitor, "Discharging Capacitor" in Testing and adjusting.)
a However, the capacitor can be discharged by using the machine monitor only when the hybrid system is
normal.
a Capacitor discharging will be displayed on the machine monitor even when failure code [GA****] is dis-
played to indicate abnormality of the hybrid system, but the feature will have no effect when executed.
(Since conditions to discharge capacitor are not met), use special capacitor discharge generator:
796-426-1800 instead.

k Since the items with the above mark are related to handling of the hybrid devices, ensure that you
understand the descriptions of 00-200 Introduction, safety, and basic information, "Handling of hy-
brid devices and high-voltage wiring", before beginning the work on them.
a For the monitoring items related to hybrid devices troubleshooting, see the list in Failure code [GA----]
(separate sheet 1).
a For the check sheet for recording test results of abnormal hybrid devices, see separate sheet 2 in Failure
code [GA----]. (Use this check sheet when making inquiries to the workshop.)

40-330 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

k Before starting troubleshooting, discharge the capacitor by using capacitor discharge tool (gen-
erator): 796-426-1800 (see previous page).
k After discharging the capacitor, confirm that both capacitor charge LEDs (1) are OFF.
k A voltage not exceeding 30 V will still remain in the capacitor after the discharging process is com-
pleted. Do not work with bare hands. Always wear insulating gloves.
a After disconnecting connector HB01 (at capacitor), cover the connector (both of wiring harness and ca-
pacitor sides) with a plastic bag to prevent entry of foreign matter.
a Perform troubleshooting while the engine is stopped.
a Do not connect the multimeter probe directly to the capacitor side connector (female side of HB01).

1. Capacitor charge LEDs

1) Right and left LEDs are ON: High-voltage output in progress
2) Only right LED is ON: Charged with high voltage
3) Right and left LEDs are OFF: Voltage is under 30 V
q If test results for the failure code indicate a possible problem in the high voltage system, follow the common
troubleshooting procedures 1. to 7. to check by disconnecting the power cable from each device.

HB205-1, HB215LC-1 40-331

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Failure codes that not allow capacitor discharging using machine monitor 40-3 1

Errors related to high-voltage circuit Errors related to motor-generator circuit

Failure Failure
Failure name Failure name
code code
GA00NS HYB Equipment Overheat GA17KR Gen. Mot. Drv. Communication Failure
GA02KZ DC Line Open & Short Circuit GA17KZ Gen. Motor Driver Open/Short Circuit
GA01KA Power Cable Interlock Open Circuit GA17MB Gen. Mot. Drv. Function Degraded
GA04KG Abnormal DC HW Volt. Before Booster GA19KK Gen. Mot. Drv. Sub-CPU Low Sup. Volt.
GA05KG Abnormal DC SW Volt. Before Booster GA19KR Gen. Motor Driver Sub-CPU Comm. Failure
GA05KP Low DC SW Output Volt. Bef. Booster GA19KT Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.
GA06KZ DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster GA19MA Gen. Mot. Drv. Sub-CPU Malfunction
GA08KG Abnorm. DC HW Volt. After Booster GA19MC Gen. Mot. Drv. Sub-CPU Defect. Operation
GA09KG Abnorm. DC SW Volt. After Booster GA19NA Gen. Mot. Drv. Sub-CPU Start Disabled
GA09KP Low DC SW Output Volt. After Booster GA1BMA Gen. Mot. Dr. DC Vlt. Sens. Malfunction
GA0AKZ DC Vlt. Sen. Op./Shrt cir. Aft. booster GA25MA Gen. Motor Driver IGBT0 Abnormality
GA12NK HYB Cont. Pow. Suppl. Not Turn. ON GA26MA Gen. Motor Driver IGBT1 Abnormality
GA12NL HYB Cont. Pow. Suppl. Not Turn. OFF GA60N1 Generator Motor Overrun
GA18MC Gen. Mo.Dr. Excite. Pow. Sup. Failure GA62KY Gen. Mot. Ph-A Cur. Sen. Power Short Cir
GA1SFS Contactor Locked GA62KZ Gen. Mot. Ph-A Cur. Sen. Open/Short Cir
GA1SMC Contactor Failure GA62MA Gen. Mot. Ph-A Current Sen. Malfunction
GA1VMC Capacitor Contactor Failure GA63KY Gen. Mot. Ph-B Cur. Sen. Power Short Cir.
GA63KZ Gen. Mot. Ph-B Cur. Sen. Open/Short Cir.
GA63MA Gen. Mot. Ph-B Current Sen. Malfunction
GA64KY Gen. Mot. Ph-C Cur. Sen. Power Short Cir.
GA64KZ Gen. Mot. Ph-C Cur. Sen. Open/Short Cir.
GA64MA Gen. Mot. Ph-C Current Sen. Malfunction
GA70MD HYB Swing Motor Defective Stirr. Motion

40-332 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Layout of high voltage devices, power cables, and connectors 40-3 3

Serial No.: 1001 2634

1. Capacitor enclosure A: Motor-generator

2. Inverter enclosure B: Electrical control unit
3. High-voltage wiring (electric swing motor) C: Electric swing motor
4. High-voltage wiring (capacitor)
5. High-voltage wiring (motor-generator)

a Connector GM01 is located at the bottom of mo-

tor-generator (A) housing.

HB205-1, HB215LC-1 40-333

(04)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Serial No.: 2635 and up

1. Capacitor enclosure A: Motor-generator

2. Inverter enclosure B: Electrical control unit
3. High-voltage wiring (electric swing motor) C: Electric swing motor
4. High-voltage wiring (capacitor)
5. High-voltage wiring (motor-generator)

a Connector GM01 is located at the bottom of mo-

tor-generator (A) housing.

40-333-1 HB205-1, HB215LC-1

(04)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

HB205-1, HB215LC-1 40-333-2

(04)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Precautions for connecting power cables

a Power cable connector has its top and bottom positions.Connect power cable connector and the compo-
nent to be connected to mate the faces marked as I, II, III, IIII.

40-334 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

HB205-1, HB215LC-1 40-335

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Common troubleshooting procedures for high voltage devices 40-3 2

q Common troubleshooting flowchart

40-336 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

HB205-1, HB215LC-1 40-337

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

1. Capacitor troubleshooting
If test results for the failure code indicate a possible problem in the capacitor, proceed with the following trou-
bleshooting procedures.
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC06.
(Capacitor side connector HB01 must be connected)
a Capacitor enclosure must be wiped clean.
a Take measurement after 1 minute if value is unstable.
a A megohmmeter is recommended to use.
Between HC06 (DC+) (male): red tester probe and
Capacitor system insulation Resistance Min. 10 Mz
1 capacitor enclosure: black tester probe
deteriorated
Between HC06 (DC+) (male): black tester probe and
Resistance Min. 10 Mz
capacitor enclosure: red tester probe
Between HC06 (DC-) (male): red tester probe and
Resistance Min. 10 Mz
capacitor enclosure: black tester probe
Between HC06 (DC-) (male): black tester probe and
Resistance Min. 10 Mz
capacitor enclosure: red tester probe
If no failure is found by check on cause 1, other high voltage devices may be defective.
Proceed to troubleshooting for other suspicious high voltage devices.
If any failure is found, proceed to 5. Capacitor power cable troubleshooting. If power cable is normal, replace capacitor.

2. Electric swing motor troubleshooting 40-3 6

If test results for the failure code indicate a possible problem in the electric swing motor, proceed with the fol-
lowing troubleshooting procedures.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC05.
a Swing motor has coil resistance between motor's lead wires.
Open circuit in swing motor
1
between motor's lead wires Between HC05 (U) (male) and HC05 (V) (male) Resistance Max. 1 z
Between HC05 (V) (male) and HC05 (W) (male) Resistance Max. 1 z
Between HC05 (W) (male) and HC05 (U) (male) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC05 and capacitor power cable
connector HB01.
a Inverter enclosure must be wiped clean.
a Take measurement after 1 minute when value is unstable.
Swing motor system insulation a A megohmmeter is recommended to use.
2
deteriorated a Take measurement at any of three lead wires, U, V, or W.
Between HC05 (U) (male): red tester probe and
Resistance Min. 10 Mz
inverter enclosure (ground): black tester probe
Between HC05 (U) (male): black tester probe and
Resistance Min. 10 Mz
inverter enclosure (ground): red tester probe
If no failure is found by checks on cause 1 or 2, other high voltage devices may be defective.
Proceed to troubleshooting for other suspicious high voltage devices.
If any failure is found, proceed to 6. Electric swing motor power cable troubleshooting. If power cable is normal, replace
electric swing motor.

40-338 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Circuit diagram related to high voltage devices 40-3 7

HB205-1, HB215LC-1 40-339

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)

40-340 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

3. Motor-generator troubleshooting 40-3 9

If test results for the failure code indicate a possible problem in the motor-generator, proceed with the follow-
ing troubleshooting procedures.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connectors HC03 and HC04.
a Motor-generator has coil resistance between motor's lead wires.
Open circuit in motor-genera-
1
tor between motor's lead wires Between HC03 (A1) (male) and HC04 (A2) (male) Resistance Max. 1 z
Between HC03 (B1) (male) and HC04 (B2) (male) Resistance Max. 1 z
Between HC03 (C1) (male) and HC04 (C2) (male) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connectors HC03 and HC04.
a Take measurement at either of connectors HC03 and HC04.
Short circuit in motor-generator
2 Between HC03 (A1) (male) and HC03 (B1) (male) Resistance Min. 10 Mz
between motor's lead wires
Between HC03 (B1) (male) and HC03 (C1) (male) Resistance Min. 10 Mz
Between HC03 (C1) (male) and HC03 (A1) (male) Resistance Min. 10 Mz
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connectors HC03, HC04 and capacitor power
cable connector HB01.
a Inverter enclosure must be wiped clean.
a Take measurement after 1 minute if value is unstable.
a A megohmmeter is recommended to use.
a Take measurement at either of connectors HC03 and HC04.
Between HC03 (A1) (male): red tester probe and
Resistance Min. 10 Mz
inverter enclosure (ground): black tester probe
Motor-generator system insula- Between HC03 (A1) (male): black tester probe and Resistance Min. 10 Mz
3 inverter enclosure (ground): red tester probe
tion deteriorated
Between HC03 (B1) (male): red tester probe and
Resistance Min. 10 Mz
inverter enclosure (ground): black tester probe
Between HC03 (B1) (male): black tester probe and
Resistance Min. 10 Mz
inverter enclosure (ground): red tester probe
Between HC03 (C1) (male): red tester probe and
Resistance Min. 10 Mz
inverter enclosure (ground): black tester probe
Between HC03 (C1) (male): black tester probe and
Resistance Min. 10 Mz
inverter enclosure (ground): red tester probe
If no failure is found by checks on causes 1 to 3, other high voltage devices may be defective.
Proceed to troubleshooting for other suspicious high voltage devices.
If any failure is found, proceed to 7. Motor-generator power cable troubleshooting. If power cable is normal, replace
motor-generator.

HB205-1, HB215LC-1 40-341

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Circuit diagram related to high voltage devices 40-340

40-342 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)

HB205-1, HB215LC-1 40-343

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

4. Inverter troubleshooting 40-342

If test results for the failure code indicate a possible problem in the inverter, proceed with the following trou-
bleshooting procedures.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connectors HC03 to HC06 and capacitor
power cable connector HB01.
a Inverter enclosure must be wiped clean.
a Take measurement after 1 minute if value is unstable.
a A megohmmeter is recommended to use.
Between HC06 (DC+) (female): red tester probe
Resistance Min. 10 Mz
1 Inverter insulation deteriorated and inverter enclosure: black tester probe
Between HC06 (DC+) (female): black tester probe
Resistance Min. 10 Mz
and inverter enclosure: red tester probe
Between HC06 (DC-) (female): red tester probe and
Resistance Min. 10 Mz
inverter enclosure: black tester probe
Between HC06 (DC-) (female): black tester probe
Resistance Min. 10 Mz
and inverter enclosure: red tester probe
If no failure is found by check on cause 1, other high voltage devices may be defective.
Proceed to troubleshooting for other suspicious high voltage devices.
If any failure is found, replace inverter.
Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)

40-344 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Circuit diagram related to high voltage devices 40-343

HB205-1, HB215LC-1 40-345

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

5. Capacitor power cable troubleshooting 40-345

If test results for the failure code indicate a possible problem in the capacitor power cable, proceed with the
following troubleshooting procedures.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC06 and capacitor power cable
connector HB01.
1 Open circuit in power cable
Between HC06 (DC+) (male) and HB01 (DC+) (male) Resistance Max. 1 z
Between HC06 (DC-) (male) and HB01 (DC-) (male) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC06 and capacitor power cable
2 Short circuit in power cable connector HB01.
Between HC06 (DC+) (male) and HB06 (DC-) (male) Resistance Min. 10 Mz
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC06 and capacitor power cable
connector HB01.
a Metal part of cable housing must be wiped clean.
a Take measurement after 1 minute if value is unstable.
a A megohmmeter is recommended to use.
Between HC06 (DC+) (male): red tester probe and
Power cable insulation deterio- cable housing metal part (P): black tester probe Resistance Min. 10 Mz
3
rated
Between HC06 (DC+) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
Between HC06 (DC-) (male): red tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC06 (DC-) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
If any failure is found by checks on causes 1 to 3, replace capacitor power cable.

Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)

40-346 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Circuit diagram related to high voltage devices 40-346

HB205-1, HB215LC-1 40-347

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

6. Electric swing motor power cable troubleshooting 40-348

If test results for the failure code indicate a possible problem in the electric swing motor power cable, proceed
with the following troubleshooting procedures.
*: *: If connector HB01 is already disconnected.
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC05 and swing motor power
cable connector PM02.
(Leave capacitor side connector HB01 disconnected)*
1 Open circuit in power cable
Between HC05 (U) (male) and PM02 (U) (male) Resistance Max. 1 z
Between HC05 (V) (male) and PM02 (V) (male) Resistance Max. 1 z
Between HC05 (W) (male) and PM02 (W) (male) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC05 and swing motor power
cable connector PM02.
(Leave capacitor side connector HB01 disconnected)*
2 Short circuit in power cable
Between HC05 (U) (male) and HC05 (V) (male) Resistance Min. 10 Mz
Between HC05 (V) (male) and HC05 (W) (male) Resistance Min. 10 Mz
Between HC05 (W) (male) and HC05 (U) (male) Resistance Min. 10 Mz
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC05 and swing motor power
cable connector PM02.
(Leave capacitor side connector HB01 disconnected)*
a Metal part of cable housing must be wiped clean.
a Take measurement after 1 minute if value is unstable.
a A megohmmeter is recommended to use.
Between HC05 (U) (male): red tester probe and cable
Resistance Min. 10 Mz
housing metal part (P): black tester probe
Power cable insulation deterio- Between HC05 (U) (male): black tester probe and Resistance Min. 10 Mz
3 cable housing metal part (P): red tester probe
rated
Between HC05 (V) (male): red tester probe and cable
Resistance Min. 10 Mz
housing metal part (P): black tester probe
Between HC05 (V) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
Between HC05 (W) (male): red tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC05 (W) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
If any failure is found by checks on causes 1 to 3, replace swing motor power cable.

40-348 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Circuit diagram related to high voltage devices 40-349

HB205-1, HB215LC-1 40-349

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)

40-350 HB205-1, HB215LC-1

(01)

Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices
7. Motor-generator power cable troubleshooting
If test results for the failure code indicate a possible problem in the motor-generator power cable, proceed
with the following troubleshooting procedures.
*: *: If connector HB01 is already disconnected.
Cause
1 Open circuit in power cable
2 Short circuit in power cable
Power cable insulation deterio-
3 Between HC03 (B1) (male): red tester probe and
rated
HB205-1, HB215LC-1
(01)
Troubleshooting by failure code [GA****] (code display)
40-351
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connectors HC03, HC04 and motor-gener-
ator power cable connectors GM02 and GM03.
(Leave capacitor side connector HB01 disconnected)*
Between HC03 (A1) (male) and GM02 (A1) (male) Resistance Max. 1 z
Between HC03 (B1) (male) and GM02 (B1) (male) Resistance Max. 1 z
Between HC03 (C1) (male) and GM02 (C1) (male) Resistance Max. 1 z
Between HC04 (A2) (male) and GM03 (A2) (male) Resistance Max. 1 z
Between HC04 (B2) (male) and GM03 (B2) (male) Resistance Max. 1 z
Between HC04 (C2) (male) and GM03 (C2) (male) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connectors HC03, HC04 and motor-gener-
ator power cable connectors GM02 and GM03.
(Leave capacitor side connector HB01 disconnected)*
Between HC03 (A1) (male) and HC03 (B1) (male) Resistance Min. 10 Mz
Between HC03 (B1) (male) and HC03 (C1) (male) Resistance Min. 10 Mz
Between HC03 (C1) (male) and HC03 (A1) (male) Resistance Min. 10 Mz
Between HC04 (A2) (male) and HC04 (B2) (male) Resistance Min. 10 Mz
Between HC04 (B2) (male) and HC04 (C2) (male) Resistance Min. 10 Mz
Between HC04 (C2) (male) and HC04 (A2) (male) Resistance Min. 10 Mz
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connectors HC03, HC04 and motor-gener-
ator power cable connectors GM02 and GM03.
(Leave capacitor side connector HB01 disconnected)*
a Metal part of cable housing must be wiped clean.
a Take measurement after 1 minute if value is unstable.
a A megohmmeter is recommended to use.
Between HC03 (A1) (male): red tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC03 (A1) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC03 (B1) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
Between HC03 (C1) (male): red tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC03 (C1) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
Between HC04 (A2) (male): red tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC04 (A2) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
40-351
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Cause Procedure, measuring location, criteria and remarks

Between HC04 (B2) (male): red tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC04 (B2) (male): black tester probe and
Resistance Min. 10 Mz
Power cable insulation deterio- cable housing metal part (P): red tester probe
3
rated Between HC04 (C2) (male): red tester probe and
cable housing metal part (P): black tester probe Resistance Min. 10 Mz

Between HC04 (C2) (male): black tester probe and

Resistance Larger than
cable housing metal part (P): red tester probe
If any failure is found by checks on causes 1 to 3, replace defective motor-generator power cable.

40-352 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Circuit diagram related to high voltage devices 40-353

HB205-1, HB215LC-1 40-353

(01)
Troubleshooting by failure code [GA****] (code display)
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage devices

Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)

40-354 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA----] Hybrid devices monitoring items list and check sheet

Failure code [GA----] Hybrid devices monitoring items list and check
sheet 40-35
List of monitoring items for hybrid devices troubleshooting
(Separate sheet 1)
Motor Electric
Capaci- Unit Re-
No. Monitoring item Code genera- Inverter swing Monitoring item
tor Range marks
tor motor
1 Swing LEFT PPC Sensor2 Volt. 09006 mV

2 Swing RIGHT PPC Sensor2 Volt. 09007 mV

Arm-Dump PPC Pres. Sen2 Volt-
3 07602 mV
age
4 Arm-Dig PPC Pres. Sen2 Voltage 07202 mV

5 Swing Motor DC Current 09100 A A A

6 DC Current, High-Voltage Side 09200 V V V

7 Capacitor Voltage 09300 V

Voltage at booster low-voltage
8 09400 V
side
9 Capacitor Base Temperature 09304 C

10 Capacitor Busbar Temperature 09305 C

11 Capacitor Cell Temperature 09306 C

12 Booster IGBT Base Temperature 09403 C

13 Booster IGBT JCT Temperature 09404 C

14 Booster Inductor Temperature 09402 C

15 Swing Motor Coil Temperature 09101 C

Swing Driver Phase U IGBT Base
16 09504 C
Temperature
Swing Driver Phase V IGBT Base
17 09505 C
Temperature
Swing Driver Phase W IGBT Base
18 09506 C
Temperature
Generator Driver IGBT Base Tem-
19 09607 C
perature #0
Generator Driver IGBT Base Tem-
20 09608 C
perature #1
Swing driver IGBT JCT Tempera-
21 09507 C
ture
HYB swing holding
22 Hybrid Controller Solenoid 09700 ON, OFF
brake
23 Generator Motor Rev. Speed 09602 r/min

24 Generator Motor Torque 09603 Nm

25 Gen. Motor Axial Output 09604 kW

26 Gen. Motor Target Rev. Speed 09605 r/min

27 Gen. Motor Target Torque 09606 Nm

28 Capacitor Target Voltage 09303 V

29 Capacitor Current 09307 A

30 Swing Lever Stroke 42103 %

31 Boom Lever Stroke 42104 %

32 Arm Lever Stroke 42105 %

33 EGOV Down Point 12301 r/min

34 Swing RIGHT PPC Pressure #2 09008 MPa

HB205-1, HB215LC-1 40-355

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA----] Hybrid devices monitoring items list and check sheet

Motor Electric
Capaci- Unit Re-
No. Monitoring item Code genera- Inverter swing Monitoring item
tor Range marks
tor motor
35 Swing LEFT PPC Pressure #2 09009 MPa

36 Generator Motor Temperature 09600 C

37 Bucket Lever Stroke 42106 %

Motor-generator speed
ON, OFF
control
Motor-generator torque
ON, OFF
control
Control output of hybrid system
38 09701 Motor-generator servo
controller ON, OFF
ON
Swing motor servo ON ON, OFF
Low speed matching
ON, OFF
ON
Key Switch
ON, OFF
(HYB controller)
39 Hybrid system controller SW input 09702 Emergency stop input ON, OFF

Operation lock lever ON, OFF

40 Swing Motor Rev. Speed 09102 r/min

41 Swing Motor Torque 09103 Nm

42 Swing Motor Axial Output 09104 kW

43 Swing Motor Target Rev. Speed 09105 r/min

44 Swing Motor Torque Limit Value 09106 Nm

45 Bad Insulating Sensor Voltage 09900 mV

Assembly part number
46 20255
(Hybrid System Controller)
Serial number
47 20417
(Hybrid System Controller)
Program part number
48 20256
(Hybrid System Controller)
Program version
49 20257
(Hybrid System Controller)
Booster start failure ON, OFF
50 Hybrid System Controller Warning 09703
Emergency stop input ON, OFF
Program part number
51 20269
(Hybrid System Controller Swing)
Program version
52 20270
(Hybrid System Controller Swing)
Program part number
53 (Hybrid System Controller Genera- 20271
tor)
Program version
54 (Hybrid System Controller Genera- 20272
tor)

40-356 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA----] Hybrid devices monitoring items list and check sheet

Check sheet for abnormal hybrid devices

(Separate sheet 2)
Model HB205-1/HB215LC-1 Work No.
Machine serial No. # Date of testing / /
Engine SAA4D107E-1 Service meter reading _________ hours
Engine serial No. # Worker's name

A. Failure

B. Visual check Pass Fail

1 Damage of wire and cable
2 Poor connection of connectors

C. Checking with machine monitor (abnormality record, monitoring) Pass Fail

3 Checking error and failure codes
Check of monitoring information
Testing Mea-
Display item Code condi- Unit Reference value sured Pass Fail
tions value
Engine Speed 01002 r/min 600 2,200
Throttle Position 31701 % 0 100
Swing Motor DC Current 09100 A 400
Capacitor Voltage 09300 V 150 300
Voltage at booster low-volt-
09400 V 150 300
age side
Capacitor Base Temperature 09304 C -30 to 65
Capacitor Busbar Tempera-
09305 C -30 to 65
ture
Capacitor Cell Temperature 09306 C -30 to 65
Booster IGBT Temperature 09403 C -30 to 100
Booster IGBT JCT Tempera-
09404 -30 to 100
ture
Booster Inductor Temperature 09402 C -30 to 130
4
Swing Motor Coil Temperature 09101 C -30 to 160
Swing Driver Phase U IGBT
09504 C -30 to 85
Base Temperature
Swing Driver Phase V IGBT
09505 C -30 to 85
Base Temperature
Swing Driver Phase W IGBT
09506 C -30 to 85
Base Temperature
Generator Driver IGBT Base
09607 C -30 to 180
Temperature #0
Generator Driver IGBT Base
09608 C -30 to 70
Temperature #1
Swing driver IGBT JCT Tem-
09507 C -30 to 135
perature
Hybrid Controller Solenoid 09700
Same as engine
Generator Motor Rev. Speed 09602 r/min
speed
Gen. Motor Target Rev. Speed 09605 r/min 600 2,500
Capacitor Target Voltage 09303 V 185 298

HB205-1, HB215LC-1 40-357

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA----] Hybrid devices monitoring items list and check sheet

Testing Mea-
Display item Code condi- Unit Reference value sured Pass Fail
tions value
-100 100
Swing Lever Stroke 42103 % (Zero with lever at
NEUTRAL)
-100 100
Boom Lever Stroke 42104 % (Zero with lever at
NEUTRAL)
-100 100
Arm Lever Stroke 42105 % (Zero with lever at
NEUTRAL)
-100 100
Bucket Lever Stroke 42106 % (Zero with lever at
NEUTRAL)
Control output of hybrid sys-
09701
tem controller
Hybrid system controller SW
4 input 09702
Swing Motor Rev. Speed 09102 r/min 8311
Swing Motor Target Rev.
09105 r/min 8311
Speed
Starting
switch at
ON,
Bad Insulating Sensor Voltage 09900 mV 4650
before
starting
engine
Assembly part number
---
(Hybrid System Controller)
Serial number
20417 1001 and up
(Hybrid System Controller)
Program part number
20256 787523R400
(Hybrid System Controller)
Program version
20257 4.1.18.0
(Hybrid System Controller)

40-358 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA00NS] HYB devices overheat

Failure code [GA00NS] HYB devices overheat 40-359

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
k Be careful not to burn yourself.

User code Failure code HYB device overheat

Failure
(Hybrid controller system)
E09 GA00NS
q Temperature of at least one of hybrid devices exceeded limit shown below resulting in system shut-
down.
Detail of failure q Swing motor coil: 160 C, motor-generator: 190 C, (temperature inside inverter at:) booster trans-
former: 130 C, booster IGBT junction: 135 C, booster IGBT base: 100 C, swing motor IGBT
junction: 135 C, generator driver IGBT base: 100 C
q Disables swing motor, stops motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Upper structure does not swing and low speed matching function does not operate.
machine
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1 Defective hybrid devices If another failure code is displayed, perform troubleshooting for it first.
2 Defective hybrid cooling system Perform troubleshooting for Y mode, "Y-8" to "Y-11".

HB205-1, HB215LC-1 40-359

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA01KA] Power Cable Interlock Open Circuit

Failure code [GA01KA] Power Cable Interlock Open Circuit 40-360

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Open circuit in power cable interlock

Failure
(Hybrid controller system)
E09 GA01KA
q Power cable connector that connects to inverter, motor-generator, capacitor or electric swing motor
is disconnected.
Detail of failure
q Cover for power cable joint to inverter, generator motor or swing motor is removed.
q Power cable connector is connected upside down. (Turn harness side connector 180 deg..)
q Stops motor-generator control, and applies swing holding brake.
q Stops swing motor control or limits swing speed, etc.
Action of con- q Disables low speed matching function.
troller q Disables hoist matching function.
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing or swing speed, etc. are limited.
machine q Low speed matching function does not operate.
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Related infor-
q When failure code [GA1VFS] is displayed at the same time, power cable connector HC06 may be
mation
loose or connected 180 deg. upside down.

Cause Procedure, measuring location, criteria and remarks

Disconnected power
1 Visually check power cable connector for disconnection.
cable connector
Improper fitting or fail-
2 ure of power cable Visually check power cable connector for improper fitting.
connector
Removed cover from
3 Visually check cover of power cable joint for removal.
power cable connector
1. Check that the mark (four lines) on power cable connector HC06 is on the same side of
Improper connection
the mark (four lines) on the component to be connected. (Harness side connector is
4 of power cable con-
180 deg. opposite.)
nector
2. Check power cable connector HC06 for looseness.
Open circuit in 1. Turn starting switch to OFF position.
motor-generator,
5 a Check with all power cable connectors except HC02 connected.
swing motor, or har-
ness Between HC02 (female) (14) and (24) Resistance Max. 1 z
a If no failure is found by check on cause 4, this check is not required.
Open circuit in 1. Turn starting switch to OFF position.
6 motor-generator 2. Disconnect connector GM01 and connect T-adapters to male side.
(internal open circuit)
Between GM01 (male) (7) and (8) Resistance Max. 1 z
a If no failure is found by check on cause 4, this check is not required.
Open circuit in swing 1. Turn starting switch to OFF position.
7 motor (internal open 2. Disconnect connector PM01 and connect T-adapters to male side.
circuit)
Between PM01 (male) (9) and (10) Resistance Max. 1 z

40-360 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA01KA] Power Cable Interlock Open Circuit

Cause Procedure, measuring location, criteria and remarks

a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch OFF.
2. Disconnect connectors HC02, PM01, and GM01, and connect T-adapters to each
Open circuit in wiring
8 female side.
harness
Between HC02 (female) (14) and PM01 (female) (10) Resistance Max. 1 z
Between PM01 (female) (9) and GM01 (female) (8) Resistance Max. 1 z
Between GM01 (female) (7) and HC02 (female) (24) Resistance Max. 1 z
Ground fault in wiring 1. Turn starting switch OFF.
9 harness (contact with 2. Disconnect connector HC02 and connect T-adapters to female side.
ground circuit) Between HC02 (female) (14) or (24) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wir-
2. Disconnect connector HC02 and connect T-adapters to female side.
10 ing harness (contact
3. Turn starting switch to ON position.
with 24 V circuit)
Between HC02 (female) (14) or (24) and ground Voltage Max. 1 V

Defective inverter If no failure is found by checks on causes 1 to 9, inverter (hybrid controller) is defective.
11
(Hybrid controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to power cable interlocks 40-361

HB205-1, HB215LC-1 40-361

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA02KZ] DC Line Open/Short Circuit

Failure code [GA02KZ] DC Line Open/Short Circuit 40-362

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Open or short circuit in DC line

Failure
(Hybrid controller system)
E09 GA02KZ
Detail of failure q Insulation of cable connecting capacitor and inverter is deteriorated.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective insulation
between hybrid sys-
1 q Visually check cables for damaged insulation, etc.
tem components and
chassis ground
Defective hybrid com-
q Perform steps 1. to 7. of "common troubleshooting procedures for high voltage devic-
2 ponents at high volt-
es".
age systems

40-362 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster

Failure code [GA04KG] Abnormal DC HW Volt. Before Booster 40-363

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code High power supply voltage error detected by hardware in DC line
Failure before booster
E09 GA04KG (Hybrid controller system)

Detail of failure q 390 V or higher capacitor voltage is detected by hardware.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Capacitor voltage can be checked with monitoring function.
Related infor-
(Code: 09300 Capacitor voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Perform step 1 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
1 Defective capacitor
shooting by failure code [GA****] .
Capacitor power cable Perform step 5 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
2
defective shooting by failure code[GA****].

Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

HB205-1, HB215LC-1 40-363

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster

Failure code [GA05KG] Abnormal DC SW Volt. Before Booster 40-364

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code High power supply voltage error detected by software in DC line
Failure before booster
E09 GA05KG (Hybrid controller system)

Detail of failure q 340 V or higher capacitor voltage is detected by software.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Capacitor voltage can be checked with monitoring function.
Related infor-
(Code: 09300 Capacitor voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Perform step 1 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
1 Defective capacitor
shooting by failure code [GA****].
Capacitor power cable Performstep 5 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
2
defective shooting by failure code [GA****].

Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

40-364 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster

Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster 40-365

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Low power supply voltage error detected by software in DC line
Failure before booster
E09 GA05KP (Hybrid controller system)

Detail of failure q 100 V or lower capacitor voltage is detected by software.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Capacitor voltage can be checked with monitoring function.
Related infor-
(Code: 09300 Capacitor voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Perform step 1 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
1 Defective capacitor
shooting by failure code [GA****].
Capacitor power cable Perform step 5 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
2
defective shooting by failure code [GA****].

Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

HB205-1, HB215LC-1 40-365

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster

Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster 40-36
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Open or short circuit in voltage sensor in DC line before booster
Failure open or short circuit
E09 GA06KZ (Hybrid controller system)

Detail of failure q Capacitor voltage sensor in inverter is abnormal.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Capacitor voltage can be checked with monitoring function.
Related infor-
(Code: 09300 Capacitor voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

40-366 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster

Failure code [GA08KG] Abnormal. DC HW Volt. After Booster 40-367

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code High power supply voltage error detected by hardware in DC line
Failure after booster
E09 GA08KG (Hybrid controller system)

Detail of failure q Overvoltage is detected at power train hardware.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Voltage of power train can be checked with monitoring function.
Related infor-
(Code: 09200 High current, high voltage system DC voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective motor-gen-
1
erator
2 Defective swing motor
Perform steps 1 to 7 of "Common troubleshooting procedures for hybrid devices".
Defective inverter
3
(hybrid controller)

4 Defective capacitor

HB205-1, HB215LC-1 40-367

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster

Failure code [GA09KG] Abnormal. DC SW Volt. After Booster 40-368

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code High power supply voltage error detected by software in DC line
Failure after booster
E09 GA09KG (Hybrid controller system)

Detail of failure q Overvoltage is detected at power train by software.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Voltage of power train can be checked with monitoring function.
Related infor-
(Code: 09200 High current, high voltage system DC voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective motor-gen-
1
erator
2 Defective swing motor
Perform steps 1 to 7 of "Common troubleshooting procedures for hybrid devices".
Defective inverter
3
(hybrid controller)

4 Defective capacitor

40-368 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA09KP] Low DC SW Output Volt. After Booster

Failure code [GA09KP] Low DC SW Output Volt. After Booster 40-369

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Low power supply voltage error detected by software in DC line
Failure after booster
E09 GA09KP (Hybrid controller system)

Detail of failure q Output voltage drop is detected at power train by software.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Voltage of power train can be checked with monitoring function.
Related infor-
(Code: 09200 High current, high voltage system DC voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

HB205-1, HB215LC-1 40-369

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster

Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster 40-370
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Open or short circuit in voltage sensor in DC line after booster
Failure
(Hybrid controller system)
E09 GA0AKZ
Detail of failure q Power train voltage sensor in inverter is abnormal.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Voltage of power train can be checked with monitoring function.
Related infor-
(Code: 09200 High current, high voltage system DC voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

40-370 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA0BKZ] AC Line Open/Short Circuit

Failure code [GA0BKZ] AC Line Open/Short Circuit 40-371

User code Failure code Open or short circuit in AC line

Failure
(Hybrid controller system)
E09 GA0BKZ
q Insulation of cable connecting between swing motor or motor-generator and inverter is deteriorat-
Detail of failure
ed.
q Stops swing motor and motor-generator control, and applies swing holding brake.
Action of con- q Disables low speed matching function.
troller q Disables hoist matching function.
q If cause of failure disappears, machine becomes normal by itself.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: After engine is started, turn starting switch to OFF position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective insulation
between hybrid
1 q Visually check cables for damaged insulation, etc.
devices and chassis
ground
Defective hybrid
2 device at high voltage q Perform steps 1 to 7 of "Common troubleshooting procedures for hybrid devices".
part

HB205-1, HB215LC-1 40-371

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure

Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure 40-372

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of HYB controller high power supply
Failure
(Hybrid controller system)
E09 GA12MC
q Capacitor voltage does not drop below 10 V when discharge operation is completed using machine
Detail of failure
monitor.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Capacitor voltage can be checked by using monitoring function.
Related infor-
(Code: 09300 Capacitor voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defective capacitor
Defective capacitor
2
power cable
Perform step 1 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
shooting by failure code [GA****].
Perform step 5 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
shooting by failure code [GA****].

Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

40-372 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON

Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON 40-373
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Failure in voltage increase of HYB controller high power supply
Failure
(Hybrid controller system)
E09 GA12NK
Detail of failure q Electrical system in inverter does not start.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform step 1 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
1 Defective capacitor
shooting by failure code [GA****].
Defective motor-gen- Perform step 3 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
2
erator shooting by failure code [GA****].
Defective capacitor Perform step 5 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
3
power cable shooting by failure code [GA****].
Defective generator Perform step 7 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
4
power cable shooting by failure code [GA****].

Defective inverter
5 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

HB205-1, HB215LC-1 40-373

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF

Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF 40-374
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Failure in voltage drop of HYB controller high power supply
Failure
(Hybrid controller system)
E09 GA12NL
Detail of failure q Although a certain time has passed, voltage of power train does not drop below specified level.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Voltage of power train can be checked with monitoring function.
Related infor-
(Code: 09200 High current, high voltage system DC voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective motor-gen- Perform step 3 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
1
erator shooting by failure code [GA****].
Defective motor-gen- Performstep 7 of "Common troubleshooting procedures for hybrid devices" in "Trouble-
2
erator power cable shooting by failure code [GA****].

Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

40-374 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF

HB205-1, HB215LC-1 40-375

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure

Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure 40-376

User code Failure code Malfunction of HYB controller sensor power supply
Failure
(Hybrid controller system)
E09 GA13MC
Detail of failure q Voltage of 5 V sensor power supply circuit dropps below 2.5 V or exceeds above 6.0 V.
q Shuts off power supply to 5 V sensor.
q Disables low speed matching function.
q Disables hoist matching function.
Action of con-
q Stops swing motor control.
troller
q Applies swing holding brake.
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn the starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect following sensors one by one, and turn starting switch to ON position for
each troubleshooting.
a If this failure code disappears, disconnected sensor is defective.
3. After each troubleshooting, turn starting switch to OFF position.
Defective hybrid sys- Sensor Connector
tem pressure sensor
1 Arm IN pressure sensor HP05
(short circuit in inter-
nal wiring) Arm OUT PPC pressure sensor HP03
Boom LOWER PPC pressure sensor HP07
Swing RIGHT PPC pressure sensor HP06
Swing LEFT PPC pressure sensor HP04
a Measure voltage before controller stops power supply.
1. Turn starting switch to OFF position.
Hot short circuit in wir- 2. Disconnect connectors HP03 to HP07.
2 ing harness (contact 3. Connect T-adapters to female side of any of disconnected connectors (eg HP07).
with 24 V circuit) 4. Turn starting switch to ON position (with connectors HP03 to HP07 disconnected).
Between HP07 (female) (3) and ground Voltage 4.5 5.5 V
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors HC02 and HP03 to HP07.
3 harness (contact with 3. Connect T-adapters to female side of connector HC02.
ground circuit)
Between HC02 (female) (7) and ground Resistance Min. 1 Mz
Defective inverter If no failure is found by above checks, inverter (hybrid controller) is defective. (Since this is
4
(hybrid controller) an internal defect, troubleshooting cannot be performed.)

40-376 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure

Circuit diagram related to hybrid controller sensor power supply 40-37

HB205-1, HB215LC-1 40-377

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure

Failure code [GA14KR] HYB Control. KOMNET Comm. Failure 40-378

User code Failure code KOMNET communication error of HYB controller

Failure
(Hybrid controller system)
E09 GA14KR

Detail of failure q Inverter (hybrid controller) fails in CAN communication with pump controller or engine controller.

q Continues to control by using CAN information obtained before failure detection.

q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Limits swing speed, etc.
q If cause of failure disappears, machine becomes normal by itself.
q Low speed matching function does not operate.
Problem on
q Swing speed, etc. are limited.
machine
q Machine monitor may not operate normally or may not display correct information.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if this failure code is
displayed on machine monitor, wiring harness (CAN communication line) is free from ground fault,
Related infor-
short circuit and hot short.
mation
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF position.
q Since active CAN communication line signal is pulse voltage, it cannot be measured by using mul-
timeter.

Cause Procedure, measuring location, criteria and remarks

1 [If failure code [DA2RMC] is also displayed, perform troubleshooting for it first.
Improper power supply
2 Perform troubleshooting for failure code [DAFRMC], cause 2 first.
to pump controller

Defective inverter If no failure is found by above checks, hybrid controller is defective. (Since this is an inter-
3
(hybrid controller) nal defect, troubleshooting cannot be performed.)

40-378 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir

Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir 40-379

User code Failure code Open or short circuit in bad insulation sensor of HYB controller
Failure
(Hybrid controller system)
E09 GA15KZ
Detail of failure q Sensor that detects insulation deterioration between hybrid device and chassis ground is abnormal.
Action of con-
q None in particular.
troller
Problem on
q No current leakage can be detected.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position, or start engine and then
mation turn starting switch to OFF position.

Cause Procedure, measuring location, criteria and remarks

Defective hybrid
Perform teps 1 to 7 of "Common troubleshooting procedures for hybrid devices" in "Trou-
1 devices at high voltage
bleshooting by failure code [GA****].
part

Failure code [GA17KR] Gen. Mot. Drv. Communication Failure 40-379

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Communication error of motor-generator driver

Failure
(Hybrid controller system)
E09 GA17KR
Detail of failure q Internal communication failure 2 of inverter is detected by motor-generator controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

HB205-1, HB215LC-1 40-379

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit

Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit 40-380
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Short circuit in motor-generator driver power line
Failure
(Hybrid controller system)
E09 GA17KY
Detail of failure q Short circuit is detected in power line for motor-generator driver.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit 40-380

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Open or short circuit in motor-generator driver

Failure
(Hybrid controller system)
E09 GA17KZ
Detail of failure q Open or short circuit is detected in motor-generator driver circuit.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

40-380 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded

Failure code [GA17MB] Gen. Mot. Drv. Function Degraded 40-381

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Reduced performance of motor-generator driver

Failure
(Hybrid controller system)
GA17MB
Detail of failure q Internal communication failure 1 of inverter is detected by motor-generator controller.
q None in particular.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q None in particular.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)

Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure 40-381
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of motor-generator driver excitation power supply
Failure
(Hybrid controller system)
E09 GA18MC
Detail of failure q Electrical system in inverter does not start.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform step 3 of "Common troubleshooting procedures for hybrid devices" in
1 Defective motor-generator
"Troubleshooting by failure code [GA****].
Perform step 7 of "Common troubleshooting procedures for hybrid devices" in
2 Defective generator power cable
"Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-381

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt

Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt 40-382
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Motor-generator driver sub-CPU power supply voltage drop
Failure
(Hybrid controller system)
E09 GA19KK
Detail of failure q Abnormal power supply voltage is detected in motor-generator controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure 40-382
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Communication failure of motor-generator driver sub-CPU

Failure
(Hybrid controller system)
E09 GA19KR
Detail of failure q Communication failure is detected in sub-CPU of motor-generator driver.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-382 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con.

Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. 40-383
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Internal failure of motor-generator driver sub-CPU controller
Failure
(Hybrid controller system)
E09 GA19KT
Detail of failure q Inverter internal communication failure 3 is detected by motor-generator controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction 40-383

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of motor-generator driver sub-CPU

Failure
(Hybrid controller system)
E09 GA19MA
Detail of failure q Program written in the motor-generator controller is abnormal.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-383

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation

Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation 40-384
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of motor-generator driver sub-CPU

Failure
(Hybrid controller system)
E09 GA19MC
Detail of failure q CPU reset of motor-generator controller occures.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled 40-384
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Startup failure of motor-generator driver sub-CPU

Failure
(Hybrid controller system)
E09 GA19NA
Detail of failure q Internal communication initialization failure of inverter is detected by motor-generator controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-384 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction

Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction 40-385
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of motor-generator driver DC voltage sensor

Failure
(Hybrid controller system)
E09 GA1BMA
Detail of failure q Malfunction of motor-generator driver DC voltage sensor is detected.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA1FKR] Swing Mot. Drv. Communication Failure 40-385

User code Failure code Communication failure of swing motor driver

Failure
(Hybrid controller system)
E09 GA1FKR
Detail of failure q Inverter internal communication failure 2 is detected by swing motor controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-385

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1FMA] Abnormal Swing Motor Driver

Failure code [GA1FMA] Abnormal Swing Motor Driver 40-386

User code Failure code Failure of swing motor driver

Failure
(Hybrid controller system)
E09 GA1FMA
Detail of failure q Abnormality of swing motor inverter output circuit is detected.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform step 2 of "Common troubleshooting procedures for hybrid devices" in
1 Defective swing motor
"Troubleshooting by failure code [GA****].
Defective swing motor power Perform step 6 of "Common troubleshooting procedures for hybrid devices" in
2
cable "Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU 40-386

User code Failure code Voltage drop of swing motor driver sub-CPU power supply
Failure
(Hybrid controller system)
E09 GA1GKK
Detail of failure q Abnormal power supply voltage is detected in swing motor controller power supply.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-386 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure

Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure 40-387

User code Failure code Communication failure of swing motor driver sub-CPU
Failure
(Hybrid controller system)
E09 GA1GKR
Detail of failure q Communication failure is detected in swing motor driver sub-CPU.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal 40-387

User code Failure code Internal failure of swing motor driver sub-CPU controller
Failure
(Hybrid controller system)
E09 GA1GKT
Detail of failure q Inverter internal communication failure 3 is detected by swing motor controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-387

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction

Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction 40-38

User code Failure code Malfunction of swing motor driver sub-CPU

Failure
(Hybrid controller system)
E09 GA1GMA
Detail of failure q Program written in swing motor controller is abnormal.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded 40-38

User code Failure code Performance drop of swing motor driver sub-CPU
Failure
(Hybrid controller system)
GA1GMB
Detail of failure q Inverter internal communication failure 1 is detected by swing motor controller.
q None in particular.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q None in particular.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-388 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op.

Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op. 40-389

User code Failure code Malfunction of swing motor driver sub-CPU

Failure
(Hybrid controller system)
E09 GA1GMC
Detail of failure q CPU reset of swing motor controller occures.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled 40-389

User code Failure code Startup failure of swing motor driver sub-CPU
Failure
(Hybrid controller system)
E09 GA1GNA
Detail of failure q Internal communication initialization failure of inverter is detected by swing motor controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-389

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir.

Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. 40-390

User code Failure code Open or short circuit in U-phase temperature sensor of swing
Failure motor driver
E09 GA1HKZ (Hybrid controller system)

Detail of failure q Temperature sensor failure is detected in U-phase output circuit of swing motor inverter.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor coil temperature can be checked with monitoring function.
Related infor-
(Code: 09500 Swing inverter phase U temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. 40-390

User code Failure code Open or short circuit in V-phase temperature sensor of swing
Failure motor driver
E09 GA1JKZ (Hybrid controller system)

Detail of failure q Temperature sensor failure is detected in V-phase output circuit of swing motor inverter.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor coil temperature can be checked with monitoring function.
Related infor-
(Code: 09501 Swing inverter phase V temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-390 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir

Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir 40-391

User code Failure code Open or short circuit in W-phase temperature sensor of swing
Failure motor driver
E09 GA1KKZ (Hybrid controller system)

Detail of failure q Temperature sensor failure is detected in W-phase output circuit of swing motor inverter.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor coil temperature can be checked with monitoring function.
Related infor-
(Code: 09502 Swing inverter phase W temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir. 40-391

User code Failure code Open or short circuit in swing motor driver current sensor
Failure
(Hybrid controller system)
E09 GA1LKZ
Detail of failure q Open or short circuit is detected in swing motor inverter current sensor.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-391

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir.

Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir. 40-392

User code Failure code Open or short circuit in swing motor driver DC voltage sensor
Failure
(Hybrid controller system)
E09 GA1MKZ
Detail of failure q DC voltage sensor failure of swing motor inverter is detected.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-392 HB205-1, HB215LC-1

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat

q Reference

a Remove the plug on elbow and install nipple and

O-ring U1, joint U2, hose U3, and pressure
gauge U4, then measure the pressure.

40-393-1 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat

HB205-1, HB215LC-1 40-393-2

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat

Failure code [GA1NNS] Swing Motor Driver IGBT Overheat 40-392

User code Failure code Swing motor driver IGBT overheat

Failure
(Hybrid controller system)
GA1NNS
Detail of failure q Estimated junction temperature of swing motor driver IGBT inside inverter exceeds 134 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Excessive charging or discharging
1 Check for excessive swinging or swing stop.
of capacitor
Within the
1 Check coolant level in hybrid radiator Coolant
sight gauge
q Check visually with sight gauge (1). level
range
2 Check hybrid radiator fins (2) for clogging
3 Check water pump (3) (when key is turned to
ON position)
q Check pump vibration by bare hand
Malfunction of hybrid system cool-
2 q Check pump operation sound, and water
ing circuit
flow sound
4 Check coolant flow (pressure measurement) Pressure is
q Remove plug (4) on top of the swing motor
larger than "0".
coolant inlet elbow and connect the (normal level:
Pressure
low-pressure bourdon tube pressure approximately
gauge, then measure the pressure after key
is turned to ON position. 0.5 kg/cm2)
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-393

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1SFS] Contactor Locked

Failure code [GA1SFS] Contactor Locked 40-393

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Contactor locked

Failure
(Hybrid controller system)
E09 GA1SFS
Detail of failure q Contactor inside inverter is locked.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA1SMC] Contactor Failure 40-394

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of contactor

Failure
(Hybrid controller system)
E09 GA1SMC
Detail of failure q Contactor inside inverter does not work.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Capacitor voltage and booster low voltage can be checked with monitoring function.
Related infor-
(Code: 09300 Capacitor voltage, 09400 Booster low voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-394 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1TKP] Capacitor Low Output Voltage

Failure code [GA1TKP] Capacitor Low Output Voltage 40-395

User code Failure code Capacitor output voltage drop

Failure
(Hybrid controller system)
E09 GA1TKP
Detail of failure q Capacitor voltage is under 140 V.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Capacitor voltage can be checked with monitoring function.
Related infor-
(Code: 09300 Capacitor voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Perform step 1 of "Common troubleshooting procedures for hybrid devices" in
1 Defective capacitor
"Troubleshooting by failure code [GA****].
Perform step 5 of "Common troubleshooting procedures for hybrid devices" in
2 Defective capacitor power cable
"Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-395

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1TNS] Capacitor Overheat

Failure code [GA1TNS] Capacitor Overheat 40-396

User code Failure code Capacitor overheat

Failure
(Hybrid controller system)
GA1TNS
Detail of failure q Capacitor cell center temperature exceeds 65 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Capacitor cell center temperature and capacitor base temperature can be checked with monitoring
function.
Related infor- (Code: 09306 Capacitor cell temperature, 09304 Capacitor base temperature)
mation q Capacitor cell center temperature is an estimated value which is calculated from capacitor base
temperature.
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Excessive charging or discharging
1 Check for excessive swinging or swing stop.
of capacitor
1. Turn starting switch to OFF position.
Short circuit in capacitor base 2. Disconnect connector HP01 and connect T-adapters to male side.
2
temperature sensor q Capacitor base temperature sensor 0.1
Resistance
Between HP01 (male) (4) and (8) 500 kz
1. Be ready with starting switch at OFF, then perform troubleshooting without
turning starting switch to ON position.
2. Disconnect connectors HC02 and HP01, and connect T-adapters to either
Ground fault in wiring harness
3 female side.
(contact with ground circuit)
q Capacitor base temperature sensor
Between HC02 (female) (27) or HP01 (female) (4) Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
Defective water pump 2. Disconnect connector HK01 and connect T-adapters to male side.
4
(internal open circuit)
Between HK01 (male) (1) and (2) Resistance Min. 1 z
Malfunction of hybrid system cool-
5 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
q Perform step 1 of "Common troubleshooting procedures for hybrid devices"
6 Defective capacitor
in "Troubleshooting by failure code [GA****].

40-396 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1TNS] Capacitor Overheat

Circuit diagram related to capacitor 40-397

HB205-1, HB215LC-1 40-397

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir.

Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir. 40-398

User code Failure code Open or short circuit in capacitor temperature sensor
Failure
(Hybrid controller system)
E09 GA1UKZ
q Difference between capacitor base temperature and capacitor busbar temperature is more than
Detail of failure
54.4 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Capacitor base temperature and capacitor busbar temperature can be checked with monitoring
Related infor- function.
mation (Code: 09304 Capacitor base temperature, Code: 09305 Capacitor busbar temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector HP01 and connect T-adapters to male side.
Defective capacitor base tempera-
1 ture sensor 0.1
Between HP01 (male) (4) and (12) Resistance
(internal open or short circuit) 500 kz
Between HP01 (male) (4) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector HP01 and connect T-adapters to male side.
Defective capacitor busbar tem-
2 perature sensor (internal open or 0.1
Between HP01 (male) (5) and (12) Resistance
short circuit) 500 kz
Between HP01 (male) (5) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors HC01 and HP01, and connect T-adapters to each
female side.
Open circuit in wiring harness Between HC01 (female) (7) and HP01 (female) (1) Resistance Max. 1 z
3 (wire breakage or defective con- Between HC01 (female) (20) and HP01 (female)
tact of connector) Resistance Max. 1 z
(12)
Between HC02 (female) (27) and HP01 (female) (4) Resistance Max. 1 z
Between HC02 (female) (37) and HP01 (female) (5) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector HP01 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Hot short circuit in wiring harness q Capacitor base temperature sensor
4 Between HC02 (female) (27) or HP01 (female) (4) Voltage Max. 1 V
(contact with 24 V circuit)
and ground
q Capacitor busbar temperature sensor
Between HC02 (female) (37) or HP01 (female) (5) Voltage Max. 1 V
and ground
Malfunction of hybrid system cool-
5 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
q Perform step 1 of "Common troubleshooting procedures for hybrid devices"
6 Defective capacitor
in "Troubleshooting by failure code [GA****].
Defective inverter (hybrid control- If no failure is found by above checks, inverter (hybrid controller) is defective.
7
ler) (Since this is an internal defect, troubleshooting cannot be performed.)

40-398 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir.

Circuit diagram related to capacitor temperature sensor 40-39

HB205-1, HB215LC-1 40-399

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1VFS] Capacitor Contactor Locked

Failure code [GA1VFS] Capacitor Contactor Locked 40-40

User code Failure code Capacitor contactor locked

Failure
(Hybrid controller system)
E09 GA1VFS
q Contactor inside of capacitor is locked.
Detail of failure
q Power cable connector is connected upside down. (Turn harness side connector 180 deg..)
q Limits swing speed, etc.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q When failure code [GA1VFS] is displayed at the same time, power cable connector HC06 may be
Related infor-
loose or connected 180 deg. upside down.
mation
q Capacitor voltage can be checked with monitoring function.
(Code: 09300 Capacitor voltage)

Cause Procedure, measuring location, criteria and remarks

Improper connection of power
1
cable connector
2 Hot short circuit in wiring harness
3 Defective capacitor
Defective inverter (hybrid control-
4 Since this is an internal defect, troubleshooting cannot be performed.
ler)
1. Check that the mark (four lines) on power cable connector HC06 is on the
same side of the mark (four lines) on the component to be connected.
(Harness side connector is 180 deg. opposite.)
2. Check power cable connector HC06 for looseness.
1. Turn starting switch to OFF position.
2. Disconnect connector HP01 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Between HP01 (female) (6) and ground Voltage Max. 1 V
Between HP01 (female) (7) and ground Voltage Max. 1 V
Before discharging (if capacitor voltage is 30 V or higher), check capacitor
LED through window with power at OFF. If both LEDs light up, capacitor is
defective.

40-400 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1VFS] Capacitor Contactor Locked

Circuit diagram related to capacitor contactor 40-401

HB205-1, HB215LC-1 40-401

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1VMC] Capacitor Contactor Failure

Failure code [GA1VMC] Capacitor Contactor Failure 40-402

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of capacitor contactor

Failure
(Hybrid controller system)
E09 GA1VMC
Detail of failure q Contactor inside of capacitor does not connect.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors HC01 and HP01, and connect T-adapters to each
Open circuit in wiring harness
female side.
1 (wire breakage or defective con-
tact of connector) Between HC01 (female) (3) and HP01 (female) (6) Resistance Max. 1 z
Between HC01 (female) (9) and HP01 (female) (7) Resistance Max. 1 z
2 Defective capacitor
Defective inverter (hybrid control- Since this is an internal defect, troubleshooting cannot be performed.
3
ler)

Circuit diagram related to capacitor contactor 40-402

40-402 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ.

Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. 40-403

User code Failure code Open or short circuit in booster inductor temperature sensor
Failure
(Hybrid controller system)
E09 GA1XKZ
Detail of failure q Abnormality of booster inductor temperature sensor in the inverter is detected.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Booster inductor temperature can be checked with monitoring function.
(Code: 09402 Booster inductor temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q If any of the failure code [GA00NS] or [GA1YNS] or [GA1NNS] or [GA1ZNS] or [GA22NS] or
Related infor-
[GA25NS] or [GA26NS] which indicates the overheat in the inverter is displayed at the same time,
mation
hybrid system cooling circuit may be defective.
q Inductor temperature which can be checked with monitoring function is at normal level (the tem-
perature is equal to ambient temperature or higher. The temperature range is 16 C to 190 C), hy-
brid system cooling circuit may be deactive.

Cause Procedure, measuring location, criteria and remarks

Malfunction of hybrid system cool-
1 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
Defective inverter (hybrid control-
2 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-403

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1YNS] Booster Inductor Overheat

Failure code [GA1YNS] Booster Inductor Overheat 40-403

User code Failure code Booster inductor overheat

Failure
(Hybrid controller system)
GA1YNS
Detail of failure q Temperature of booster inductor inside inverter exceeds 125 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Booster inductor temperature can be checked with monitoring function.
Related infor-
(Code: 09402 Booster inductor temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Excessive charging or discharging
1 Check for excessive swinging or swing stop.
of capacitor
Malfunction of hybrid system cool-
2 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-404 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ.

Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. 40-404

User code Failure code Open or short circuit in booster IGBT temperature sensor
Failure
(Hybrid controller system)
E09 GA1ZKZ
Detail of failure q Abnormality of booster IGBT temperature sensor in inverter is detected.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Booster IGBT base temperature can be checked with monitoring function.
Related infor-
(Code: 09403 Booster IGBT base temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-404-1

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat

Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat 40-404

User code Failure code Booster IGBT temperature sensor overheat

Failure
(Hybrid controller system)
GA1ZNS
Detail of failure q Temperature of booster IGBT inside inverter exceeds 80 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Booster IGBT base temperature can be checked with monitoring function.
Related infor-
(Code: 09403 Booster IGBT base temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Excessive charging or discharging
1 Check for excessive swinging or swing stop.
of capacitor
Malfunction of hybrid system cool-
2 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-404-2 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA21KB] Booster IGBT Short Circuit

Failure code [GA21KB] Booster IGBT Short Circuit 40-405

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Short circuit in booster IGBT

Failure
(Hybrid controller system)
E09 GA21KB
Detail of failure q Overcurrent flows through booster IGBT inside inverter.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-404-3

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA21KB] Booster IGBT Short Circuit

40-404-4 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA22NS] Booster IGBT Junction Overheat

Failure code [GA22NS] Booster IGBT Junction Overheat 40-405

User code Failure code Booster IGBT junction overheat

Failure
(Hybrid controller system)
GA22NS
Detail of failure q Estimated junction temperature of booster IGBT inside inverter exceeds 130 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Booster IGBT junction temperature can be checked with monitoring function.
Related infor-
(Code: 09404 Booster IGBT junction temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Excessive charging or discharging
1 Check for excessive swinging or swing stop.
of capacitor
Malfunction of hybrid system cool-
2 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-405

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sens.0 Opn/Short Cir.

Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sens.0 Opn/Short Cir. 40-406

User code Failure code Open or short circuit in motor-generator driver temperature sen-
Failure sor 0
E09 GA23KZ (Hybrid controller system)

Detail of failure q Open or short circuit is detected in motor-generator driver temperature sensor 0.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir. 40-406

User code Failure code Open or short circuit in motor-generator driver temperature sen-
Failure sor 1
E09 GA24KZ (Hybrid controller system)

Detail of failure q Open or short circuit is detected in motor-generator driver temperature sensor 1.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-406 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality

Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality 40-407

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Motor-generator driver IGBT0 abnormal

Failure
(Hybrid controller system)
E09 GA25MA
Detail of failure q Motor-generator driver IGBT0 is abnormal.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform step 3 of "Common troubleshooting procedures for hybrid devices" in
1 Defective motor-generator
"Troubleshooting by failure code [GA****].
Perform step 7 of "Common troubleshooting procedures for hybrid devices" in
2 Defective generator power cable
"Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-407

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA25NS] Gen. Motor Driver IGBT0 overheat

Failure code [GA25NS] Gen. Motor Driver IGBT0 overheat 40-407

User code Failure code Motor-generator driver IGBT 0 overheat

Failure
(Hybrid controller system)
GA25NS
Detail of failure q Motor-generator driver IGBT temperature exceeds 80 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Excessive charging or discharging
1 Check for excessive swinging or swing stop.
of capacitor
Malfunction of hybrid system cool-
2 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-407-1 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality

Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality 40-408

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Motor-generator driver IGBT1 abnormality

Failure
(Hybrid controller system)
E09 GA26MA
Detail of failure q Motor-generator driver IGBT1 is abnormal.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform step 3 of "Common troubleshooting procedures for hybrid devices" in
1 Defective motor-generator
"Troubleshooting by failure code [GA****].
Perform step 7 of "Common troubleshooting procedures for hybrid devices" in
2 Defective generator power cable
"Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal failure, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-407-2

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA26NS] Gen. Motor Driver IGBT1 overheat

Failure code [GA26NS] Gen. Motor Driver IGBT1 overheat 40-408

User code Failure code Motor-generator driver IGBT 1 overheat

Failure
(Hybrid controller system)
GA26NS
Detail of failure q Motor-generator driver IGBT temperature exceeds 80 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Excessive charging or discharging
1 Check for excessive swinging or swing stop.
of capacitor
Malfunction of hybrid system cool-
2 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-408 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA27KZ] DC before boosting sensor open or short circuit

Failure code [GA27KZ] DC before boosting sensor open or short circuit40-409

User code Failure code Open or short circuit in DC current sensor before booster
Failure
(Hybrid controller system)
E09 GA27KZ
Detail of failure q Open or short circuit is detected in DC current sensor before booster.
Action of con-
q Limits swing speed, etc.
troller
Problem on
q Swing speed, etc. are limited.
machine
q Capacitor current can be checked with monitoring function.
Related infor-
(Code: 09307 Capacitor current)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA28KZ] DC after boosting sensor open or short circuit 40-409

User code Failure code Open or short circuit in DC current sensor after booster
Failure
(Hybrid controller system)
E09 GA28KZ
Detail of failure q Open or short circuit is detected in DC current sensor after booster.
Action of con-
q Limits swing speed, etc.
troller
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor DC can be checked with monitoring function.
Related infor-
(Code: 09100 Swing motor DC)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-409

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA60MC] Generator Motor Failure

Failure code [GA60MC] Generator Motor Failure 40-410

User code Failure code Malfunction of motor-generator

Failure
(Hybrid controller system)
E09 GA60MC
Detail of failure q Difference between motor-generator speed and engine speed exceeds 200 rpm.
Action of con-
q If cause of failure disappears, machine becomes normal by itself.
troller
Problem on
q None in particular.
machine
q Motor-generator speed and engine speed can be checked with monitoring function.
Related infor- (Code: 09602 Motor-generator speed, 01002 Engine speed)
mation q For motor-generator speed sensor, see failure code [GA60N1].
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defective motor-generator Since this is an internal defect, troubleshooting cannot be performed.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and GM01, and connect T-adapters to each
female side.
Open circuit in wiring harness
2 (wire breakage or defective con- Between HC02 (female) (4) and GM01 (female) (2) Resistance Max. 1 z
tact of connector) Between HC02 (female) (7) and GM01 (female) (1) Resistance Max. 1 z
Between HC02 (female) (33) and GM01 (female)
Resistance Max. 1 z
(3)
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and GM01, and connect T-adapters to each
Ground fault in wiring harness
3 female side.
(contact with ground circuit)
Between HC02 (female) (4) or GM01 (female) (2)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector GM01, and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between GM01 (female) (2) and ground Voltage Max. 1 V
Defective inverter (hybrid control-
5 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Circuit diagram related to motor-generator speed sensor 40-410

40-410 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA60MD] Gen. Mot. Defective Movement

Failure code [GA60MD] Gen. Mot. Defective Movement 40-41

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of motor-generator

Failure
(Hybrid controller system)
E09 GA60MD
Detail of failure q Motor-generator speed measured at inverter is abnormal.
Action of con-
q If cause of failure disappears, machine becomes normal by itself.
troller
Problem on
q None in particular.
machine
Related infor- q For motor-generator speed sensor, see failure code [GA60N1].
mation q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defective motor-generator Since this is an internal defect, troubleshooting cannot be performed.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and GM01, and connect T-adapters to each
female side.
Open circuit in wiring harness
2 (wire breakage or defective con- Between HC02 (female) (4) and GM01 (female) (2) Resistance Max. 1 z
tact of connector) Between HC02 (female) (7) and GM01 (female) (1) Resistance Max. 1 z
Between HC02 (female) (33) and GM01 (female)
Resistance Max. 1 z
(3)
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and GM01, and connect T-adapters to either
Ground fault in wiring harness
3 female side.
(contact with ground circuit)
Between HC02 (female) (4) or GM01 (female) (2)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector GM01 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between GM01 (female) (2) and ground Voltage Max. 1 V
Defective inverter (hybrid control-
5 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Circuit diagram related to motor-generator speed sensor 40-41

HB205-1, HB215LC-1 40-411

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA60N1] Generator Motor Overrun

Failure code [GA60N1] Generator Motor Overrun 40-412

k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Overrun of motor-generator

Failure
(Hybrid controller system)
E09 GA60N1
Detail of failure q Overrun of motor-generator is detected.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [GA60MD]

q Reference
1. Speed sensor (2) is installed on rotor (1) of
motor-generator. Speed sensor (2) can be
replaced individually by removing plate (3).
2. Wiring harness (4) is connected to connector
GM01.
a Pump assembly is removed in the drawing.
3. Tools [1] and [2] are needed to replace rotor (1)
of motor-generator (see "Disassembly and
assembly").
a Tool [1] is needed when replacing mo-
tor-generator rotor (1) together with housing
assembly (2) (see "Disassembly and assem-
bly").

a (2): Motor-generator housing

40-412 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA60N1] Generator Motor Overrun

HB205-1, HB215LC-1 40-413

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir.

Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir. 40-414

User code Failure code Open or short circuit in motor-generator temperature sensor
Failure
(Hybrid controller system)
E09 GA61KZ
Detail of failure q Open or short circuit is detected in motor-generator temperature sensor.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q For replacement procedure of motor-generator temperature sensor, see failure code [GA61NS].
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q Generator motor temperature can be checked with monitoring function.
(Code: 09600 Generator Motor Temperature)
Related informa- q If any of the failure code [GA00NS] or [GA1YNS] or [GA1NNS] or [GA1ZNS] or [GA22NS] or
tion [GA25NS] or [GA26NS] which indicates the overheat in the inverter is displayed at the same time,
hybrid system cooling circuit may be defective.
q If generator motor temperature which can be checked with monitoring function is at normal level
(the temperature is equal to ambient temperature or higher, the temperature range is 16 C to
190 C), hybrid system cooling circuit may be defective.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector GM01 and connect T-adapters to male side.
Defective motor-generator tempera-
1
ture sensor Between GM01 (male) (4) and (5) Resistance 0.1 500 kz
Between GM01 (male) (4) and ground Resistance Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and GM01, and connect T-adapters to each
Open circuit in wiring harness
female side.
2 (wire breakage or defective contact
Between HC02 (female) (28) and GM01
of connector) Resistance Max. 1 z
(female) (4)
Between HC02 (female) (17) and GM01
Resistance Max. 1 z
(female) (5)
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and GM01, and connect T-adapters to either
Ground fault in wiring harness
3 female side.
(contact with ground circuit)
Between HC02 (female) (28) or GM01
Resistance Min. 1 Mz
(female) (4) and ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector GM01 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between GM01 (female) (4) and ground Voltage Max. 5.5 V
Malfunction of hybrid system cooling
5 Perform the troubleshooting for [GA1NNS], Cause 2.
circuit
6 Defective motor-generator
Since this is an internal defect, troubleshooting cannot be performed.
7 Defective inverter (hybrid controller)

40-414 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir.

Circuit diagram related to motor-generator temperature sensor 40-415

HB205-1, HB215LC-1 40-415

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat

Failure code [GA61NS] Generator Motor Temp. Sensor Overheat 40-416

User code Failure code Motor-generator temperature sensor overheat

Failure
(Hybrid controller system)
GA61NS
Detail of failure q Motor-generator temperature exceeds 180 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation q See "Y-9" of Troubleshooting hybrid system (Y-mode).

Cause Procedure, measuring location, criteria and remarks

Excessive charging or discharging
1 Check for excessive swinging or swing stop.
of capacitor
Malfunction of hybrid system cool-
2 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and GM01, and connect T-adapters to either
Ground fault in wiring harness
3 female side.
(contact with ground circuit)
Between HC02 (female) (28) or GM01 (female) (4)
Resistance Min. 1 Mz
and ground
4 Defective motor-generator
Defective inverter (hybrid control- Since this is an internal defect, troubleshooting cannot be performed.
5
ler)

q Reference
a To replace the motor-generator temperature
sensor, motor-generator (1) housing must be re-
placed (see Disassembly and assembly).
1. Install tool [1] to remove motor-generator
housing (1) and rotor (2) assembly.
2. Remove plate (3) and disconnect the connector
for wiring harness (4) at the inside.
3. With tool [1] still installed, remove rotor (2).

a Pump assembly is removed and connector for

wiring harness (4) is disconnected in the draw-
ing.

40-416 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir

Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir 40-417
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Short circuit in A-phase current sensor power line of motor-gen-
Failure erator
E09 GA62KY (Hybrid controller system)

Detail of failure q Overcurrent is detected in A-phase wire of motor-generator .

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform step 3 of "Common troubleshooting procedures for hybrid devices" in
1 Defective motor-generator
"Troubleshooting by failure code [GA****].
Defective power cable connecting Perform step 7 of "Common troubleshooting procedures for hybrid devices" in
2
motor-generator and inverter "Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-417

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir

Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir 40-418
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Open or short circuit in A-phase current sensor of motor-genera-
Failure tor
E09 GA62KZ (Hybrid controller system)

Detail of failure q Open or short circuit is detected in A-phase wire of motor-generator.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective power cable connecting Perform step 7 of "Common troubleshooting procedures for hybrid devices" in
1
motor-generator and inverter "Troubleshooting by failure code [GA****].
Perform step 3 of "Common troubleshooting procedures for hybrid devices" in
2 Defective motor-generator
"Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-418 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction

Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction 40-419
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of motor-generator A-phase current sensor

Failure
(Hybrid controller system)
E09 GA62MA
Detail of failure q Malfunction of motor-generator A-phase current sensor is detected.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir. 40-419
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Short circuit in B-phase current sensor power line of motor-gen-
Failure erator
E09 GA63KY (Hybrid controller system)

Detail of failure q Overcurrent is detected in B-phase wire of motor-generator.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform step 3 of "Common troubleshooting procedures for hybrid devices" in
1 Defective motor-generator
"Troubleshooting by failure code [GA****].
Defective power cable connecting Perform step 7 of "Common troubleshooting procedures for hybrid devices" in
2
motor-generator and inverter "Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-419

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir

Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir 40-420
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Open or short circuit in B-phase current sensor of motor-genera-
Failure tor
E09 GA63KZ (Hybrid controller system)

Detail of failure q Open or short circuit is detected in B-phase wire of motor-generator.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective power cable connecting Perform step 7 of "Common troubleshooting procedures for hybrid devices" in
1
motor-generator and inverter "Troubleshooting by failure code [GA****].
Perform step 3 of "Common troubleshooting procedures for hybrid devices" in
2 Defective motor-generator
"Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction 40-420
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of motor-generator B-phase current sensor

Failure
(Hybrid controller system)
E09 GA63MA
Detail of failure q Malfunction of motor-generator B-phase current sensor is detected.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-420 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir.

Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir. 40-421
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Short circuit in C-phase current sensor power line of motor-gen-
Failure erator
E09 GA64KY (Hybrid controller system)

Detail of failure q Overcurren is detected in C-phase wire of motor-generator.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform step 3 of "Common troubleshooting procedures for hybrid devices" in
1 Defective motor-generator
"Troubleshooting by failure code [GA****].
Defective power cable connecting Perform step 7 of "Common troubleshooting procedures for hybrid devices" in
2
motor-generator and inverter "Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-421

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir.

Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir. 40-42
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Open or short circuit in C-phase current sensor of motor-genera-
Failure tor
E09 GA64KZ (Hybrid controller system)

Detail of failure q Open or short circuit is detected in C-phase wire of motor-generator.

q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective power cable connecting Perform step 7 of "Common troubleshooting procedures for hybrid devices" in
1
motor-generator and inverter "Troubleshooting by failure code [GA****].
Perform step 3 of "Common troubleshooting procedures for hybrid devices" in
2 Defective motor-generator
"Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction 40-42
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of motor-generator C-phase current sensor

Failure
(Hybrid controller system)
E09 GA64MA
Detail of failure q Malfunction of motor-generator C-phase current sensor is detected.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-422 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA70KB] HYB Swing Motor Short Circuit

Failure code [GA70KB] HYB Swing Motor Short Circuit 40-423

User code Failure code Short circuit in HYB swing motor

Failure
(Hybrid controller system)
E09 GA70KB
Detail of failure q Short circuit is detected in swing motor.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform step 2 of "Common troubleshooting procedures for hybrid devices" in
1 Defective swing motor
"Troubleshooting by failure code [GA****].
Defective power cable connecting Perform step 6 of "Common troubleshooting procedures for hybrid devices" in
2
motor-generator and inverter "Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion 40-423
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.

User code Failure code Malfunction of HYB swing motor

Failure
(Hybrid controller system)
E09 GA70MD
Detail of failure q Swing motor speed measured by inverter is abnormal.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid control-
1 Since this is an internal defect, troubleshooting cannot be performed.
ler)

HB205-1, HB215LC-1 40-423

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA70NS] HYB Swing Motor Overheat

Failure code [GA70NS] HYB Swing Motor Overheat 40-424

User code Failure code HYB swing motor overheat

Failure
(Hybrid controller system)
GA70NS
Detail of failure q Swing motor temperature exceeds 140 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor coil temperature can be checked with monitoring function.
Related infor- (Code: 09101 Swing motor coil temperature)
mation q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q See "Y-8" of Troubleshooting hybrid system (Y-mode).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and PM01, and connect T-adapters to either
Ground fault in wiring harness
1 female side.
(contact with ground circuit)
Between HC02 (female) (18) or PM01 (female) (7)
Resistance Min. 1 Mz
and ground
Excessive charging or discharging
2 Check for excessive swinging or swing stop.
of capacitor
Malfunction of hybrid system cool-
3 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
4 Defective swing motor
Defective inverter (hybrid control- Since this is an internal defect, troubleshooting cannot be performed.
5
ler)

40-424 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA70NS] HYB Swing Motor Overheat

Circuit diagram related to hybrid system swing motor temperature sensor 40-424

HB205-1, HB215LC-1 40-425

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir.

Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. 40-426

User code Failure code Open or short circuit in hybrid swing motor temperature sensor
Failure
(Hybrid controller system)
E09 GA71KZ
Detail of failure q Abnormality of swing motor temperature sensor is detected.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor coil temperature can be checked with monitoring function.
(Code: 09101 Swing motor coil temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q If any of the failure code [GA00NS] or [GA1YNS] or [GA1NNS] or [GA1ZNS] or [GA22NS] or
Related infor-
[GA25NS] or [GA26NS] which indicates the overheat in the inverter is displayed at the same time,
mation
hybrid system cooling circuit may be defective.
q If swing motor coil temperature which can be checked with monitoring function is at normal level
(the temperature is equal to ambient temperature or higher. The temperature range is 16 C to
190 C), hybrid system cooling circuit may be defective.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector PM01 and connect T-adapters to male side.
Defective swing motor temperature
1
sensor Between PM01 (male) (7) and (8) Resistance 0.1 500 kz
Between PM01 (male) (7) and ground Resistance Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and PM01, and connect T-adapters to each
Open circuit in wiring harness female side.
2
(open circuit or defective contact) Between HC02 (female) (18) and PM01
Resistance Max. 1 z
(female) (7)
Between HC02 (female) (17) and PM01
Resistance Max. 1 z
(female) (8)
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and PM01, and connect T-adapters to either
Ground fault in wiring harness
3 female side.
(contact with ground circuit)
Between HC02 (female) (18) or PM01
Resistance Min. 1 Mz
(female) (7) and ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector PM01 and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between PM01 (female) (7) and ground Voltage Max. 5.5 V
Malfunction of hybrid system cool-
5 Perform the troubleshooting for [GA1NNS], Cause 2.
ing circuit
6 Defective swing motor
Since this is an internal defect, troubleshooting cannot be performed.
7 Defective inverter (hybrid controller)

40-426 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir.

Circuit diagram related to swing motor temperature sensor 40-427

HB205-1, HB215LC-1 40-427

(03)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction

Failure code [GA72MA] HYB Swing Motor Resolver Malfunction 40-428

User code Failure code Malfunction of HYB swing motor resolver

Failure
(Hybrid controller system)
E09 GA72MA
Detail of failure q Malfunction of swing motor resolver is detected.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring harness
1 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
2 Between HC02 (female) (15) or PM01 (female) (2)
(contact with ground circuit)
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and PM01, and connect T-adapters to each
female side.
Between HC02 (female) (5) and PM01 (female) (1) Resistance Max. 1 z
Between HC02 (female) (6) and PM01 (female) (3) Resistance Max. 1 z
Between HC02 (female) (15) and PM01 (female) (2) Resistance Max. 1 z
Between HC02 (female) (16) and PM01 (female) (5) Resistance Max. 1 z
Between HC02 (female) (26) and PM01 (female) (4) Resistance Max. 1 z
Between HC02 (female) (36) and PM01 (female) (6) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and PM01, and connect T-adapters to either
female side.
Between HC02 (female) (5) or PM01 (female) (1)
Resistance Min. 1 Mz
and ground
Between HC02 (female) (6) or PM01 (female) (3)
Resistance Min. 1 Mz
and ground
Resistance Min. 1 Mz
and ground
Between HC02 (female) (16) or PM01 (female) (5)
Resistance Min. 1 Mz
and ground
Between HC02 (female) (26) or PM01 (female) (4)
Resistance Min. 1 Mz
and ground
Between HC02 (female) (36) or PM01 (female) (6)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector HC02 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Between HC02 (female) (5) and ground Voltage Max. 1 V

Hot short circuit in wiring harness Between HC02 (female) (6) and ground Voltage Max. 1 V
3
(contact with 24 V circuit) Between HC02 (female) (15) and ground Voltage Max. 1 V
Between HC02 (female) (16) and ground Voltage Max. 1 V
Between HC02 (female) (26) and ground Voltage Max. 1 V
Between HC02 (female) (36) and ground Voltage Max. 1 V

40-428 HB205-1, HB215LC-1

(03)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction

Cause Procedure, measuring location, criteria and remarks

4 Defective swing motor
Defective inverter (hybrid control- Since this is an internal defect, troubleshooting cannot be performed.
5
ler)

Circuit diagram related to hybrid system swing motor resolver 40-429

HB205-1, HB215LC-1 40-429

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.

Failure code [GA72MC] HYB Swing Motor Resolver Defect Op. 40-430

User code Failure code Malfunction of HYB swing motor resolver

Failure
(Hybrid controller system)
E09 GA72MC
Detail of failure q Malfunction of swing motor resolver is detected.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [GA72MA].

Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. 40-430

User code Failure code Open or short circuit in swing motor power cable
Failure
(Hybrid controller system)
E09 GA81KZ
Detail of failure q Open or short circuit is detected in swing motor power cable.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform step 2 of "Common troubleshooting procedures for hybrid devices" in
1 Defective swing motor
"Troubleshooting by failure code [GA****].
Defective power cable connecting Perform step 6 of "Common troubleshooting procedures for hybrid devices" in
2
swing motor and inverter "Troubleshooting by failure code [GA****].
Defective inverter (hybrid control-
3 Since this is an internal defect, troubleshooting cannot be performed.
ler)

40-430 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GAA100] Swing emergency stop switch operated

Failure code [GAA100] Swing emergency stop switch operated 40-431

User code Failure code Swing emergency stop switch operated

Failure
(Hybrid controller system)
GAA100
Detail of failure q Swing emergency stop switch operated
Action of con- q Stops swing motor and motor-generator control, and applies swing holding brake.
troller q Disables hoist matching function.
Problem on
q Upper structure does not swing.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation

Cause Procedure, measuring location, criteria and remarks

q Check if swing emergency stop switch was operated when no problems were present.
Swing emergency stop
q If switch was operated, turn swing emergency stop switch to OFF position and then turn
switch operated
1 starting switch to ON position.
(when system works
q If no failure codes are displayed and no other problems are found, machine can be re-
properly)
turned to service.

HB205-1, HB215LC-1 40-431

(01)
Troubleshooting by failure code [GA****] (code display)
Failure code [GAA2KB] Swing Brake sol. Supply Line short cir.

Failure code [GAA2KB] Swing Brake sol. Supply Line short cir. 40-432

User code Failure code Swing holding brake solenoid power line short circuit
Failure
(Pump controller system)
E03 GAA2KB
Detail of failure q When command to drive swing holding brake solenoid is ON, short circuit is detected.
q Shuts off power supply to swing holding brake solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Upper structure does not swing (swing holding brake is not released).
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing holding
brake cancel switch to RELEASE position. (However, swing holding brake is not released when
starting switch is in OFF position.
q Be sure to set swing lock switch and emergency stop switch to OFF position during troubleshoot-
ing.
q Brake is released when current flows through swing holding brake solenoid.
Related infor-
q Controller's command (ON/OFF) to swing holding brake solenoid can be checked with monitoring
mation
function. (If controller sends solenoid ON command, monitoring screen displays ON even if sole-
noid is not switched to ON due to short circuit.)
(Code: 09700 Hybrid controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position.
q Swing holding brake solenoid is powered from pin (8) of inverter (hybrid controller) connector HC01
or F01 of fuse box F01.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and HC01, and connect T-adapters to female
Ground fault in wiring harness side of HC01.
1
(contact with ground circuit) 3. Turn starting switch to ON position.
Between HC01 (female) (21) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Defective inverter (hybrid control- 2. Disconnect connector HC01 and connect T-adapters to male side.
2
ler)
Between HC01 (male) (21) and HC01 (male) (13) Resistance Min. 1 kz
If no failure to is found by above checks, pump controller is defective. (Since
3 Defective pump controller
this is an internal defect, troubleshooting cannot be performed.)

40-432 HB205-1, HB215LC-1

(01)
 Troubleshooting by failure code [GA****] (code display)
Failure code [GAA2KB] Swing Brake sol. Supply Line short cir.

Circuit diagram related to swing holding brake solenoid 40-43

HB205-1, HB215LC-1 40-433

(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)

Troubleshooting of electrical system (E-mode) 40-434

E-1 Engine does not start (Engine does not crank) 40-434
Failure q Engine does not start (Engine does not crank).
q Engine starting circuit has following two start lock mechanisms.
1) Start lock by password protection of machine monitor
2) Start lock by lock lever position
Related infor- q For failure symptom "Battery relay operation sound is not heard" when starting switch is turned to
mation ON position, perform troubleshooting for E-1 also.
q If failure symptom is "Machine monitor displays nothing" when starting switch is turned to ON po-
sition, main electric power supply system may be defective. So, perform troubleshooting for E-3
(lines connecting to fusible link F05 and fuse No 17).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Loose terminal connection or open
1 Check terminals of starting motor, alternator, battery relay, grounds T04 and
circuit at terminal
T08, etc.
1. Turn starting switch to OFF position.
Between battery relay terminal R01 and ground
Defective contact (grounding) a Use machine frame as ground.
2
between battery relay and frame a Loosened or rusted terminal T08 Resistance Max. 1 z
a Rusted contact faces of battery bracket and
frame
a Be ready with starting switch at OFF position, then perform troubleshooting
without turning starting switch to ON position.
3 Insufficient battery capacity Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (one piece) Min. 1.26

If failure codes [DA2RMC] and/or [DAFRMC] for failure in engine controller

4 Defective engine controller system
power and ACC signal are displayed, perform troubleshooting for them first.

Defective fuse No. 3 in fuse box If fuse is blown, circuit probably has ground fault. (See troubleshooting on
5
F01 cause 22).
1. Turn starting switch to ON position (to connect ACC).
6 Defective battery relay system a If battery relay operation sound is not heard, go to troubleshooting on cause
19.

1. Turn starting switch to OFF position. Remove fuse No. 3 in fuse box F01.
2. Turn starting switch to ON position (to connect ACC).
Defective fusible link F04, defec-
7 Between input terminal (1A) of fuse box F01-3 and
tive wiring harness Voltage 20 30 V
ground
a If voltage is abnormal, go to troubleshooting on cause 10.
1. Turn starting switch to OFF position.
2. Remove fuse No. 19 in fuse box F01. (To prevent engine start during trou-
Defective starting switch, lock bleshooting)
lever switch, starting motor cut-off 3. Insert T-adapters into connector R17.
8 relay R06, personal code relay 4. Turn starting switch to START position and hold (two persons required for
R07, battery relay, or wiring har- this check).
ness Between R17 (1) and ground Voltage 20 30 V
a If voltage is abnormal, go to cause 13.

40-434 HB205-1, HB215LC-1

(01)

Cause
Defective starting motor safety
9 4. Turn starting switch to START position and hold (two persons required for
relay, battery relay, wiring harness
10 Defective fusible link F04
Open circuit in wiring harness 1
11 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness 1
12
(contact with ground circuit)
Defective starting switch
13
(internal open circuit)
Defective lock lever switch
14
(internal open circuit)
HB205-1, HB215LC-1
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Remove fuse No. 19 in fuse box F01. (To prevent engine start during trou-
bleshooting)
3. Insert T-adapters into connector E10.
this check).
Between E10 (1) and ground Voltage 20 30 V
a If voltage is abnormal, go to troubleshooting on causes 16 and 20.
a If no failure is found by check on cause 7, this check is not required.
If fusible link has blown out, circuit probably has ground fault. In this case,
perform troubleshooting for causes 6 and 9 first.
q Fuse Nos. 1, 3, and 11 to 15 are connected to fusible link F04.
a Many circuits are protected by this fusible link. If no failure is found by
checks on causes 6 and 9, it is necessary to simulate ground fault and locate
failed point by sound or smell.
a If no failure is found by check on cause 7, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
(To prevent short circuit during troubleshooting)
2. Disconnect fusible link F04 and No. 6 of fuse box F01.
3. Connect T-adapters to male side of connector F04.
Between battery relay (R03) and F04 (male) (1) Resistance Max. 1 z
Between F04 (male) (2) and F01-1A Resistance Max. 1 z
a If no failure is found by check on cause 7, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect fusible link F04, No. 6 of fuse box F01, and battery relay (M)
terminal.
3. Connect T-adapters to male side of connector F04.
Between battery relay (R03) or F04 (male) (1) and
Resistance Min. 1 Mz
ground
Between F04 (male) (2) or F01-1A and ground Resistance Min. 1 Mz
a If no failure is found by check on cause 8, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector H15A and connect T-adapters to male side.
3. After troubleshooting, perform troubleshooting again with starting switch at
ON and START positions.
Between H15A (male) (1) Starting switch: OFF Resistance Min. 1 Mz
and (2) Starting switch: ON Resistance Max. 1 z
Between H15A (male) (1) Starting switch: OFF Resistance Min. 1 Mz
and (5) Starting switch: ON Resistance Max. 1 z
Between H15A (male) (1) Starting switch: OFF Resistance Min. 1 Mz
and (4) Starting switch: START Resistance Max. 1 z
a If no failure is found by check on cause 8, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector S14 and connect T-adapters to female side.
Lock lever: FREE Resistance Min. 1 Mz
Between S14 (female)
(1) and (3) Lock lever: LOCK Resistance Max. 1 z
40-435
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)

Cause Procedure, measuring location, criteria and remarks

a If no failure is found by check on cause 8, this check is not required.
1. Turn starting switch to OFF position.
2. Remove starting motor cut-off relay R06 and personal code relay R07.
Between R06 (male) (1) and (2) Resistance 200 - 600 z
Defective starting motor cut-off Between R06 (male) (3) and (4) Resistance Max. 1 z
15 relay R06 or personal code relay
R07(internal open or short circuit) Between R06 (male) (3) and (5) Resistance Min. 1 Mz
Between R07 (male) (1) and (2) Resistance 200 - 600 z
Between R07 (male) (3) and (4) Resistance Max. 1 z
Between R07 (male) (3) and (5) Resistance Min. 1 Mz
a If no failure is found by check on cause 9, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect cable only from C terminal on starting motor safety relay.
3. Insert T-adapters into connector R17.
4. Turn starting switch to START position and perform troubleshooting.
Power sup-
Between safety relay terminal B and E Voltage 20 30 V
ply
Input from
Between safety relay terminal R
alternator Voltage Max. 1 V
Defective starting motor safety (R17-2) and safety relay terminal E
16 generation
relay (internal defect) Starting
Between safety relay terminal S input to
Voltage 20 30 V
(R17-1) and safety relay terminal E starting
motor
Between safety relay terminal C (R28) Starting out-
and put to start- Voltage 20 30 V
safety relay terminal E ing motor
If power supply, input from alternator generation, and starting input to starting
motor normal but starting output to starting motor is abnormal, starting motor
safety relay is defective.
1. Turn starting switch to OFF position.
2. Turn starting switch to START position and perform troubleshooting.
Between starting motor terminal B Power sup-
Voltage 20 30 V
(SB) and ground ply
Defective starting motor Starting
17
(internal defect) Between starting motor terminal C input to
Voltage 20 30 V
(SC) and ground starting
motor
If power supply and starting input to starting motor are normal but starting
motor does not rotate, starting motor is defective.
a Be ready with starting switch at OFF, then turn starting switch to ON position
and perform troubleshooting.
Defective alternator
18 Input from
(internal short circuit) Between alternator terminal L and
alternator Voltage Max. 1 V
ground
generation
1. Turn starting switch to OFF position.
2. Disconnect connector D01 and connect T-adapters to diode.
a Measure by using multimeter in diode range.
Defective diode D01 Between D01 (male) (1) (+) and (5) (-) No continuity
19
(internal open or short circuit) Between D01 (male) (5) (+) and (1) (-) Continuity
Between D01 (male) (2) (+) and (6) (-) No continuity
Between D01 (male) (6) (+) and (2) (-) Continuity

40-436 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)

Cause Procedure, measuring location, criteria and remarks

q Battery relay
1. Turn starting switch to OFF position.
Between terminal B02 and H15 (female) (2) Resistance Max. 1 z
q Battery relay
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
a To check to where 24 V is supplied to isolate open section
Between terminals R04 and R01 Voltage 20 30 V
Between terminals R02 and R01 Voltage 20 30 V
Between terminals R03 and R01 Voltage 20 30 V
Between terminal R01 and ground Voltage Max. 1 V
q Alternator and starting motor
1. Turn starting switch to OFF position.
2. Disconnect battery ground cable.
3. Insert T-adapters into connectors H15A, S14, R07, R17, E10, and E12.
4. Connect battery ground cable.
5. Turn starting switch to START position and perform troubleshooting.
a To check to where 24 V is supplied to isolate open section
Between H15A (4) and ground Voltage 20 30 V
Between S14 (1) and ground Voltage 20 30 V
Open circuit in wiring harness
20 (wire breakage or defective con- Between S14 (3) and ground Voltage 20 30 V
tact of connector) Between R07 (4) and ground Voltage 20 30 V
Between R17 (1) and ground Voltage 20 30 V
Between R17 (2) and ground Voltage 20 30 V
Between E10 (1) and ground Voltage 20 30 V
Between E12 (1) and ground Voltage 20 30 V
Between alternator B terminal and ground Voltage 20 30 V
Between starting motor terminal B and ground Voltage 20 30 V
q If fuse or fusible link is blown, replace it with new one.
1. Turn starting switch to OFF position.
2. Disconnect connectors H15A, S14, R06, and R07.
3. Connect T-adapters to female side of H15A, R06, R07, and to male side of
S14.
4. Remove fuse F01-3.
Between H15A (female) (4) and R06 (female) (5) Resistance Max. 1 z
Between R06 (female) (3) and R07 (female) (4) Resistance Max. 1 z
Between R07 (female) (1) and S14 (male) (1) Resistance Max. 1 z
Between R07 (female) (2) and CM01 (female) (6) Resistance Max. 1 z
Between R07 (female) (3) and starting motor termi-
Resistance Max. 1 z
nal S
Between alternator B and starting motor B Resistance Max. 1 z
Between starting motor B and battery relay R03 Resistance Max. 1 z
Between alternator R and starting motor L Resistance Max. 1 z
Open circuit in wiring harness
20 (wire breakage or defective con- Between alternator R and D01 (female) (6) Resistance Max. 1 z
tact of connector)
Between F01-3 and S14 (male) (1) Resistance Max. 1 z
Between S14 (male) (3) and R06 (male) (1) Resistance Max. 1 z
Between R06 (female) (2) and ground (T07) Resistance Max. 1 z

HB205-1, HB215LC-1 40-437

(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)

Cause Procedure, measuring location, criteria and remarks

Defective battery relay
21
(Does not work)
Ground fault in wiring harness
22
(contact with ground circuit)
Hot short circuit in wiring harness 2. Insert T-adapters into connector R17 or E08.
23
(contact with 24 V circuit)
If only terminal R03 voltage is abnormal in battery relay check of troubleshoot-
ing for cause 20, battery relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors H15A, S14, R06, and R07.
3. Connect T-adapters to female side of H15A, R06, R07, and to male side of
S14.
4. Remove fuse F01-3.
Between H15A (female) (4) or R06 (female) (5) and
Resistance Min. 1 Mz
ground
Between R06 (female) (3) or R07 (female) (4) and
Resistance Min. 1 Mz
ground
Between R07 (female) (3), or R17 (female) (1) and
Resistance Min. 1 Mz
ground
Between starting motor safety relay B or battery
Resistance Min. 1 Mz
relay R02 and ground
Between starting motor safety relay C or starting
Resistance Min. 1 Mz
motor C (SC) and ground
Between F01-3 or S14 (male) (1) and ground Resistance Min. 1 Mz
Between S14 (male) (3), or R06 (female) (1) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
3. Turn starting switch to ON position.
Between R17 (female) (2) or E08 (1) and ground Voltage Max. 1 V

40-438 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)

Circuit diagram related to engine starting circuit 40-439

HB205-1, HB215LC-1 40-439

(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

E-2 Preheater does not operate 40-4 0

Failure 1) Manual preheating does not function.
a This troubleshooting describes procedures to be followed when manual preheating does not
function to heat electrical intake air heater (ribbon heater) mounting section.
q Automatic preheating and Manual preheating functions are available. When either function
is operated, preheating monitor lights up. (When only preheating monitor does not light up,
perform troubleshooting "3) While preheater is operating, preheating monitor does not light
up")
Related information
q If "Machine monitor displays nothing" or "Battery relay operation sound is not heard" when
turning starting switch to ON position, main electric power supply system may be defective.
So, perform troubleshooting for E-3 and E-1.
q If fuse No. 17 in fuse box F01 is blown, perform troubleshooting for "Machine monitor displays
nothing".
q Before performing troubleshooting, check that no related failure code is displayed.

Cause Procedure, measuring location, criteria and remarks

Loose terminal or open circuit at
1 Check terminals of heater relay, battery relay, electrical intake air heater (rib-
terminal
Open circuit or short circuit in wir-
2 Between input terminal on contact side of heater
ing harness
Defective diode D02
3
(internal open or short circuit)
4 Defective starting switch
1. Turn starting switch to OFF position.
bon heater), etc.
1. Turn starting switch to OFF position.
2. Disconnect connectors CM01 and H15A, and connect T-adapters to female
side of H15A.
Between H15A (female) (3) and ground (heater Approx.
Resistance
relay coil resistance) 20 z
q Secondary side
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
Voltage 20 30 V
relay and ground
q Primary side
1. Turn starting switch to OFF position.
2. Disconnect heater relay terminal R16.
a To prevent current from flowing through heater when starting switch is
turned to HEAT position
3. Turn starting switch to HEAT position (Connect R1).
Between heater relay terminal R15 and ground Voltage 20 30 V
a If no failure is found by check on cause 2 at primary side is normal, this
check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector D02 and connect T-adapters to diode.
a Measure by using multimeter in diode range.
Between D02 (male) (1) (+) and (5) (-) No continuity
Between D02 (male) (5) (+) and (1) (-) Continuity
a If no failure is found by check on cause 2 at primary side is normal, this
check is not required.
1. Turn starting switch to OFF position.
2. Disconnect battery ground cable.
3. Disconnect connector H15A and connect T-adapters to male side.
4. Turn starting switch to OFF/HEAT position and perform troubleshooting .
OFF Resistance Min. 1 Mz
Between H15A (male) (1) and (3)
HEAT Resistance Max. 1 z

Defective electrical intake air 1. Turn starting switch to OFF position.

5 heater (ribbon heater)
(internal open circuit)
Defective heater relay
6
(Does not work) (Terminal R16)
2. Disconnect terminal E01.
Between E01 terminal and ground Continuity
If no failure is found by check on cause 2 and heater relay operation sound is
not heard, heater relay is defective.

40-440 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

Cause Procedure, measuring location, criteria and remarks

Ground fault in wiring harness
7 Resistance Min. 1 Mz
(contact with ground circuit)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors H15A, CM01 and D02, terminals R15 and E01, and
starting motor B terminal.
Between heater relay terminal R15 (wiring harness
side) and ground
Between input terminal on contact side of heater
Resistance Min. 1 Mz
relay and ground
Between heater relay terminal E01 (wiring harness
Resistance Min. 1 Mz
side) and ground

Failure 2) Automatic preheating does not function.

q Automatic preheating starts when boost temperature is below -4 C.
(Monitoring code Boost temperature: 18500)
q If automatic preheating does not function, check if manual preheating functions.
Related informa-
q Engine controller checks primary (coil) side of preheater relay (connector R18) and generates fail-
tion
ure codes [CA2555] and [CA2556] if it is defective.
q Engine controller checks boost temperature sensor and generates failure codes [CA153] and
[CA154] if it is defective.

Cause Procedure, measuring location, criteria and remarks

Defective fuse No. 6 in fuse If fuse No. 6 in fuse box 01 is broken, circuit probably has ground fault. In this case,
1
box 01 perform troubleshooting forcause 5 first.
1. Turn starting switch to OFF position.
2. Replace preheater relay (connector R18) with horn relay (connector R08), for
Defective preheater relay example.
2 R18 (internal open or short 3. Turn starting switch to ON position.
circuit)
If automatic preheating functions when boost temperature is below -4 C, original
preheater relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors CM01, R18, and D02, and connect T-adapters to female
side of R18.
Open circuit or ground fault in a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is be-
3
wiring harness low 1 z, wiring harness has short circuit.
a Heater relay coil resistance
Between R18 (female) (5) and ground Resistance Approx. 20 z
1. Turn starting switch to OFF position.
2. Disconnect connectors R18 and CM01, and connect T-adapters to female side
Open circuit in wiring har- of R18.
4 ness (open circuit or defec- 3. Remove fuse No. 6 in fuse box F01.
tive contact) Between R18 (female) (3) and F01-6 Resistance Max. 1 z
Between R18 (female) (5) and heater relay terminal
Resistance Max. 1 z
R15
If fuse is not blown, this check is not required.
Ground fault in wiring har- 1. Turn starting switch to OFF position.
5 ness (contact with ground cir- 2. Disconnect connector R18 and connect T-adapters to female side.
cuit) 3. Remove fuse No. 6 in fuse box F01.
Between R18 (female) (3) and ground Resistance Min. 1 Mz

HB205-1, HB215LC-1 40-441

(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

Failure 3) While preheater is operating, preheating monitor does not light up.
q "Automatic preheating" and "Manual preheating" functions are available. When either function is
Related informa-
operated, preheating monitor lights up.
tion
q Check if manual preheating functions first.

Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring har-
1 ness (open circuit or defec-
tive contact)
2 Defective machine monitor
1. Turn starting switch to OFF position.
2. Disconnect connectors H15A, CM01, and R18, and connect T-adapters to each
female side.
Between H15A (female) (3) and CM01 (female) (16) Resistance Max. 1 z
Between R18 (female) (5) and CM01 (female) (16) Resistance Max. 1 z
If no failure is found by above checks, machine monitor is defective.
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector CM01.
3. Disconnect heater relay terminal R16.
a To prevent current from flowing through heater when starting switch is turned to
HEAT position
4. Turn the starting switch to HEAT position.
Between CM01 (16) and (3) Resistance 20 30 V

40-442 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

Circuit diagram related to preheating of engine 40-4 3

HB205-1, HB215LC-1 40-443

(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

40-444 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing

E-3 When starting switch is turned to ON position, machine monitor

displays nothing 40-4 5
Failure q When starting switch is turned to ON position, machine monitor displays nothing
q When starting switch is turned to ON position, machine monitor displays KOMATSU logo screen,
password input screen (if set), breaker mode confirmation screen (if selected), check before start-
Related infor-
ing screen, working mode and travel speed confirmation screen, and standard screen in order.
mation
q When engine is started, battery voltage may lower suddenly, depending on ambient temperature
and condition of battery.

Cause Procedure, measuring location, criteria and remarks

Loose terminal or open circuit at 1. Turn starting switch to OFF position.

1
terminal
Defective fuse No. 17 in fuse box
2
F01
Defective fusible link F05, wiring
3
harness, battery
4 Insufficient battery capacity
5 Defective fusible link F05
Open circuit in wiring harness 1
(wire breakage or defective con-
6
tact of connector)
Ground fault in wiring harness 1
7
(contact with ground circuit)
8 Wrong connection of connector
Defective wiring harness, starting
9
switch, or machine monitor
Check terminals of battery relay, etc.
If fuse is blown,circuit probably has ground fault. (See troubleshooting for
causes 7 and 12).
1. Turn starting switch to OFF position and disconnect ground cable from
battery.
2. Remove fuse No. 17 in fuse box F01.
3. Connect battery ground cable.
Between input terminal (16D) of fuse box F01-17
Voltage 20 30 V
and ground
a If voltage is normal, go to troubleshooting on cause 7.
a Be ready with starting switch at OFF, then perform troubleshooting without
turning starting switch to ON position.
Battery voltage (two in series) Min. 24 V
Electrolyte specific gravity (each) Min. 1.26
If fusible link or fuse is blown, circuit probably has ground fault. (See trouble-
shooting for cause 12.)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position and disconnect ground cable from
battery.
2. Disconnect fusible link F05 and No. 17 of fuse F01.
3. Connect T-adapters to male side of connector F05.
Between battery (-) and ground Resistance Max. 1 z
Between battery (+) and F05 (male) (1) Resistance Max. 1 z
Between F05 (male) (2) and F01-16D Resistance Max. 1 z
If no failure is found by checks on causes 2 and 3, this check is not required.
1. Turn starting switch to OFF position and disconnect ground cable from
battery.
2. Disconnect fusible link F05, No. 17 of fuse F01, and battery (+) terminal.
3. Connect T-adapters to male side of connector F05.
Between battery (+) or F05 (male) (1) and ground Resistance Min. 1 Mz
Between F05 (male) (2), or F01-16D and ground Resistance Min. 1 Mz
a If machine monitor is not replaced, this check is not required.
Machine monitor connector may be connected wrongly. Check it directly.
a Connector CM02 and CM03 can be installed even if they are exchanged.
Since both male and female parts of CM03 are green, check their colors.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Insert T-adapters into connector CM01.
3. Connect battery ground cable, and turn starting switch to ON position (to
connect ACC).
Between CM01 (1) and (3) Voltage 20 30 V
Between CM01 (2) and (4) Voltage 20 30 V
Between CM01 (14) and (4) (ACC line) Voltage 20 30 V

HB205-1, HB215LC-1 40-445

(01)
Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing
Cause
Defective starting switch
10
(open circuit in internal wiring)
Open circuit in wiring harness 2
11 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness 2
12
(contact with ground circuit)
13 Defective machine monitor
40-446
Procedure, measuring location, criteria and remarks
a If measured voltage (ACC line) in check on cause 9 is normal, this check is
not required.
1. Turn starting switch to OFF position.
2. Disconnect connector H15A and connect T-adapters to male side.
3. Turn starting switch to ON position and perform troubleshooting again.
Between H15A (male) (1) Starting switch: OFF Resistance Min. 1 Mz
and (5) Starting switch: ON Resistance Max. 1 z
If no failure is found by check on cause 9, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect No. 17 of fuse F01 and connectors H15A and CM01.
3. Connect T-adapters to each female side of connector H15A and CM01.
Between F01-17 and each of CM01 (female) (1)
Resistance Max. 1 z
and (2)
Between ground (T09) and each of CM01 (female)
Resistance Max. 1 z
(3) and (4)
Between F01-17 and H15 (female) (1) Resistance Max. 1 z
Between H15 (female) (5) and CM01 (female) (14) Resistance Max. 1 z
If no failure is found by check on cause 9, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect No. 17 and 20 of fuse F01 and connectors H15A, CM01, C01,
HC01, HS01, and N08.
3. Connect T-adapters to each female side of connectors H15A and CM01.
Between ground and any of F01-17, CM01 (female)
Resistance Min. 1 Mz
(1), (2) or H15A (female) (1)
Between H15A (female) (5) or CM01 (female) (14)
Resistance Min. 1 Mz
and ground
If no failure is found by above checks, machine monitor is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
HB205-1, HB215LC-1
(01)
 Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing

Circuit diagram related to machine monitor power supply 40-4 7

HB205-1, HB215LC-1 40-447

(01)
Troubleshooting of electrical system (E-mode)
E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up.

E-4 When starting switch is turned to ON position (with engine stopped),

basic check monitor lights up. 40-4 8
1) When starting switch is turned to ON position (with engine stopped), engine oil level monitor
Failure
lights up in red.
Related information

Cause Procedure, measuring location, criteria and remarks

Defective engine oil level switch
1 Perform troubleshooting for failure code [B@BAZK].
system (machine monitor system)
If no failure is detected by check on cause 1, machine monitor is defective.
2 Defective machine monitor
(Since this is an internal defect, troubleshooting cannot be performed.)

Failure 2) Radiator coolant level monitor lights up in red.

Related information

Cause Procedure, measuring location, criteria and remarks

Low radiator coolant level
1 Coolant level may be low. Check coolant level and add coolant if necessary.
(When system works properly)
Radiator sub tank coolant level
2 Perform troubleshooting for failure code [B@BCZK].
switch system

40-448 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-5 Precaution monitor lights up while engine is running

E-5 Precaution monitor lights up while engine is running 40-4 9

Failure 1) Engine coolant temperature monitor lights up in white.
q Signal of engine coolant temperature sensor is input to engine controller and then data is
transmitted to machine monitor through CAN communication system.
Related information
q Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks

Insufficient warm-up of machine
1
(when system works properly)
Defective engine coolant tempera-
2 system may be defective. Perform troubleshooting for "E-8 Engine coolant
ture gauge system
If monitor lights up in white, engine coolant temperature may be low (below
approximately 30 C). Warm up engine.
q Lighting up in white: Engine coolant temperature is low.
q Lighting up in blue: Engine coolant temperature is proper.
If no failure is found by check on cause 1, engine coolant temperature gauge
temperature gauge does not indicate properly".

Failure 2) Hydraulic oil temperature monitor lights up in white.

q Signal of hydraulic oil temperature sensor is input to pump controller and then data is trans-
mitted to machine monitor through CAN communication system.
Related information
q Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hydraulic oil temperature)

Cause Procedure, measuring location, criteria and remarks

Insufficient warm-up of machine
1
(when system works properly)
Defective hydraulic oil temperature
2 tem may be defective. Perform troubleshooting for "E-9 hydraulic oil tempera-
gauge system
If monitor lights up in white, hydraulic oil temperature may be low (below
approximately 20 C). Warm up engine.
q Lighting up in white: Hydraulic oil temperature is low.
q Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by check on cause 1, hydraulic oil temperature gauge sys-
ture gauge does not indicate properly".

Failure 3) Charge level monitor lights up while engine is running.

q Power generation signal of alternator can be checked with monitoring function.
Related information
(Code: 04300 Charge voltage)

Cause Procedure, measuring location, criteria and remarks

1 Defective alternator system Perform troubleshooting for failure code [AB00KE].

Failure 4) Fuel level monitor lights up in red.

q Signal voltage of fuel level sensor can be checked with monitoring function.
Related information
(Code: 04200 Fuel sensor voltage)

Cause Procedure, measuring location, criteria and remarks

Low fuel level (when system works
1 Fuel level may be low. Check it and add fuel if necessary.
properly)
If no failure is found by check on cause 1, fuel level gauge system may be
2 Defective fuel level gauge system defective. Perform troubleshooting for "E-7 Fuel level gauge does not indicate
properly".

HB205-1, HB215LC-1 40-449

(01)
Troubleshooting of electrical system (E-mode)
E-5 Precaution monitor lights up while engine is running

Failure 5) Air cleaner clogging monitor lights up in red.

q Air cleaner clogging switch signal can be checked with monitoring function.
Related information
(Code: 04501 Monitor input 2)

Cause Procedure, measuring location, criteria and remarks

Clogging of air cleaner
1 Air cleaner may be clogged. Check it, then clean or replace if necessary.
(when system works properly)
Defective air cleaner clogging
2 Perform troubleshooting for failure code [AA10NX].
switch system

Failure 6) Water separator monitor (water level in water separator is high)

q Signal of water detection by fuel filter sensor can be checked with monitoring function.
Related information
(Code: 18800 Condition of WIF sensor)

Cause Procedure, measuring location, criteria and remarks

High water level in water separator
1 Water is detected in water separator. Check and drain water separator.
(when system works properly)
Defective fuel filter sensor system If no failure is found by check on cause 1, fuel filter system may be defective.
2
(engine controller circuit) Perform troubleshooting for failure codes [CA428] and [CA429].
If no failure is found by checks on causes 1 and 2, machine monitor may be
3 Defective machine monitor defective
(Since this is an internal defect, troubleshooting cannot be performed.)

40-450 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-6 Emergency stop monitor lights up while engine is running

E-6 Emergency stop monitor lights up while engine is running 40-451

Failure 1) Engine coolant temperature monitor lights up in red.
q Signal of engine coolant temperature sensor is input to engine controller and then data is trans-
Related infor- mitted to machine monitor through CAN communication system.
mation q Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks

If monitor lights up in red, engine coolant temperature may be high (above approxi-
mately 102 C). Cool down engine coolant (run engine at low idle).
Overheating of engine cool-
q Lighting up in red: Engine coolant temperature is high (overheating).
1 ant (when system works
q Lighting up in blue: Engine coolant temperature is proper.
properly)
Perform troubleshooting for "S-14 Coolant temperature becomes too high (over-
heating)".
If no failure is found by check on cause 1, engine coolant temperature gauge sys-
Defective engine coolant
2 tem may be defective. Perform troubleshooting for "E-8 Engine coolant temperature
temperature gauge system
gauge does not indicate properly".

Failure 2) Hydraulic oil temperature monitor lights up in red.

q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmit-
Related infor- ted to machine monitor through CAN communication system.
mation q Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hydraulic oil temperature)

Cause Procedure, measuring location, criteria and remarks

If monitor lights up in red, hydraulic oil temperature may be high (above approxi-
Overheating of hydraulic oil
mately 102 C). Cool down hydraulic oil (run engine at low idle or stop engine).
1 (when system works prop-
q Lighting up in red: Hydraulic oil temperature is high (overheating).
erly)
q Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by check on cause 1, hydraulic oil temperature gauge system
Defective hydraulic oil tem-
2 may be defective. Perform troubleshooting for "E-9 hydraulic oil temperature gauge
perature gauge system
does not indicate properly".

Failure 3) Engine oil pressure monitor lights up in red.

q Signal of engine oil pressure switch is input to engine controller. If engine oil pressure switch is
Related infor-
turned ON while engine is running, failure code [B@BAZG] is transmitted from engine controller
mation
to machine monitor through CAN communication.

Cause Procedure, measuring location, criteria and remarks

Low engine oil pressure
Engine oil pressure may be low. Check it. If it is low, perform troubleshooting for
1 (when system works prop-
"S-12 Oil pressure decreases".
erly)
Defective engine oil pres- If no failure is found by check on cause 1 , engine oil pressure switch system may
2
sure switch system be defective. Perform troubleshooting for failure code [CA435].

HB205-1, HB215LC-1 40-451

(01)
Troubleshooting of electrical system (E-mode)
E-7 Fuel level gauge does not indicate properly

E-7 Fuel level gauge does not indicate properly 40-452

1) While fuel is added, fuel level gauge indicator does not rise above red range (E).
Failure
2) While fuel level is low, fuel level gauge indicator does not lower below green range top (F).
Related infor- q Signal voltage of fuel level sensor can be checked with monitoring function.
mation (Code: 04200 Fuel sensor voltage)

Cause Procedure, measuring location, criteria and remarks

Defective fuel level sensor
1
(internal open or short circuit)
Open circuit or short circuit in wir-
2
ing harness
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
4 female side.
(contact with ground circuit)
Hot short circuit in wiring harness
5 side of connector P21.
(contact with 24 V circuit)
6 Defective machine monitor
1. Turn starting switch to OFF position.
2. Disconnect connector P21 and connect T-adapters to male side.
Between P21 (male) (1) Fuel level: FULL Resistance 7 11 z
and ground Fuel level: EMPTY Resistance 85 95 z
1. Turn starting switch to OFF position.
2. Disconnect connector CM01 and connect T-adapters to female side.
Between CM01 (female) Fuel level: FULL Resistance 7 11 z
(9) and ground Fuel level: EMPTY Resistance 85 95 z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors CM01 and P21, and connect T-adapters to each
female side.
Between CM01 (female) (9) and P21 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors CM01 and P21, and connect T-adapters to either
Between CM01 (female) (9) and ground, or
Resistance Min. 1 Mz
between P21 (female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector P21.
3. Insert T-adapters into connector CM01 or connect T-adapters to female
4. Turn starting switch to ON position.
Between CM01 (9) and ground, or between P21 Approx. 3.3
Voltage
(female) (1) and ground V
If no failure is found by above checks, machine monitor is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to fuel level sensor 40-452

40-452 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-7 Fuel level gauge does not indicate properly

3) Indication of fuel level gauge is different from actual fuel level.

Failure
4) Indication of fuel level gauge is different from display of fuel level monitor.
Related infor- q Signal voltage of fuel level sensor can be checked with monitoring function.
mation (Code: 04200 Fuel sensor voltage)

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine and perform troubleshooting.
Fuel level Reading of fuel level gauge Color of monitor (a)
289 l 6
244,5 l 5
1 Defective machine monitor
200 l 4 Blue
100 l 3
60 l 2
41 l 1 Red

Fuel level gauge and fuel level monitor 40-453

HB205-1, HB215LC-1 40-453

(01)
Troubleshooting of electrical system (E-mode)
E-8 Engine coolant temperature gauge does not indicate properly

E-8 Engine coolant temperature gauge does not indicate properly 40-454
1) While engine coolant temperature is rising properly, temperature gauge indicator does not rise
above white range (C).
Failure
2) While engine coolant temperature remains in normal range, temperature gauge indicator rises to
red range (H).
q Signal of engine coolant temperature sensor is input to engine controller and then data is trans-
Related infor- mitted to machine monitor through CAN communication system.
mation q Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks

Defective engine coolant
1
temperature sensor system
2 Defective machine monitor
Engine coolant temperature sensor system may be defective. Perform troubleshoot-
ing for failure codes [CA144] and [CA145].
If no failure is found by check on cause 1, machine monitor may be defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

3) Indication of engine coolant temperature gauge is different from actual engine coolant tempera-
ture.
Failure
4) Indication of engine coolant temperature gauge is different from display of engine coolant temper-
ature monitor.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
Related infor- transmitted to machine monitor through CAN communication system.
mation q Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine and perform troubleshooting.
Engine coolant tempera- Reading of coolant temper-
Color of monitor (a)
ture ature gauge
105 C 6
Red
102 C 5
1 Defective machine monitor
100 C 4
85 C 3 Blue
60 C 2
30C 1 White

Engine coolant temperature gauge and coolant temperature monitor 40-454

40-454 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-8 Engine coolant temperature gauge does not indicate properly

HB205-1, HB215LC-1 40-455

(01)
Troubleshooting of electrical system (E-mode)
E-9 Hydraulic oil temperature gauge does not indicate properly

E-9 Hydraulic oil temperature gauge does not indicate properly 40-456
(1) While hydraulic oil temperature is rising properly, temperature gauge indicator does not rise above
white range (C).
Failure
(2) While hydraulic oil temperature remains in normal range, temperature gauge indicator rises to red
range (H).
q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmit-
Related infor- ted to machine monitor through CAN communication system.
mation q Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hydraulic oil temperature)

Cause Procedure, measuring location, criteria and remarks

1 Defective machine monitor See next page.
1. Turn starting switch to OFF position.
2. Disconnect connector P22 and connect T-adapters to male side.
Approx.
10C Resistance
90 kz
Defective hydraulic oil tem- Approx.
Between P22 (male) (1) and (2) 30C Resistance
2 perature sensor (internal 35 kz
a Temperature characteristics of oil
open or short circuit) Approx.
temperature sensor 80C Resistance
6.5 kz
Approx.
100C Resistance
3.5 kz
Between P22 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapters to female side.
Open circuit or short circuit in Between C01 (female) (29) and (46)
3
wiring harness a Resistance accords with value on temperature char- Resistance 3.5 to 90 kz
acteristics table in cause 2.
Between C01 (female) (29) and ground Resistance Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring har-
2. Disconnect connectors C01 and P22, and connect T-adapters to each female
ness (wire breakage or
4 side.
defective contact of connec-
tor) Between C01 (female) (29) and P22 (female) (2) Resistance Max. 1 z
Between C01 (female) (46) and P22 (female) (1) Resistance Max. 1 z
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring har-
2. Disconnect connectors C01 and P22, and connect T-adapters to either female
5 ness (contact with ground
side.
circuit)
Between C01 (female) (29) and ground, or between
Resistance Min. 1 Mz
P22 (female) (2) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector P22.
Hot short circuit in wiring har- 3. Insert T-adapters into connector C01 or connect T-adapters to female side of
6 ness (contact with 24 V cir- connector P22.
cuit) 4. Turn starting switch to ON position.
Between C01 (29) and ground, or between P22
Voltage Approx. 5 V
(female) (2) and ground
If no failure is found by above checks, pump controller is defective. (Since this is an
7 Defective pump controller
internal defect, troubleshooting cannot be performed.)

40-456 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-9 Hydraulic oil temperature gauge does not indicate properly

Circuit diagram related to hydraulic oil temperature sensor 40-457

(3) Indication of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Failure (4) Indication of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmit-
Related infor- ted to machine monitor through CAN communication system.
mation q Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hydraulic oil temperature)

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine and perform troubleshooting.
Reading of hydraulic oil
Hydraulic oil temperature Color of monitor (a)
temperature gauge
105 C 6
Red
102 C 5
1 Defective machine monitor
100C 4
85 C 3 Blue
40C 2
20C 1 White

Hydraulic oil temperature gauge and hydraulic oil temperature monitor 40-457

HB205-1, HB215LC-1 40-457

(01)
Troubleshooting of electrical system (E-mode)
E-10 HYB system temperature gauge does not indicate properly

E-10 HYB system temperature gauge does not indicate properly 40-458
1) While hybrid system temperature is rising normally, temperature gauge indicator does not rise
above white range (C).
Failure
2) While hybrid system temperature remains in normal range, temperature gauge indicator rises to
red range (H).
q Signal voltage of hybrid system temperature sensors are input to hybrid controller and then data
is transmitted to machine monitor.
q Hybrid temperatures can be checked with monitoring function.
Related infor- (Code: 09306: Capacitor cell temperature, 09403: Booster IGBT base temperature, 09404:
mation Booster IGBT junction temperature, 09402: Booster inductor temperature, 09101: Swing motor
coil temperature, 09600: Motor-generator temperature, 09607: Generator driver IGBT base
temperature #0, 09608: Generator driver IGBT base #1, 09507: Swing driver IGBT junction
temperature)

Cause Procedure, measuring location, criteria and remarks

Defective hybrid system
1
temperature sensor
2 Defective machine monitor
Hybrid system temperature sensor system may be defective. Perform troubleshoot-
ing for failure codes starting with "GA".
If no failure is found by check on cause 1, machine monitor may be defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

3) Indication of temperature gauge is different from actual hybrid system temperature.

Failure 4) Indication of hybrid system temperature gauge is different from hybrid system temperature moni-
tor.
q Signal voltage of hybrid temperature sensors are input to hybrid controller and then data is trans-
Related infor-
mitted to machine monitor through CAN communication system.
mation
q Hybrid temperatures can be checked with monitoring function (as previously mentioned).

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine and perform troubleshooting.
Hybrid device Color of
% Indicator Buzzer
temperature monitor (a)
A1 102 Red Q
Red
A2 100 I
1 Defective machine monitor
A3 95 Green
A4 50 I
White
A5 20 I
A6 0 White

a Hybrid system temperature gauge indicates in % to show temperature load of hybrid devices (see next
page for details).

40-458 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-10 HYB system temperature gauge does not indicate properly

Booster
Hybrid device Capacitor cell Booster Booster
% IGBT junction tem-
temperature temperature IGBT base temperature inductor temperature
perature
A1 102 65 80 130 125
A2 100 63 78 125 120
A3 95 60 75 110 110
A4 50 40 55 90 90
A5 20 0 0 0 0
A6 0 -30 -30 -30 -30

Hybrid device Swing motor Motor-generator Generator driver Swing inverter

%
temperature coil temperature temperature temperature junction temperature
A1 102 140 180 95 134
A2 100 120 170 85 133
A3 95 100 130 60 110
A4 50 80 110 40 90
A5 20 0 0 0 0
A6 0 -30 -30 -30 -30

Hybrid system temperature gauge and temperature monitor 40-459

a If gauge signal is not obtained due to open circuit in CAN communication line, indicator disappears.

HB205-1, HB215LC-1 40-459

(01)
Troubleshooting of electrical system (E-mode)
E-11 Displays on machine monitor are different from those for actual machine

E-11 Displays on machine monitor are different from those for actual
machine 40-460
Failure q Displays on machine monitor are different from those for actual machine
Related information

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position and perform troubleshooting (with mon-
itoring function).
Monitoring code Correct display
1 Defective model code signal HB205-1
00200 Controller model code
HB215LC-1
If display on monitor is incorrect, perform troubleshooting for failure code
[DA29KQ].
If no failure is found by check on cause 1, machine monitor is defective. (Since
2 Defective machine monitor
this is an internal defect, troubleshooting cannot be performed.)

E-12 Machine monitor does not display some items 40-460

Failure q Machine monitor does not display some items
q LCD panel may have black pixels (that do not light up) or bright pixels (that stay on). If number
Related information of bright and black pixels do not exceed ten, it does not indicate failure or defect of LCD pan-
el..

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position and perform troubleshooting.
Defective machine monitor When following switches are operated, if whole LCD panel is lighted up (whole
1
(LCD panel) surface becomes white), LCD panel has no failure.
q Operation of switches: [4] and [F2] (Press simultaneously)

Defective machine monitor If no failure is found by check on cause 1, machine monitor may be defective.
2
(body) (Since this is an internal defect, troubleshooting cannot be performed.)

E-13 Function switch does not work 40-460

Failure q Function switch does not work.
q Signal of function switch can be checked with monitoring function.
Related information
(Code: 04503 Monitor function switch)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is an internal defect, trouble-
1 Defective machine monitor
shooting cannot be performed.)

40-460 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-14 Automatic warm-up system does not operate (in cold season)

E-14 Automatic warm-up system does not operate (in cold season) 40-461
Failure q Automatic warm-up system does not operate (in cold weather).
q Automatic warm-up function increases engine speed to 1,200 rpm when engine coolant tem-
perature is below 30 C.
q With starting switch at ON position or after engine is started, if fuel control dial is kept at 70%
throttle position or higher for 3 seconds, automatic warm-up operation is canceled.
q If machine is equipped with air conditioner, when blower is turned on, ambient temperature is
Related information
below 5 C and engine coolant temperature is below 55 C, automatic warm-up function in-
creases engine speed to 1,300 rpm. If engine coolant temperature reaches 60 C, automatic
warm-up function is canceled.
q If engine coolant temperature is below 10 C, turbocharger protection function works to keep
engine speed below 1,000 rpm for up to 5 seconds after engine is started.

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine and perform trouble-
shooting.
Engine coolant tempera- Coolant temperature
Monitoring code
ture gange level
105 C 6 (a: Red)
102 C 5 (a: Red)
Defective engine coolant tempera- 04107 100 C 4 (a: Blue)
1
ture signal system Engine coolant tempera-
ture 85 C 3 (a: Blue)
60 C 2 (a: Blue)
30 C 1 (a: White)
If engine coolant temperature does not match with coolant temperature gauge
level, perform troubleshooting for "E-8 Engine coolant temperature gauge
does not indiate properly".
If no failure is found by cause 1, engine controller is defective. (Since this is an
2 Defective engine controller
internal defect, troubleshooting cannot be performed.)

Engine coolant temperature gauge and engine coolant temperature monitor 40-461

HB205-1, HB215LC-1 40-461

(01)
Troubleshooting of electrical system (E-mode)
E-15 Auto-decelerator does not operate normally

E-15 Auto-decelerator does not operate normally 40-462

1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not
Failure
go off.
Related infor- q Signal of auto-decelerator switch can be checked with monitoring function.
mation (Code: 04504 Monitor 1st, 2nd row switches)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is an internal defect, trouble-
1 Defective machine monitor
shooting cannot be performed.)

Failure 2) Auto-decelerator is not operated or canceled interlocking with work equipment lever.
q Since auto-deceleration set speed is 1,050 rpm, auto-deceleration is not operated or canceled if
Related infor-
engine speed higher than this speed is set by fuel control dial.
mation
q Auto-deceleration does not function in arm crane mode (L) for arm crane specification machines.

Cause Procedure, measuring location, criteria and remarks

a Start engine and perform troubleshooting (with monitoring function).
Monitoring code Item Correct display
Swing
Travel
When lever is operated:
01900 Boom LOWER ON
Pressure Switch 1 Boom RAISE When lever is in neutral:
OFF
Arm IN
1 Defective PPC pressure signal
Arm OUT
Bucket CURL
When lever is operated:
01901 Bucket DUMP ON
Pressure Switch 2 Service When lever is in neutral:
OFF
Travel steering
If monitoring data show any abnormality, perform troubleshooting for "E-27 to
36 Monitoring function does not display *** normally".
If no failure is found by check on cause 1, machine monitor may be defective.
2 Defective machine monitor
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by check on causes 1 and 2, pump controller may be
3 Defective pump controller defective (Since this is an internal defect, troubleshooting cannot be per-
formed.)
If no failure is found by check on causes 1 to 3, engine controller may be
4 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be per-
formed.)
If no failure is found by check on causes 1 to 4, inverter may be defective
5 Defective inverter
(Since this is an internal defect, troubleshooting cannot be performed).

40-462 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-16 Working mode does not change

E-16 Working mode does not change 40-463

Failure 1) When working mode switch is operated, working mode selection screen is not displayed.
q Signal of working mode switch can be checked with monitoring function.
Related information
(Code: 04504 Monitor 1st, 2nd line switches)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is an internal defect, trouble-
1 Defective machine monitor
shooting cannot be performed.)

Failure 2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related information

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is an internal defect, trouble-
1 Defective machine monitor
shooting cannot be performed.)
Pump controller may be defective. (Since this is an internal defect, trouble-
2 Defective pump controller
shooting cannot be performed.)

HB205-1, HB215LC-1 40-463

(01)
Troubleshooting of electrical system (E-mode)
E-17 Travel speed does not change

E-17 Travel speed does not change 40-464

Failure 1) When travel speed selector switch is operated, display of travel speed monitor does not change.
Related infor- q Signal of travel speed selector switch can be checked with monitoring function.
mation (Code: 04504 Monitor 1st, 2nd row switches)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is an internal defect, trouble-
1 Defective machine monitor
shooting cannot be performed.)

Failure 2) When selection of travel speed is changed, actual travel speed does not change.
q When failure due to cause 1 occurs, actual travel speed does not decrease when travel speed set-
Related infor- ting is changed to "Lo".
mation q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.

Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring harness
1 3. Turn starting switch to ON position.
(contact with 24 V circuit)
2 Defective machine monitor
3 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V04 and connect T-adapters to female side.
Between V04 (female) (2) and ground Voltage Max. 1 V
If no failure is found by check on cause 1, machine monitor may be defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by checks on cause 1 and 2, pump controller may be
defective (Since this is an internal defect, troubleshooting cannot be per-
formed.)

Circuit diagram related to travel speed solenoid 40-464

40-464 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-18 Alarm buzzer does not stop sounding

E-18 Alarm buzzer does not stop sounding 40-465

Failure q Alarm buzzer does not stop sounding.
q Signal of alarm buzzer cancel switch can be checked with monitoring function.
Related information (Code: 04504 Monitor 1st, 2nd line switches)
a Alarm for failure of arm crane cannot be cancelled.

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is an internal defect, trouble-
1 Defective machine monitor
shooting cannot be performed.)

E-19 When starting switch is at OFF position, service meter is not

displayed 40-465
Failure q When starting switch is at OFF position, service meter is not displayed.
q While starting switch is at OFF position, if following switches are operated, service meter is
Related information displayed at top center of screen.
Operation of switches: [4] and [1] (Press simultaneously)

Cause Procedure, measuring location, criteria and remarks

When starting switch is turned to ON position, if machine monitor displays
Defective backup power supply nothing, backup power supply system may be defective. In this case, perform
1
system troubleshooting for "E-3 When starting switch is turned to ON position,
machine monitor displays nothing".
If no failure is found by check on cause 1, machine monitor may be defective.
2 Defective machine monitor
(Since this is an internal defect, troubleshooting cannot be performed.)

E-20 Machine monitor cannot be set in service mode 40-465

Failure q Machine monitor cannot be set in service mode
q Following switch operation sets machine monitor in service mode.
Related information
Switch operation: [4] and [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in order)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is an internal defect, trouble-
1 Defective machine monitor
shooting cannot be performed.)

HB205-1, HB215LC-1 40-465

(01)
Troubleshooting of electrical system (E-mode)
E-21 All of work equipment, swing, and travel mechanism do not move or are not locked

E-21 All of work equipment, swing, and travel mechanism do not move
or are not locked 40-46
Failure 1) All of work equipment, swing, and travel mechanism do not move.
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse F01-3
Defective lock lever switch (inter-
2
nal open circuit)
Defective PPC lock solenoid
3
(internal open or short circuit)
Defective diode array D01
4
(internal short circuit)
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
6
(contact with ground circuit)
If fuse is broken, circuit probably has grounding fault. (See troubleshooting for
cause 6.)
1. Turn starting switch to OFF position.
2. Disconnect connector S14 and connect T-adapters to female side.
Between S14 (male) (1) Lock lever: LOCK Resistance Min. 1 Mz
and (2) Lock lever: FREE Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector V01 and connect T-adapters to male side.
Between V01 (male) (1) and (2) Resistance 20 60 z
Between V01 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Remove diode array D01 and connect T-adapters to male side.
a Check the continuity in diode range.
Between D01 (male) (8) (+) and (4) (-) Continuity
Between D01 (male) (4) (+) and (8) (-) No continuity
1. Turn starting switch to OFF position.
2. Set lock lever to FREE position.
3. Remove fuse F01-3.
Between F01-3 and ground (coil resistance of PPC
Resistance 20 60 z
lock solenoid)
a If no failure is found by above check, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse F01-3.
3. Disconnect connectors S14 and V01 and then connect T-adapters to male
side of S14 and female side of V01.
Between F01-3 and S14 (male) (1) Resistance Max. 1 z
Between S14 (male) (2) and V01 (female) (1) Resistance Max. 1 z
Between V01 (female) (2) and ground (T09) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Remove fuse F01-3.
3. Disconnect connectors S14, V01, and D01, and then connect T-adapters to
male side of S14 or female side of V01 or D01.
Between F01-3 or S14 (male) (1) and ground Resistance Min. 1 Mz
Between ground and S14 (male) (2), V01 (female)
Resistance Min. 1 Mz
(1) or D01 (female) (4)

40-466 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-21 All of work equipment, swing, and travel mechanism do not move or are not locked

Failure 2) All of work equipment, swing, and travel mechanism are not locked.
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector S14, and connect T-adapters to male side.
Defective lock lever switch
1
(internal short circuit) Between S14 (male) (1) Lock lever: LOCK Resistance Min. 1 Mz
and (2) Lock lever: FREE Resistance Max. 1 z
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Connect T-adapters to connector V01.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between V01 (male) (1) and (2) Voltage Max. 1 V

Circuit diagram related to PPC lock solenoid 40-467

HB205-1, HB215LC-1 40-467

(01)
Troubleshooting of electrical system (E-mode)
E-21 All of work equipment, swing, and travel mechanism do not move or are not locked

40-468 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-22 Swing holding brake does not operate properly

E-22 Swing holding brake does not operate properly 40-469

Failure 1) When swing brake cancel switch is set to CANCEL position, machine cannot swing.
Related infor- q Signal of swing lock switch can be checked with monitoring function.
mation (Pump controller system code: 02200 Switch input 1)

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse F01-1
Defective swing brake cancel
2 Resistance
switch (internal short circuit)
Defective diode array D01 or D03 Between D01 (male) (7) (+) and (3) (-)
3
(internal short circuit)
4 Defective harness
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
6
(contact with ground circuit)
If fuse F01-1 is broken, circuit probably has ground fault. In this case, perform
troubleshooting for cause 6 first.
1. Turn starting switch to OFF position.
2. Disconnect connector S25 and connect T-adapters to female side.
swing brake cancel
Min. 1 Mz
Between S25 (male) (13) switch: Normal
and (14) swing brake cancel
Resistance Max. 1 z
switch: FREE
1. Turn starting switch to OFF position.
2. Remove diode arrays D01 and D03, and connect T-adapters to male side.
a Check using multimeter in diode range.
Continuity
Between D01 (male) (3) (+) and (7) (-) No continuity
Between D03 (male) (7) (+) and (3) (-) Continuity
Between D03 (male) (3) (+) and (7) (-) No continuity
1. Turn starting switch to OFF position.
2. Disconnect connector V03 and connect T-adapters to female side.
3. Turn starting switch to ON position.
swing brake cancel
Voltage 20 30 V
Between V03 (female) switch: FREE
(1) and (2) swing brake cancel
Voltage Max. 1 V
switch: Normal
a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors V03 and S25 and connect T-adapters to each male
side.
Between V03 (female) (1) and S25 (female) (14) Resistance Max. 1 z
Between V03 (female) (2) and C02 (female) (115) Resistance Max. 1 z
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors S25, V03, D01 and D03, and connect T-adapters to
female side of V03.
Between V03 (female) (1) and ground Resistance Min. 1 Mz

HB205-1, HB215LC-1 40-469

(01)
Troubleshooting of electrical system (E-mode)
E-22 Swing holding brake does not operate properly

Failure 2) When swing brake cancel switch is set to Normal position, swing holding brake does not operate.
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector S25 and connect T-adapters to male side.
Defective swing brake cancel swing brake cancel
1 Resistance Min. 1 Mz
switch (internal short circuit) Between S25 (male) (13) switch: Normal
and (14) swing brake cancel
Resistance Max. 1 z
switch: FREE
1. Turn starting switch to OFF position.
2. Disconnect connector V03 and connect T-adapters to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
2
(contact with 24 V circuit) 4. Set swing lock switch to ON position.
Between V03 (female) (1) and ground Voltage Max. 1 V

40-470 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-22 Swing holding brake does not operate properly

Circuit diagram related to swing holding brake solenoid 40-471

HB205-1, HB215LC-1 40-471

(01)
Troubleshooting of electrical system (E-mode)
E-23 One-touch power max. function does not operate

E-23 One-touch power max. function does not operate 40-472

1) When L.H. knob switch is pressed, one-touch power max. monitor is not displayed.
Failure
2) When L.H. knob switch is pressed, work equipment power is not increased.
q One-touch power max. function does not operate when selected working mode is not power mode
Related infor- (P) or economy mode (E).
mation q Signal of L.H. knob switch can be checked with monitoring function.
(Code: 02200 Switch input 1)

Cause Procedure, measuring location, criteria and remarks

1 Defective machine monitor
2 Defective fuse No. 9
Defective left knob switch
3 Resistance Min. 1 Mz
(internal open circuit)
Open circuit or ground fault in wir- a Ignore displayed failure code.
4
ing harness
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
6 side of S11.
(contact with ground circuit)
7 Defective pump controller
When L.H. knob switch is pressed, if work equipment power is increased but
one-touch power max. monitor is not displayed on machine monitor, machine
monitor may be defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
If fuse is broken, circuit probably has grounding fault. (See troubleshooting for
cause 6.)
1. Turn starting switch to OFF position.
2. Disconnect connector S11, and connect T-adapters to male side.
L.H. knob switch:
Between S11 (male) (1) Released
and (2) L.H. knob switch:
Resistance Max. 1 z
Pressed
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapters to female side.
3. Turn starting switch to ON position.
L.H. knob switch:
Voltage Max. 1 V
Between C01 (female) Released
(41) and ground L.H. knob switch:
Voltage 20 30 V
Pressed
a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse F01-9.
3. Disconnect connectors C01 and S11 and connect T-adapters to each
female side.
Between F01-9 and S11 (female) (1) Resistance Max. 1 z
Between S11 (female) (2) and C01 (female) (41) Resistance Max. 1 z
a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse F01-9.
3. Disconnect connectors C01 and S11 and connect T-adapters to female
Between F01-9 or S11 (female) (1) and ground Resistance Min. 1 Mz
Between S11 (female) (2) or C01 (female) (41) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

40-472 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-23 One-touch power max. function does not operate

Circuit diagram related to one-touch power max. switch 40-473

HB205-1, HB215LC-1 40-473

(01)
Troubleshooting of electrical system (E-mode)
E-23 One-touch power max. function does not operate

Failure 3) When L.H. knob switch is released, work equipment power is not returned to normal.
Related informa- q Signal of L.H. knob switch can be checked with monitoring function.
tion (Code: 02200 Switch input 1)

Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring
1 harness (contact with 24 V
circuit)
2 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V02 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Between V02 (female) (1) and (2) Voltage Max. 1 V
If no failure is found by check on cause 1, pump controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to 2-stage relief solenoid 40-474

40-474 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-23 One-touch power max. function does not operate

HB205-1, HB215LC-1 40-475

(01)
Troubleshooting of electrical system (E-mode)
E-24 Travel alarm does not sound or does not stop sounding

E-24 Travel alarm does not sound or does not stop sounding 40-476
Failure 1) Alarm does not sound during travel.
q Output to travel alarm can be checked with monitoring function.
(Code: 03701 Controller output 2)
q Travel pressure switch signal (ON/OFF) can be checked with monitoring function.
Related infor-
(Monitoring code: 01900 Pressure switch 1)
mation
q Use "short connector" 799-601-7230 for 2-pin X connector in troubleshooting for cause 3.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at the pump controller connector.

Cause Procedure, measuring location, criteria and remarks

If fuse No. 15 in fuse box F01 is blown, circuit probably has ground fault. In
1 Blown fuse No. 15 in fuse box F01
this case, perform troubleshooting for cause 5 first.
1. Turn starting switch to OFF position.
Defective travel alarm (internal 2. Disconnect connector M14 and connect T-adapters to male side.
2
defect)
Between M14 (male) (1) and (2) Continuity
1. Turn starting switch to OFF position.
2. Disconnect connector P09, and connect T-adapters to female side.
Defective travel PPC pressure 3. Connect "short connector" to male side of T-adapters.
switch (internal open or short cir- 4. Turn starting switch to ON position.
3
cuit)
If travel alarm sounds, travel PPC pressure switch is defective.

1. Turn starting switch to OFF position.

2. Disconnect connectors M14 and P09 and connect T-adapters to each
female side.
Open circuit in wiring harness 3. Remove fuse No. 15 in fuse box F01.
4 (wire breakage or defective con-
Between F01-15 and M14 (female) (1) Resistance Max. 1 z
tact of connector)
Between P09 (female) (2) and M14 (female) (2) Resistance Max. 1 z
Between P09 (female) (1) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors M10 and M14, and connect T-adapters to female
Ground fault in wiring harness side of M14.
5
(contact with ground circuit) 3. Remove fuse No. 15 in fuse box F01.
Between M14 (female) (1) and ground Resistance Min. 1 Mz

Failure 2) Alarm does not stop sounding while machine is stopped.

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

Ground fault in wiring harness
1
(contact with ground circuit)
1. Turn starting switch to OFF position.
2. Disconnect connector M14 and connect T-adapters to female side.
Between M14 (female) (1) and ground Resistance Min. 1 Mz

40-476 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-24 Travel alarm does not sound or does not stop sounding

Circuit diagram related to travel alarm 40-47

HB205-1, HB215LC-1 40-477

(01)
Troubleshooting of electrical system (E-mode)
E-25 Horn does not sound or does not stop sounding

E-25 Horn does not sound or does not stop sounding 40-478
Failure 1) Horn does not sound.
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

If fuse F01(5) is broken, circuit probably has ground fault. In this case, perform
1 Defective fuse F01-5
troubleshooting for cause 7 first.
1. Turn starting switch to OFF position.
2. Replace horn relay (connector: R08) with another relay.
Defective horn relay 3. Turn starting switch to ON position.
2
(internal open or short circuit) 4. Press L.H. knob switch.
If horn sounds, original horn relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector S10 and connect T-adapters to male side.
Defective horn switch
3
(internal open or short circuit) Between S10 (male) (1) Switch: OFF Resistance Min. 1 Mz
and (2) Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors M07 and M08, and connect T-adapters to each
Defective high-tone horn (M07) or
male side.
4 low-tone horn (M08) (internal open
or short circuit) Between M07 (male) (1) and (2) Continuity
Between M08 (male) (1) and (2) Continuity
1. Turn starting switch to OFF position.
2. Disconnect connector R08 and connect T-adapters to female side.
3. Turn starting switch to ON position.
5 Defective harness 4. Press L.H. knob switch.
Between R08 (female) (1) and (2) Voltage 20 30 V
Between R08 (female) (3) and (2) Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Disconnect connector R08 and connect T-adapters to female side.
Between R08 (female) (5) and ground Continuity
Between R08 (female) (1) and ground Continuity
a If no failure is found by above checks, this check is not required.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
6 (wire breakage or defective con- 2. Remove fuse F01-5.
tact of connector) 3. Disconnect connectors R08 and S10, and connect T-adapters to each
female side.
Between F01-5 and S10 (female) (1) Resistance Max. 1 z
Between S10 (female) (2) and R08 (female) (1) Resistance Max. 1 z
Between R08 (female) (2) and ground Resistance Max. 1 z
Between R08 (female) (3) and F01(5) Resistance Max. 1 z
a If fuse is not blown, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse F01-5.
3. Disconnect connectors R08, M07, and M08, and connect T-adapters to
Ground fault in wiring harness female side of R08.
7
(contact with ground circuit)
Between R08 (female) (1) and ground Resistance Min. 1 Mz
Between R08 (female) (3) and ground Resistance Min. 1 Mz
Between R08 (female) (5) and ground Resistance Min. 1 Mz

40-478 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-25 Horn does not sound or does not stop sounding

Cause Procedure, measuring location, criteria and remarks

Defective horn
8 If no failure is found by above checks, horn may be defective.
(internal defect)

Failure 2) Horn does not stop sounding.

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective horn relay (R08) 2. Remove horn relay (connector R08).
1 3. Turn starting switch to ON position.
(internal open or short circuit)
If horn stops sounding, original horn relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors M07 and M08, and connect T-adapters to each
female side.
Hot short circuit in wiring harness
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between M07 (female) (2) and (1) Voltage Max. 1 V
Between M08 (female) (2) and (1) Voltage Max. 1 V

Circuit diagram related to horn 40-479

HB205-1, HB215LC-1 40-479

(01)
Troubleshooting of electrical system (E-mode)
E-26 Windshield wiper and window washer do not operate

E-26 Windshield wiper and window washer do not operate 40-480

Failure 1) When wiper switch is operated, wiper monitor does not light up or go off.
Related infor- q Signal of wiper switch can be checked with monitoring function.
mation (Code: 04504 Monitor 1st, 2nd row switches)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is an internal defect, trouble-
1 Defective machine monitor
shooting cannot be performed.)

Failure 2) When wiper switch is operated, windshield wiper does not operate.
q Signal of window rear limit switch can be checked with monitoring function.
Related infor- (Code: 02204 Switch input 5)
mation q Wiper motor is checked and its failure is expressed in failure code [DY20KA], [DY20MA],
[DY2DKB], or [DY2EKB].

Cause Procedure, measuring location, criteria and remarks

Defective window rear limit switch
1 Resistance
(Internal short circuit)
Defective wiper motor
2
(internal open circuit)
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
4 3. Set front window in position.
(contact with ground circuit)
5 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector W03.
Front window: when set
Min. 1 Mz
Between W03 (male) (1) in position
and (2) Front window: when
Resistance Max. 1 z
pulled up
1. Turn starting switch to OFF position.
2. Disconnect connector M05 and connect T-adapters to female side.
Between M05 (female) (1) and (3) Continuity
a Wiper motor system
See troubleshooting for failure codes [DY20KA], [DY20MA], [DY2DKB], and
[DY2EKB].
a Wiper rear limit switch system
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapters to female side.
3. Pull up front window.
Between C01 (female) (57) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapters to female side.
Between C01 (female) (57) and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Failure 3) When window washer switch is operated, window washer does not operate.
q Signal of window washer switch can be checked with monitoring function.
Related infor-
(Code: 04504 Monitor 1st, 2nd row switches)
mation
q Window washer is checked and its failure is expressed in failure codes [DY2CKA] or [DY2CKB].

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is an internal defect, trouble-
1 Defective machine monitor
shooting cannot be performed.)

40-480 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-26 Windshield wiper and window washer do not operate

Circuit diagram related to wiper 40-481

HB205-1, HB215LC-1 40-481

(01)
Troubleshooting of electrical system (E-mode)
E-27 "BOOM LOWER" indicator is not displayed properly with monitoring function

E-27 "BOOM LOWER" indicator is not displayed properly with moni-

toring function 40-482
Failure "Boom LOWER" operation signal is not displayed properly on monitoring screen.
q Monitoring code: 01900 Pressure switch 1
Related infor- q Use "short connector" 799-601-7230 for 2-pin X connector in troubleshooting for cause 6.
mation q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.

Cause Procedure, measuring location, criteria and remarks

Defective boom LOWER PPC
1 pressure switch (internal open or
short circuit)
Defective harness or pump con-
2 R.H. work equipment
troller
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
4
(contact with ground circuit)
Hot short circuit in wiring harness 2. Disconnect connector P02 and connect T-adapters to female side.
5
(contact with 24 V circuit)
6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector P02 and connect T-adapters to male side.
3. Start engine.
4. Operate R.H. work equipment control lever and perform troubleshooting.
R.H. work equipment
Resistance Min. 1 Mz
control lever: NEUTRAL
Between P02 (male) (1)
and (2) R.H. work equipment
control lever: Boom Resistance Max. 1 z
LOWER
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector P02.
3. Start engine.
4. Operate R.H. work equipment control lever and perform troubleshooting.
Voltage Approx. 7 V
control lever: NEUTRAL
Between P02 (2) and (1) R.H. work equipment
control lever: Boom Voltage Max. 1 V
LOWER
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P02 and connect T-adapters to each
female side.
Between C01 (female) (14) and P02 (female) (1) Resistance Max. 1 z
Between P02 (female) (2) and ground (T10) Resistance Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P02 and connect T-adapters to either
female side.
Between ground and C01 (female) (14) or P02
Resistance Min. 1 Mz
(female) (1)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
3. Turn starting switch to ON position.
Between P02 (female) (1) and ground Voltage Approx. 7 V
1. Turn starting switch to OFF position.
2. Disconnect connector P02 and connect T-adapters to female side.
3. Connect "short connector" to male side of T-adapters.
4. Turn starting switch to ON position.
If voltage between P02 (1) and (2) is below 1 V but displayed "Boom LOWER"
operation signal is "OFF", pump controller is defective.
a After finishing troubleshooting, return connector to condition as it was.

40-482 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-27 "BOOM LOWER" indicator is not displayed properly with monitoring function

Circuit diagram related to boom LOWER PPC pressure switch 40-483

HB205-1, HB215LC-1 40-483

(01)
Troubleshooting of electrical system (E-mode)
E-28 "ARM OUT" indicator is not displayed properly with monitoring function

E-28 "ARM OUT" indicator is not displayed properly with monitoring

function 40-484
Failure "Arm OUT" operation signal is not displayed properly on monitoring screen.
q Monitoring code: 01900 Pressure switch 1
Related infor- q Use "short connector" 799-601-7230 for 2-pin X connector in troubleshooting for cause 6.
mation q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P08 and connect T-adapters to male side.
3. Start engine.
Defective Arm OUT PPC pressure 4. Operate L.H. work equipment control lever and perform troubleshooting.
1 switch (internal open or short cir- L.H. work equipment
cuit) Resistance Min. 1 Mz
Between P08 (male) (1) control lever: NEUTRAL
and (2) L.H. work equipment
Resistance Max. 1 z
control lever: Arm OUT
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector P08.
3. Start engine.
4. Operate L.H. work equipment control lever and perform troubleshooting.
Defective harness or pump con-
2 L.H. work equipment
troller Voltage Approx. 7 V
control lever: NEUTRAL
Between P08 (2) and (1)
L.H. work equipment
Voltage Max. 1 V
control lever: Arm OUT
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors C01 and P08 and connect T-adapters to each
3 (wire breakage or defective con- female side.
tact of connector) Between C01 (female) (15) and P08 (female) (1) Resistance Max. 1 z
Between P08 (female) (1) and ground (T10) Resistance Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C01 and P08 and connect T-adapters to either
4
(contact with ground circuit) female side.
Between ground and C01 (female) (15) or P08
Resistance Min. 1 Mz
(female) (1)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector P08, and connect T-adapters to female side.
5
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Between P08 (female) (1) and ground Voltage Approx. 7 V
1. Turn starting switch to OFF position.
2. Disconnect connector P08, and connect T-adapters to female side.
3. Connect "short connector" to male side of T-adapter.
6 Defective pump controller 4. Turn starting switch to ON position.
If voltage between P08 (1) and (2) is below 1 V but displayed "Arm OUT" oper-
ation signal is "OFF", pump controller is defective.

40-484 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-28 "ARM OUT" indicator is not displayed properly with monitoring function

Circuit diagram related to arm OUT PPC pressure switch 40-485

HB205-1, HB215LC-1 40-485

(01)
Troubleshooting of electrical system (E-mode)
E-29 "ARM IN" indicator is not displayed properly with monitoring function

E-29 "ARM IN" indicator is not displayed properly with monitoring func-
tion 40-486
Failure "Arm IN" operation signal is not displayed properly on monitoring sceen.
Related information q Monitoring code: 01900 Pressure switch 1

Cause Procedure, measuring location, criteria and remarks

Defective arm IN PPC pressure
1 sensor system (internal open or Perform troubleshooting for failure code [DHS3MA].
short circuit)

E-30 "BOOM RAISE" indicator is not displayed properly with monitoring

function 40-486
Failure "Boom RAISE" operation signal is not displayed properly on monitoring screen.
Related informa-
q Monitoring code: 01900 Pressure switch 1
tion

Cause Procedure, measuring location, criteria and remarks

Defective boom RAISE PPC
pressure sensor system
1 Perform troubleshooting for failure code [DHS8MA].
(internal open or short cir-
cuit)

E-31 "BUCKET CURL" indicator is not displayed properly with moni-

toring function 40-486
Failure "Bucket CURL" operation signal is not displayed properly on monitoring screen.
Related information q Monitoring code: 01901 Pressure switch 2

Cause Procedure, measuring location, criteria and remarks

Defective bucket CURL PPC pres-
1 Perform troubleshooting for failure code [DHS4MA].
sure sensor system

40-486 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-32 "BUCKET DUMP" indicator is not displayed properly with monitoring function

E-32 "BUCKET DUMP" indicator is not displayed properly with moni-

toring function 40-487
Failure "Bucket DUMP" operation signal is not displayed properly on monitoring screen.
Related information q Monitoring code: 01901 Pressure switch 2

Cause Procedure, measuring location, criteria and remarks

Defective bucket DUMP PPC pres-
1 Perform troubleshooting for failure code [DHSDMA].
sure sensor system

E-33 "SWING" indicator is not displayed properly with monitoring func-

tion 40-487
Failure "Swing" operation signal is not displayed properly on monitoring screen.
Related information q Monitoring code: 01900 Pressure switch 1

Cause Procedure, measuring location, criteria and remarks

Defective swing PPC pressure
1 sensor system Perform troubleshooting for failure codes [DHSAMA] and [DHSBMA].
(internal open or short circuit)

HB205-1, HB215LC-1 40-487

(01)
Troubleshooting of electrical system (E-mode)
E-34 "TRAVEL" indicator is not displayed properly with monitoring function

E-34 "TRAVEL" indicator is not displayed properly with monitoring func-

tion 40-48
Failure "Travel" operation signal is not displayed properly on monitoring screen.
q Monitoring code: 01900 Pressure switch 1
q For safety, use "short connector" 799-601-7230 for 2-pin X connector in troubleshooting for cause
1.
Related infor-
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
mation
sured at pump controller connector.
k Pressure switch connectors must not be checked when engine is started and travel levers
are operated.

Cause Procedure, measuring location, criteria and remarks

Defective travel PPC pressure
1 sensor system (internal open or
short circuit)
2 Defective diode array D02
Defective wiring harness or pump 3. Start engine.
3
controller
Open circuit in wiring harness
4 (wire breakage or defective con- Between C01 (female) (55) and D02 (female) (8)
tact of connector)
A. When "Travel" operation signal displayed on monitoring screen is not "ON"
when engine is started and both travel levers are simultaneously operated
1. Turn starting switch to OFF position.
2. Disconnect P09 and connect "short connector" to male side.
3. Insert T-adapters into D02.
4. Turn starting switch to ON position.
a After finishing troubleshooting, return connectors as they were.
If "Travel" operation signal displayed on monitoring screen changes to "ON",
travel PPC pressure switch (P09) is defective.
a If voltage between D02 (8) and ground is below 1 V but "Travel" operation
signal displayed on monitoring screen remains "OFF", pump controller is
defective.
B. If "Travel" operation signal displayed on monitoring screen is "ON" when
starting switch is turned to ON position.
1. Turn starting switch to OFF position.
2. Disconnect P09.
3. Insert T-adapters into C01.
4. Turn starting switch to ON position.
If "Travel" operation signal displayed on monitoring screen changes to "OFF",
travel PPC pressure switch (P09) is defective.
a If voltage between D02 (8) and ground is approx. 7 V but "Travel" operation
signal displayed on monitoring screen is "ON", pump controller is defective.
1. Turn starting switch to OFF position.
2. Remove diode array D02 and connect T-adapters to diode array .
a Check by using multimeter in diode range.
Between D02 (male) (4) (+) and (8) (-) No continuity
Between D02 (male) (8) (+) and (4) (-) Continuity
k
Make sure that no person and no obstacles are near machine before
travelling.
1. Turn starting switch to OFF position.
2. Insert T-adapters into D02.
4. Operate travel lever and perform troubleshooting.
Between D02 (8) and
Travel lever: NEUTRAL Voltage Approx. 7 V
ground
Between D02 (8) and Travel lever: both oper-
Voltage Max. 1 V
ground ated simultaneously
1. Turn starting switch to OFF position.
2. Disconnect connectors C01, D02, and P09, and connect T-adapters to
each female side.
Resistance Max. 1 z
Between D02 (female) (4) and P09 (female) (2) Resistance Max. 1 z
Between P09 (female) (1) and ground (T06) Resistance Max. 1 z

40-488 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-34 "TRAVEL" indicator is not displayed properly with monitoring function

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors C01, D02, P09, and F02-15, and connect
T-adapters to either female side.
Ground fault in wiring harness
5 Between C01 (female) (55) or D02 (female) (8) and
(contact with ground circuit) Resistance Min. 1 Mz
ground
Between D02 (female) (4) or P09 (female) (2) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect D02 and connect T-adapters to female side.
6 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between D02 (female) (8) and ground Voltage Approx. 7 V
If no failure is found by above checks, pump controller is defective. (Since this
7 Defective pump controller
is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to travel PPC pressure switch 40-489

HB205-1, HB215LC-1 40-489

(01)
Troubleshooting of electrical system (E-mode)
E-35 "TRAVEL STEERING" indicator is not displayed properly with monitoring function

E-35 "TRAVEL STEERING" indicator is not displayed properly with moni-

toring function 40-490
Failure "Travel steering" operation signal is not displayed properly on monitoring screen.
q Monitoring code: 01901 Pressure switch 2
q For safety, use "short connector" 799-601-7230 for 2-pin X connector in troubleshooting for cause
6.
Related infor-
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
mation
sured at pump controller connector.
k Pressure switch connectors must not be checked when engine is started and travel levers
are operated.

Cause Procedure, measuring location, criteria and remarks

Defective travel steering PPC
1 "ON" travel steering PPC pressure switch (P10) is defective.
pressure switch
Defective harness or pump con-
2 3. Start engine.
troller
Open circuit in wiring harness
3 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
4
(contact with ground circuit)
Hot short circuit in wiring harness
5
(contact with 24 V circuit)
A. If "Travel steering" operation signal displayed on monitoring screen is not
change "ON" when engine is started and one of travel levers is operated
1. Turn starting switch to OFF position.
2. Disconnect P10 and connect a "short connector" to male side.
3. Turn starting switch to ON position.
a After finishing troubleshooting, return connectors as they were.
If "Travel steering" operation signal displayed on monitoring screen changes to
B. If "Travel steering" operation signal displayed on monitoring screen is "ON"
when starting switch is turned to ON position.
1. Turn starting switch to OFF position.
2. Disconnect P10.
3. Turn starting switch to ON position.
If "Travel steering" operation signal displayed on monitoring screen changes to
"OFF" travel steering PPC pressure switch (P10) is defective.
k Make sure that no person and no obstacles are near machine before
travelling.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector P10.
a Extend multimeter probe and measure inside cab.
4. Operate travel lever and perform troubleshooting.
Travel lever: NEUTRAL Voltage Approx. 7 V
Between P10 (2) and
(1) Travel lever: either one
Voltage Max. 1 V
operated
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P10 and connect T-adapters to each
female side.
Between C01 (female) (36) and P10 (female) (2) Resistance Max. 1 z
Between P10 (female) (1) and ground (T06) Resistance Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P10 and connect T-adapters to either
female side.
Between C01 (female) (36) or P10 (female) (2) and
Resistance Min. 1 Mz
ground
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector P10 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Between P10 (female) (2) and ground Voltage Approx. 7 V

40-490 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-35 "TRAVEL STEERING" indicator is not displayed properly with monitoring function

Cause Procedure, measuring location, criteria and remarks

6 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector P10 and connect T-adapters to female side.
3. Connect "short connector" to male side of T-adapter.
4. Turn starting switch to ON position.
If voltage between P10 (2) and (1) is below 1 V but "Travel steering" operation
signal displayed on monitoring screen is "OFF", pump controller is defective.
1. Turn starting switch to OFF position.
2. Disconnect P10 and connect T-adapters to male side.
3. Turn starting switch to ON position.
If voltage between P10 (female) (2) and (1) is approx. 7 V but "Travel pressure
difference" signal displayed on monitoring screen is "ON", pump controller is
defective.

Circuit diagram related to travel steering PPC pressure switch 40-491

HB205-1, HB215LC-1 40-491

(01)
Troubleshooting of electrical system (E-mode)
E-36 "SERVICE" indicator is not displayed properly with monitoring function

E-36 "SERVICE" indicator is not displayed properly with monitoring

function 40-492
Failure "Attachment" operation signal is not displayed properly on monitoring screen.
q Monitoring code: 01901 Pressure switch 2
q For safety, use "short connector" 799-601-7230 for 2-pin X connector in troubleshooting for
Related information cause 1 and 2.
k Do not check pressure switch connector while engine is running.

Cause Procedure, measuring location, criteria and remarks

A. If "Service" operation signal displayed on monitoring screen is not "ON"

when engine is started and attachment control pedal is depressed at front end
1. Turn starting switch to OFF position.
2. Disconnect connector P14 and connect "short connector" to male side.
3. Turn starting switch to ON position.
a After finishing troubleshooting, return connectors as they were.

Defective PPC pressure switch
1 (P14) for front end of attachment
control pedal
If "Service" operation signal displayed on monitoring screen changes to "ON",
front service PPC pressure switch (P14) is defective (Note 1).
B. If "Service" operation signal displayed on monitoring screen is ON" when
starting switch is turned to ON position
1. Turn starting switch to OFF position.
2. Disconnect connector P14.
3. Turn starting switch to ON position.

If "Service" operation signal displayed on monitoring screen changes to

"OFF", front service PPC pressure switch (P14) is defective (Note 2).

A. If "Service" operation signal displayed on monitoring screen is not "ON"

when engine is started and attachment control pedal is depressed at rear end
1. Turn starting switch to OFF position.
2. Disconnect connector P15 and connect "short connector" to male side.
3. Turn starting switch to ON position.
a After finishing troubleshooting, return connectors as they were.

Defective PPC pressure switch
2 (P15) for rear end of attachment
control pedal
If "Service" operation signal displayed on monitoring screen changes to "ON",
rear service PPC pressure switch (P15) is defective (Note 1).
B. If "Service" operation signal displayed on monitoring screen is ON" when
starting switch is turned to ON position
1. Turn starting switch to OFF position.
2. Disconnect connector P15.
3. Turn starting switch to ON position.

If "Service" operation signal displayed on monitoring screen changes to

"OFF", rear service PPC pressure switch (P15) is defective (Note 2).
1.
Turn starting switch to OFF position.
2.
Insert T-adapters into P13.
3.
Start engine.
4.
Operate attachment control pedal, and perform troubleshooting.
Defective wiring harness or pump
3 attachment control pedal:
controller Between P13 (1) and (2) Voltage Approx. 7 V
Neutral
attachment control pedal:
Between P13 (1) and (2) front end or rear end Voltage Max. 1 V
depressed

40-492 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-36 "SERVICE" indicator is not displayed properly with monitoring function

Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
5
(contact with ground circuit)
6 Short circuit in wiring harness
7 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connectors C01, P14, and P15, and connect T-adapters to
each female side.
Between C01 (female) (52) and P14 (female) (1) Resistance Max. 1 z
Between C01 (female) (52) and P15 (female) (1) Resistance Max. 1 z
Between P14 (female) (2) and ground (T06) Resistance Max. 1 z
Between P15 (female) (2) and ground (T06) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors C01, P14, and P15, and connect T-adapters to
either female side.
Between ground and C01 (female) (52), P14
Resistance Min. 1 Mz
(female) (1) or P15 (female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connectors P14 and P15, and connect T-adapters to either
female side.
3. Turn starting switch to ON position.
Between P14 (female) (1) and ground, or between
Voltage Approx. 7 V
P15 (female) (1) and ground
If no failure is found by above checks, pump controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)

Note 1: If "Service" operation signal displayed on monitoring screen is "OFF" while voltage between C01 (52)
and ground is below 1 V, pump controller is defective.
Note 2: If "Service" operation signal displayed on monitoring screen is "ON" while voltage between C01 (52)
and ground is approximately 7 V, pump controller is defective.

Circuit diagram related to service pressure switch 40-493

HB205-1, HB215LC-1 40-493

(01)
Troubleshooting of electrical system (E-mode)
E-37 Attachment hydraulic circuit cannot be changed

E-37 Attachment hydraulic circuit cannot be changed 40-494

q Attachment circuit can not be changed
Failure 1) When working mode P or E is selected, crusher circuit (two-way circuit) is not selected.
2) When working mode B is selected, breaker circuit (one-way circuit) is not selected.
Related infor- q Failures (open circuit/short circuit) in attachment oil return selector solenoid are indicated by failure
mation codes [DWA2KA] and [DWA2KB].

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment oil return 2. Disconnect connector SSTC and connect T-adapters to male side.
1 selector solenoid (internal short
Between V06 (male) (1) and (2) Resistance 20 - 60 z
circuit)
Between V06 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector V06 and connect T-adapters to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between V06 (female) (1) and ground Voltage Max. 1 V

Circuit diagram related to attachment oil return selector solenoid 40-494

40-494 HB205-1, HB215LC-1

(01)
 Troubleshooting of electrical system (E-mode)
E-38 KOMTRAX system does not operate properly

E-38 KOMTRAX system does not operate properly 40-495

Failure q KOMTRAX system does not operate properly.
q Perform following troubleshooting if administrator of KOMTRAX system requests to check
whether failure is in system of machine.
Related information
q Even when KOMTRAX system is defective, no problem appears on machine.
q Perform troubleshooting on service menu screen of machine monitor.
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to ON position.
2. Display Terminal status screen.
1 Defective communication 1
Check item:
Completed
Station establishment
1. Turn starting switch to ON position.
2. Display GPS & Communication Status screen.
N ###.##.## (Latitude)
Check item:
E ###.##.## (Longitude)
2 Defective positioning by GPS Positioning
In positioning
If latitude and longitude are not displayed within 5 minutes with machine
stayed outdoor where opens clearly for sky, contact KOMTRAX service hot
line.
1. Turn starting switch to ON position.
2. Display GPS & Communication Status screen.
Check item:
Defective communication environ- Communication range 1 to 3
3 Communication
ment
If displayed communication status does not fall in communication range 1 to
3, contact KOMTRAX service hot line.

1. Turn starting switch to ON position.

2. Display GPS & Communication Status screen.
4 Defective communication 2
Check item:
0 to 60 (normally 0)
Number of message not yet sent
a Select Terminal Status from 12 Display of a Select GPS & Communication Status from 12
KOMTRAX setting in service menu of machine Display of KOMTRAX setting in service menu of
monitor. machine monitor.

HB205-1, HB215LC-1 40-495

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
System diagram of hydraulic and mechanical system

Troubleshooting of hydraulic and mechanical system (H-mode) 40-496

System diagram of hydraulic and mechanical system 40-496

40-496 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
System diagram of hydraulic and mechanical system

a This system diagram is a rough general hydraulic circuit diagram made as reference material for trouble-
shooting of the hydraulic and mechanical systems.

HB205-1, HB215LC-1 40-497

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
Information in troubleshooting table (H mode)

Information in troubleshooting table (H mode) 40-498

(Rev. 2010/03)
a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
understand that information fully.
Failure Problem on machine
Related infor-
Information related to the detected failure or troubleshooting
mation

Cause Criteria and troubleshooting procedure

2
Probable Probable causes for trou- <Contents of description>
causes and cri- ble (Given numbers are q Standard value in normal condition to judge probable
teria 3
reference numbers, which causes
do not indicate priority.) q Remarks on judgment
4

40-498 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-1 Speed or power of all work equipment and travel is low

H-1 Speed or power of all work equipment and travel is low 40-49
Failure q Speed or power of all work equipment and travel is low.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
1 Malfunction of unload valve Control lever Unload pressure
All levers in the NEUTRAL posi- 3.5 1.0 MPa
tion {36 10 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
Main relief pressure
lever
Defective adjustment or mal- 33.3 36.8 MPa
2
function of main relief valve Arm IN relief
{340 375 kg/cm2}
If normal oil pressure is not obtained by adjustment, main relief
valve may malfunction or have internal defect. Check main relief
valve directly.
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Malfunction of self-reducing Control lever Control circuit source pressure
3
pressure valve
2.84 3.43 MPa
All levers in NEUTRAL position
{29 35 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
Possible low speed and full speed.
causes and cri- PC-EPC valve out-
teria Engine Control lever
Malfunction of PC-EPC put pressure
4 2.9 MPa
valve Low speed
All levers in the NEU- {30 kg/cm2}
TRAL position 0.52 0.91 MPa
Full speed
{5.3 9.3 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Measured oil pres- Measurement condi-
Oil pressure ratio
sure tion
Defective adjustment or mal- Pump delivery pres-
5 Swing lock switch: 1
function of PC valve sure
ON
PC valve output pres- Approx. 0.6 (Approx.
Arm IN relief
sure 3/5)
If normal oil pressure is not obtained after adjustment, PC valve
may malfunction or have internal defect. Check PC valve directly.
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
LS-EPC valve output
Travel speed Travel lever
pressure
6 Malfunction of LS-EPC valve Approx. 2.9 MPa
Lo NEUTRAL
{30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}

HB205-1, HB215LC-1 40-499

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-1 Speed or power of all work equipment and travel is low

Cause Criteria and troubleshooting procedure

Defective adjustment or mal-
Probable 7 way)
function of LS valve
causes and cri-
teria
8 Malfunction of servo piston
9 Defective piston pump
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Operation of levers and oil pressure ratio
Measured oil pres- Run the track idle
sure All levers in the NEU-
(Lever operated half-
TRAL position
Pump delivery pres-
1
sure Almost same pres-
PC valve output pres- sure Approx. 0.6 (Approx.
sure 3/5)
If normal oil pressure is not obtained by adjustment, the LS valve
may malfunction or have internal defect. Check LS valve directly.
Servo piston may malfunction. Check it directly.
Piston pump may have performance deterioration, malfunction or
internal defect.

40-500 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-2 Engine speed lowers significantly or engine stalls

H-2 Engine speed lowers significantly or engine stalls 40-501

Failure q Engine speed lowers significantly or engine stalls.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
Main relief pressure
lever
Defective adjustment or mal- 33.3 36.8 MPa
1
function of main relief valve Arm IN relief
{340 375 kg/cm2}
If normal oil pressure is not obtained by adjustment, main relief
valve may malfunction or have internal defect. Check main relief
valve directly.
a Be ready with engine stopped, then troubleshoot with engine at
low speed and full speed.
PC-EPC valve out-
Engine Control lever
Malfunction of PC-EPC put pressure
2 2.9 MPa
valve Low speed
All levers in the NEU- {30 kg/cm2}
TRAL position 0.52 0.91 MPa
Full speed
{5.3 9.3 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Possible Measured oil pres- Measurement condi-
Oil pressure ratio
causes and cri- sure tion
teria Defective adjustment or mal- Pump delivery pres-
3 Swing lock switch: 1
function of PC valve sure
ON
PC valve output pres- Approx. 0.6 (Approx.
Arm IN relief
sure 3/5)
If normal oil pressure is not obtained after adjustment, PC valve
may malfunction or have internal defect. Check PC valve directly.
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Operation of levers and oil pressure ratio
Measured oil pres- Run the track idle
sure All levers in the NEU-
(Lever operated half-
Defective adjustment or mal- TRAL position
4 way)
function of LS valve Pump delivery pres-
1
sure Almost same pres-
PC valve output pres- sure Approx. 0.6 (Approx.
sure 3/5)
If normal oil pressure is not obtained by adjustment, the LS valve
may malfunction or have internal defect. Check LS valve directly.
Clogging of orifice or filter in Orifices or filters in pump servo devices may be clogged. Check
5
serve device them directly.
6 Malfunction of servo piston Servo piston may malfunction. Check it directly.

HB205-1, HB215LC-1 40-501

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-3 All work equipment and travel systems do not work

H-3 All work equipment and travel systems do not work 40-502
Failure q All work equipment and travel systems do not work.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
PPC lock solenoid valve
Lock lever
Malfunction of PPC lock output pressure
1 0 MPa
solenoid valve LOCK
{0 kg/cm2}
2.9 MPa
FREE
{30 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
Possible full speed.
causes and cri- Malfunction of self-pressure Control lever Control circuit source pressure
2
teria reducing valve
All levers in the NEUTRAL posi- 2.84 3.43 MPa
tion {29 35 kg/cm2}
Piston pump may malfunction or have internal defect. Check it by
following method.
1) Remove plugs from pump delivery pressure pickup ports (F and
3 Defective piston pump R).
2) Crank engine at flywheel (manually).
3) If the oil flows out of the pump delivery pressure pickup ports, it
is normal.
Pump shaft may not revolve because of internal defect of damper.
4 Defective damper
Check damper directly.

H-4 Unusual noise comes out from around hydraulic pump 40-502
Failure q Unusual noise comes out from around hydraulic pump.
Related infor-
mation

Cause Criteria and troubleshooting procedure

Lowering of hydraulic oil
1 Hydraulic oil level may be low. Check it directly.
level
Possible 2 Defective hydraulic oil Air may be mixed in hydraulic oil. Check oil directly.
causes and cri- Clogging of hydraulic tank Negative pressure may be generated in hydraulic tank because of
teria 3
cap clogged hydraulic tank cap. Check cap directly.
Clogging of hydraulic tank Negative pressure may be generated in suction circuit because of
4
strainer clogged hydraulic tank strainer. Check strainer directly.
5 Defective piston pump Piston pump may have internal defect. Check it directly.

40-502 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-5 Auto-decelerator does not operate

H-5 Auto-decelerator does not operate 40-503

Failure q Auto-decelerator does not operate.
q Perform this troubleshooting if auto-decelerator does not operate while travel lever is operated.
Related infor- Shuttle valve (in PPC valve) is installed between PPC valve and oil pressure switch of only in travel
mation circuit.
q Perform all troubleshooting in power mode (P) of working mode.

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Possible
Travel lever PPC valve output pressure
causes and cri- Malfunction of travel PPC
teria 1 0 MPa
valve (shuttle valve) NEUTRAL
{0 kg/cm2}
FORWARD 2.84 3.43 MPa
REVERSE {29 35 kg/cm2}

H-6 Fine control performance or response is low 40-503

Failure q Fine control performance or response is low.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
LS-EPC valve
Travel speed Travel lever
output pressure
1 Malfunction of LS-EPC valve Approx. 2.9 MPa
Lo NEUTRAL
{Approx. 30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}
Orifice of LS circuit (pump piping control valve) may be
2 Clogging of LS circuit orifice
clogged. Check it directly.
Possible
a Be ready with engine stopped, then troubleshoot with engine at
causes and cri-
full speed.
teria
Operation of levers and oil pressure ratio
Measured oil pres- Run the track idle
sure All levers in the NEU-
(Lever operated half-
Defective adjustment or mal- TRAL position
3 way)
function of LS valve Pump delivery pres-
1
sure Almost same pres-
PC valve output pres- sure Approx. 0.6 (Approx.
sure 3/5)
If normal oil pressure is not obtained by adjustment, the LS valve
may malfunction or have internal defect. Check LS valve directly.
4 Malfunction of servo piston Servo piston may malfunction. Check it directly.

HB205-1, HB215LC-1 40-503

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Speed or power of boom is low

H-7 Speed or power of boom is low 40-504

Failure q Speed or power of boom is low.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Right work equipment control
PPC valve output pressure
Malfunction of right PPC lever
1 0 MPa
valve (boom circuit) NEUTRAL
{0 kg/cm2}
Boom RAISE 2.84 3.43 MPa
Boom LOWER {29 35 kg/cm2}
Malfunction of merge-divider
2 Merge-divider main EPC valve may malfunction. Check it directly.
main EPC valve
Malfunction of merge-divider
3 Merge-divider LS-EPC valve may malfunction. Check it directly.
LS-EPC valve
Malfunction of merge-divider
4 Merge-divider main valve may malfunction. Check it directly.
main valve
Malfunction of merge-divider
5 Merge-divider LS valve may malfunction. Check it directly.
LS valve
Malfunction of boom control
6 Spool of boom control valve may malfunction. Check it directly.
valve (spool)
Possible Malfunction of boom control
Pressure compensation valve of boom control valve may malfunc-
causes and cri- 7 valve (pressure compensa-
tion. Check it directly.
teria tion valve)
Malfunction of boom control Regeneration valve of boom control valve may malfunction. Check
8
valve (regeneration valve) it directly.
Malfunction of boom control Lock valve of boom control valve may malfunction. Check it
9
valve (lock valve) directly.
Malfunction or defective
Safety valve for lock valve may malfunction or sealing may be
10 sealing of safety valve for
defective. Check it directly.
lock valve
Malfunction or defective
Suction valve of boom control valve may malfunction or sealing
11 sealing of boom control
may be defective. Check it directly.
valve (suction valve)
Malfunction or defective
Safety-suction valve of boom control valve may malfunction or
12 sealing of boom control
sealing may be defective. Check it directly.
valve (safety-suction valve)
Malfunction of each control LS shuttle valve of left travel control valve, bucket control valve, or
13
valve (LS shuttle valve) service control valve may malfunction. Check it directly.
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
14 Defective boom cylinder Right work equipment control
Leakage from boom cylinder
lever
Boom RAISE relief 20 cc/min

40-504 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-8 Speed or power of arm is low

H-8 Speed or power of arm is low 40-505

Failure q Speed or power of arm is low.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
PPC valve output pressure
Malfunction of left PPC valve lever
1 0 MPa
(arm circuit) NEUTRAL
{0 kg/cm2}
Arm IN 2.84 3.43 MPa
Arm OUT {29 35 kg/cm2}
Malfunction of merge-divider
2 Merge-divider main EPC valve may malfunction. Check it directly.
main EPC valve
Malfunction of merge-divider
3 Merge-divider LS-EPC valve may malfunction. Check it directly.
LS-EPC valve
Malfunction of merge-divider
4 Merge-divider main valve may malfunction. Check it directly.
main valve
Malfunction of merge-divider
5 Merge-divider LS valve may malfunction. Check it directly.
LS valve
Malfunction of arm control
6 Spool of arm control valve may malfunction. Check it directly.
valve (spool)
Malfunction of arm control
Possible Pressure compensation valve of arm control valve may malfunc-
7 valve (pressure compensa-
causes and cri- tion. Check it directly.
tion valve)
teria Malfunction of arm control Regeneration valve of arm control valve may have malfunction.
8
valve (regeneration valve) Check it directly.
Malfunction of arm control Quick return valve of arm control valve may have malfunction.
9
valve (quick return valve) Check it directly.
Malfunction or defective
Safety valve for lock valve may malfunction or sealing may be
10 sealing of safety valve for
defective. Check it directly.
lock valve
Malfunction or defective
Suction valve of arm control valve may malfunction. Check it
11 sealing of arm control valve
directly.
(suction valve)
Malfunction or defective
Safety-suction valve of arm control valve may malfunction or seal-
12 sealing of arm control valve
ing may be deflective. Check it directly.
(safety-suction valve)
LS shuttle valve of right travel control valve, boom control valve,
Malfunction of each control
13 left travel control valve, bucket control valve, or service control
valve (LS shuttle valve)
valve may malfunction. Check it directly.
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
14 Defective arm cylinder Left work equipment control
Leakage from arm cylinder
lever
Arm IN relief 20 cc/min

HB205-1, HB215LC-1 40-505

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-9 Speed or power of bucket is low

H-9 Speed or power of bucket is low 40-506

Failure q Speed or power of bucket is low.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

Malfunction of right PPC
1 0 MPa
valve (bucket circuit)
Malfunction of bucket control
2 Spool of bucket control valve may malfunction. Check it directly.
Possible valve (spool)
causes and cri- Malfunction of bucket control
teria 3 valve (pressure compensa-
tion valve)
Malfunction or defective
4 sealing of bucket control
valve (safety-suction valve)
Malfunction of service con-
5
trol valve (LS shuttle valve)
6 Defective bucket cylinder
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Right work equipment control
PPC valve output pressure
lever
NEUTRAL
{0 kg/cm2}
Bucket CURL 2.84 3.43 MPa
Bucket DUMP {29 35 kg/cm2}
Pressure compensation valve of bucket control valve may malfunc-
tion. Check it directly.
Safety-suction valve of bucket control valve may malfunction or
sealing may be defective. Check it directly.
LS shuttle valve of service control valve may malfunction.
Check it directly.
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Right work equipment control Leakage amount from bucket
lever cylinder
Bucket CURL relief 20 cc/min

H-10 Work equipment does not move in its single operation 40-506
(1) Boom does not move independently.
Failure (2) Arm does not move independently.
(3) Bucket does not move independently.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Work equipment control lever PPC valve output pressure
Possible
causes and cri- 1 Malfunction of PPC valve 0 MPa
NEUTRAL
teria {0 kg/cm2}
2.84 3.43 MPa
Operated
{29 35 kg/cm2}
Malfunction of control valve
2 Spool of control valve may malfunction. Check it directly.
(spool)

40-506 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-11 Hydraulic drift of work equipment is large

H-11 Hydraulic drift of work equipment is large 40-507

Failure (1) Hydraulic drift of boom is large.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
1 Defective boom cylinder Right work equipment control
Possible Leakage from boom cylinder
lever
causes and cri-
teria Boom RAISE relief 20 cc/min
Defective seal of boom con- Sealing of the lock valve of the boom control valve may be defec-
2
trol valve (lock valve) tive. Check it directly.
Defective seal of safety Seal of safety valve for lock valve may be defective. Check it
3
valve for lock valve directly.

Failure (2) Hydraulic drift of arm is large.

Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
1 Defective arm cylinder Left work equipment control
Leakage from arm cylinder
lever
Arm IN relief 20 cc/min
Defective seal of arm con-
2 Seal of arm control valve spool may be defective. Check it directly.
Possible trol valve (spool)
causes and cri- Defective seal of arm con-
Seal of pressure compensation valve of arm control valve may be
teria 3 trol valve (pressure compen-
defective. Check it directly.
sation valve)
Seal of suction valve of arm control valve may be defective. Check
it directly.
Defective seal of arm con-
4 * Judgment can be made by checking a change of phenomenon
trol valve (suction valve)
after exchanging suction valve with one for other than the arm con-
trol valve.
Defective seal of safety Seal of safety valve for lock valve may be defective. Check it
5
valve for lock valve directly.

HB205-1, HB215LC-1 40-507

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-11 Hydraulic drift of work equipment is large

Failure (3) Hydraulic drift of bucket is large.

Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

1 Defective bucket cylinder
Possible Defective seal of bucket con-
2
causes and cri- trol valve (spool)
teria Defective seal of bucket con-
3 trol valve (pressure compen-
sation valve)
Defective seal of bucket con- Check it directly.
4 trol valve (safety-suction
valve)
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
Leakage from bucket cylinder
lever
Bucket CURL relief 20 cc/min
Seal of bucket control valve spool may be defective. Check it
directly.
Seal of pressure compensation valve of bucket control valve may
be defective. Check it directly.
Seal of safety-suction valve of bucket control valve may defective.
* Judgment can be made by checking a change of phenomenon
after exchanging safety-suction valves of control valves on the
head side and on the bottom side.

40-508 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-12 Time lag of work equipment is large

H-12 Time lag of work equipment is large 40-509

Failure q Time lag of work equipment is large.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
LS-EPC valve
Travel speed Travel lever
output pressure
1 Malfunction of LS-EPC valve Approx.2.9 MPa
Lo NEUTRAL
{Approx. 30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}
Possible Malfunction of control valve
Regeneration valve of control valve may malfunction. Check it
causes and cri- 2 (regeneration valve) [Boom
directly.
teria and arm only]
Safety-suction valve of control valve may malfunction. Check it
directly.
* Judgment can be made by checking a change of phenomenon
Malfunction of control valve
3 after exchanging safety-suction valves of control valves with those
(safety-suction valve)
on a normal control valve.
(However, only the valves for the boom head circuit have a differ-
ent set pressure.)
Malfunction of control valve
Pressure compensation valve of control valve may malfunction.
4 (pressure compensation
Check it directly.
valve)

H-13 When part of work equipment is relieved singly, other parts of work
equipment move 40-509
Failure q When part of work equipment is relieved singly, other parts of work equipment move.
Related infor-
mation

Cause Criteria and troubleshooting procedure

Possible
causes and cri- Defective seal of control
Seal of pressure compensation valve of control valve on moving
teria 1 valve (pressure compensa-
side may be defective. Check it directly.
tion valve) on moving side

HB205-1, HB215LC-1 40-509

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-14 Power maximizing function does not work

H-14 Power maximizing function does not work 40-510

Failure q Power maximizing function does not work.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
2-stage relief solenoid valve
Possible Swing lock switch
Malfunction of 2-stage relief output pressure
causes and cri- 1 0 MPa
solenoid valve OFF
teria {0 kg/cm2}
2.9 MPa
ON
{30 kg/cm2}
Malfunction of main relief
2 The main relief valve may malfunction. Check it directly.
valve

H-15 In combined operation of work equipment, speed of part loaded

more is low 40-510
Failure q Work equipment loaded more is slower during combined operation
Related infor-
mation

Cause Criteria and troubleshooting procedure

Pressure compensation valve of control valve on smaller load side
may malfunction. Check it directly.
Combination of com-
Larger load side Smaller load side
bined operation
Boom RAISE
+ Boom RAISE Arm IN
Arm IN
Possible Boom RAISE
causes and cri- Malfunction of control valve + Arm OUT Boom RAISE
teria 1 (pressure compensation Arm OUT
valve) on smaller load side Boom RAISE
+ Boom RAISE Bucket CURL
Bucket CURL
Arm OUT
+ Arm OUT Bucket CURL
Bucket CURL
Boom LOWER
+ Arm OUT Boom LOWER
Arm OUT

H-16 When machine swings and travels simultaneously, travel speed is

low 40-510
Failure q When machine swings and travels simultaneously, travel speed is low.
Related infor- q If speed of single travel operation is also low, carry out troubleshooting for "H-18 Travel speed is
mation low" first.

Possible Cause Criteria and troubleshooting procedure

causes and cri- Malfunction of each control LS shuttle valve of left travel control valve or swing control valve
teria 1
valve (LS shuttle valve) may malfunction. Check it directly.

40-510 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-17 Machine deviates during travel

H-17 Machine deviates during travel 40-51

Failure q Machine deviates during travel.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Travel lever PPC valve output pressure
Malfunction of travel PPC
1 0 MPa
valve NEUTRAL
{0 kg/cm2}
FORWARD 2.84 3.43 MPa
REVERSE {29 35 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Malfunction of self-pressure Control lever Control circuit source pressure
2
reducing valve
All levers in the NEUTRAL posi- 2.84 3.43 MPa
tion {29 35 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Operation of levers and oil pressure ratio
Measured oil pres- Run the track off
sure All levers in the NEU- ground.
Defective adjustment or mal- TRAL position (Lever operated half-
3 way)
function of LS valve
Possible Pump delivery pres-
1
causes and cri- sure Almost same pres-
teria PC valve output pres- sure Approx. 0.6 (Approx.
sure 3/5)
If normal oil pressure is not obtained by adjustment, the LS valve
may malfunction or have internal defect. Check LS valve directly.
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Travel junction solenoid valve
Travel lever
Malfunction of travel junc- output pressure
4 Both sides in the NEUTRAL 0 MPa
tion solenoid valve
position {0 kg/cm2}
2.9 MPa
Either side operated
{30 kg/cm2}
Malfunction of travel junc-
5 Travel junction valve may malfunction. Check it directly.
tion valve
Malfunction of travel control
6 Spool of travel control valve may malfunction. Check it directly.
valve (spool)
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
7 Defective travel motor Travel lever Leakage from travel motor
Travel relief 27.2 l/min
Final drive may have internal defect. Check it directly.
8 Defective final drive * The defect can be judged by unusual noise, abnormal heat, metal
chips in drained oil, etc.

HB205-1, HB215LC-1 40-511

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-18 Travel speed is low

H-18 Travel speed is low 40-512

Failure q Travel speed is low.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Travel lever PPC valve output pressure
Malfunction of travel PPC
1 0 MPa
valve NEUTRAL
{0 kg/cm2}
FORWARD 2.84 3.43 MPa
REVERSE {29 35 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Malfunction of self-pressure Control lever Control circuit source pressure
2
reducing valve
All levers in the NEUTRAL posi- 2.84 3.43 MPa
tion {29 35 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Measured oil pres- LS-EPC valve
Travel lever
sure output pressure
Possible 3 Malfunction of LS-EPC valve Approx. 2.9 MPa
causes and cri- Lo NEUTRAL
teria {Approx. 30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}
Malfunction of travel control
4 Spool of travel control valve may malfunction. Check it directly.
valve (spool)
Malfunction of travel control
Pressure compensation valve of control valve may malfunction.
5 valve (pressure compensa-
Check it directly.
tion valve)
Malfunction of travel control
6 Suction valve of control valve may malfunction. Check it directly.
valve (suction valve)
Malfunction of bucket control LS shuttle valve of bucket control valve may malfunction.
7
valve (LS shuttle valve) Check it directly.
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
8 Defective travel motor Travel lever Leakage from travel motor
Travel relief 27.2 l/min
Final drive may have internal defect. Check it directly.
9 Defective final drive * The defect can be judged by unusual noise, abnormal heat, metal
chips in drained oil, etc.

40-512 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-19 Machine is not steered well or sterring power is low

H-19 Machine is not steered well or sterring power is low 40-513

Failure q Machine is not steered well or steering power is low.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
PPC valve output pressure
Travel lever
Malfunction of travel PPC (steering)
1 Both sides in the NEUTRAL 0 MPa
valve (steering spool)
position {0 kg/cm2}
2.84 3.43 MPa
Either side operated
{29 35 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Travel junction solenoid valve
Travel lever
Malfunction of travel junc- output pressure
2 Both sides in the NEUTRAL 0 MPa
tion solenoid valve
position {0 kg/cm2}
2.9 MPa
Either side operated
{30 kg/cm2}
Malfunction of travel junc-
3 Travel junction valve may malfunction. Check it directly.
tion valve
Malfunction of merge-divider
4 Merge-divider main EPC valve may malfunction. Check it directly.
main EPC valve
Malfunction of merge-divider
5 Merge-divider LS-EPC valve may malfunction. Check it directly.
Possible LS-EPC valve
causes and cri- Malfunction of merge-divider
6 Merge-divider main valve may malfunction. Check it directly.
teria main valve
Malfunction of merge-divider
7 Merge-divider LS valve may malfunction. Check it directly.
LS valve
Malfunction of travel control
8 Spool of travel control valve may malfunction. Check it directly.
valve (spool)
Malfunction of travel control
Pressure compensation valve of travel control valve may malfunc-
9 valve (pressure compensa-
tion. Check it directly.
tion valve)
Malfunction of travel control Suction valve of travel control valve may malfunction. Check it
10
valve (suction valve) directly.
Malfunction of bucket control LS shuttle valve of bucket control valve may malfunction. Check it
11
valve (LS shuttle valve) directly.
Defective seal of check valve
Seal of check valve of LS pressure sensing part (control valve
12 of LS pressure sensing part
side) may be defective. Check it directly.
(control valve side)
Seal of safety valve of travel motor may be defective. Check it
directly.
Defective seal of travel
13 * Judgment can be made by checking a change of phenomenon
motor (safety valve)
after exchanging safety valves between forward and reverse circuit
of the same motor or between right and left motor circuits.
Seal of check valve of travel motor may be defective. Check it
directly.
Defective seal of travel
14 * Judgment can be made by checking a change of phenomenon
motor (check valve)
after exchanging check valves between forward and reverse circuit
of the same motor or between right and left motor circuits.

HB205-1, HB215LC-1 40-513

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-20 Travel speed does not shift or travel speed is low or high

H-20 Travel speed does not shift or travel speed is low or high 40-514
Failure q Travel speed does not change or travel speed is too low or high
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

a Troubleshoot with engine at full speed (with monitoring func-
tion).
Monitoring
Travel speed Travel lever
code: 01500
663 mA
Lo
(See *)
Mi Operated 424 mA
Hi 0 mA
1 Malfunction of LS-EPC valve
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
LS-EPC valve
Travel speed Travel lever
Possible output pressure
causes and cri- Approx. 2.9 MPa
Lo NEUTRAL
teria {Approx. 30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Travel speed shifting
Travel speed Travel lever solenoid valve output
Malfunction of travel speed pressure
2
shifting solenoid valve 0 MPa
Lo NEUTRAL
{0 kg/cm2}
Approx. 2.9 MPa
Hi Operated
{Approx. 30 kg/cm2}
Malfunction of travel motor Speed shifting section of travel motor may malfunction. Check it
3
(speed shifting section) directly.
*: Travel speed Lo can be adjusted with the adjusting function of the machine monitor. Accordingly, if the initial
value has been changed, the measured value varies more or less.

40-514 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-21 Travel system does not work (only one side)

H-21 Travel system does not work (only one side) 40-515
Failure q Travel system does not work (only one side).
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

Cause Criteria and troubleshooting procedure

Defective seal of travel con- Seal of suction valve of travel motor may malfunction. Check it
1
trol valve (suction valve) directly.
Seal of safety valve of travel motor may malfunction. Check it
directly.
Defective seal of travel
2 * Judgment can be made by checking a change of phenomenon
motor (safety valve)
after exchanging safety valves between forward and reverse circuit
of the same motor or between right and left motor circuits.
Seal of check valve of travel motor may malfunction. Check it
directly.
Possible Defective seal of travel
3 * Judgment can be made by checking a change of phenomenon
causes and cri- motor (check valve)
after exchanging check valves between forward and reverse circuit
teria of the same motor or between right and left motor circuits.
Malfunction of travel motor
4 Parking brake of travel motor may malfunction. Check it directly.
(parking brake)
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
5 Defective travel motor Travel lever Leakage from travel motor
Travel system relief 27.2 l/min
Final drive may have internal defect. Check it directly.
6 Defective final drive * The defect can be judged by unusual noise, abnormal heat, metal
chips in drained oil, etc.

HB205-1, HB215LC-1 40-515

(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-22 Upper structure does not swing

H-22 Upper structure does not swing 40-516

Failure (1) Upper structure does not swing in both right and left directions.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.

Failure (2) Upper structure does not swing in only one direction.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to the hybrid system.

H-23 Swing acceleration or swing speed of upper structure is low 40-516

Failure (1) Swing acceleration performance is poor or swing speed is slow in both right and left directions.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to the hybrid system.

Failure (2) Swing acceleration performance is poor or swing speed is slow in only one direction.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.

H-24 Upper structure overruns remarkably when it stops swinging 40-516

Failure (1) Upper structure overruns excessively when it stops swinging in both right and left directions.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to the hybrid system.

Failure (2) Upper structure overruns excessively when it stops swinging in only one direction.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.

40-516 HB205-1, HB215LC-1

(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-25 Large shock is made when upper structure stops swinging

H-25 Large shock is made when upper structure stops swinging 40-517
Failure q Large shock is made when upper structure stops swinging
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.

H-26 Large sound is made when upper structure stops swinging 40-517
Failure q Large sound is made when upper structure stops swinging
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation

See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.

H-27 Upper structure lowers largely by its own weight 40-517

Failure (1) Upper structure lowers largely by its own weight (when parking brake is applied)
q When swing lock switch is turned to ON position or when swing brake cancel switch is set to normal
Related infor- position, swing holding brake is applied and swinging motion of upper structure is stopped with disc
mation brake.
q Perform all troubleshooting in power mode (P) of working mode.

See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.

Failure (2) Upper structure lowers largely by its own weight (when parking brake is released).
q When swing brake cancel switch is set to RELEASE position, swing holding brake is released and
Related infor- swinging motion of upper structure is held with swing electric motor. (However, this applies only
mation while hybrid system is operating normally)
q Perform all troubleshooting in power mode (P) of working mode.

See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.

HB205-1, HB215LC-1 40-517

(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

Troubleshooting of engine (S-mode) 40-518

Method of using troubleshooting chart 40-518

The troubleshooting chart consists of the "Ques-

tions", "Check items", "Causes", and "Troubleshoot-
ing" blocks.
The Questions and Check items are used to narrow
down high probability causes by simple inspection
or from symptoms without using troubleshooting
tools.
Next, use troubleshooting tools or perform direct in-
spection to check the selected Causes in the order
of probability to determine the real cause according
to the troubleshooting procedure.
Questions:
Questions placed in the sections A and B in the
table on the right are those to be answered by
the customer or operator.
Questions in section A are for basic information
about the failure. Depth and accuracy of their an-
swers to the questions in section B may depend
on their concerns on the machine condition.
Check items:
Check items placed in the section C in the table
on the right are to be simply checked by the tech-
nician to select highly probable causes.
Causes:
Various causes are listed is this block.
The technician will be able to narrows down the
probable causes by taking the actions listed in
the blocks A, B, and C.
Troubleshooting:
This section includes various items of trouble-
shooting that are performed in order to verify the
results of the diagnosis made by asking the
questions and inspecting the machine. The trou-
bleshooting is performed in order from the most
probable one by applying troubleshooting tools
or direct inspection.

40-518 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: Reference information for estimation of the cause
Q: Information and inspection result that indicate the cause of the failure
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w > Q when determining the cause.
Don't count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.

HB205-1, HB215LC-1 40-519

(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

<Example of troubleshooting> Exhaust gas is black (Incomplete combustion) 40-520

Let us assume that a trouble of Exhaust gas is black occurred and we checked the [Questions] and [Check
items] and found the following 3 items to be the causal symptoms; [Color of exhaust gas gradually became
black], [Power was lost gradually], and [Dust indicator indicates a red zone].

40-520 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 Step 3 shown below.

HB205-1, HB215LC-1 40-521

(01)
Troubleshooting of engine (S-mode)
S-1 Engine startability is poor

S-1 Engine startability is poor 40-52

General causes why startability is poor Causes

Leakage or clogging of fuel piping or air in the fuel piping

q Defective electrical system

q Insufficient supply of fuel

q Insufficient intake of air

Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat

Defective alternator (generator section)

Defective alternator (regulator section)
q Improper selection of fuel

Stuck or seized supply pump plunger

Defective intake air heater system

a Common rail fuel injection system (CRI) controls the fuel injection timing

Defective or deteriorated battery

electrically. Therefore, there are cases where the engine does not start

Clogged air cleaner element

Worn piston ring or cylinder

before the crankshaft makes two revolutions maximum after starting op-

Clogged fuel filter element

eration. This is not an abnormal state, however.

Defective injector
Check recent repair history
Degree of use
Operated for long period E E E
of machine
It becomes worse gradually Q w w Q
Questions

Startability:
Engine starts easily when warm w w
Fuel other than specified one is used Q Q Q
Filters are not replaced as indicated in the Operation and Maintenance w w Q Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating w
During operation, charge level monitor indicates abnormal charge w w
Dust indicator indicates a red zone w
Air breather hole in fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
No response or heavy resistance is felt when operating the priming w Q
Starting motor rotates engine slowly w
Even if air bleeding plug of fuel filter head is removed,
w
While engine is fuel does not flow out
cranked: If spill hose from injector is disconnected, little fuel
Check items

w
spills
When exhaust manifold is touched immediately after starting engine,
w
temperature of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
Engine hunts Q w Q
Blowby gas is excessive w
Inspect air cleaner directly q
When compression pressure is measured, it is found to be low q q
When air bleeding operation for fuel system is performed, air comes q
Troubleshooting

Inspect fuel filter or strainer directly q

Perform troubleshooting for "Supply pump pressure low error accord- q
When a certain cylinder is cut out, engine speed does not change q
During pre-heating operation, intake air heater mount is cold q
Does voltage (20 to 30 V) appear between alternator termi- Yes q
nals B and E with engine at low idle? None q
Specific gravity of electrolyte and voltage of battery are low q
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean

Clean

Clean

Remedy

*1: Displayed failure codes [CA559] and [CA2249]

40-522 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
S-2 Engine does not start

S-2 Engine does not start 40-523

a) Engine does not crank Causes

Defective starting motor (motor section)

General causes why engine does not crank

Defective connection of battery cable

q Internal parts of engine seized

Defective or deteriorated battery

oSee "S-4 Engine stops during operations"

Defective starting circuit wiring

q

Broken flywheel ring gear

Defective electrical system

Defective hydraulic pump

Defective starting switch
Defective battery relay

Defective safety relay

q Problem in drive devices on installed machine side
oPerform troubleshooting for devices on installed machine

Check recent repair history

Degree of use of
Questions

Operated for long period E E

machine
Condition of horn when Horn does not sound Q Q w
starting switch is turned
Horn volume is low w
ON
Battery electrolyte level is low w
Battery cable terminal is loose w
Starting switch is turned ON, but no battery relay operating sound is heard Q w
Starting switch is turned to START, but pinion does not plunge Q Q w
Check items

When starting switch is Speed of rotation is low w

turned to START, start- Unusual noise is heard w w
ing pinion moves out, Pinion disengages soon w
but: Unusual noise is heard and engine does not rotate Q Q Q Q
Inspect flywheel ring gear directly q

Perform troubleshooting in H-mode

Perform troubleshooting in E-mode
Specific gravity of electrolyte and voltage of battery are low q
Voltage (20 to 30 V) between battery relay terminal B and
q
terminal E is not found
Troubleshooting

When terminal B and terminal C of starting switch are

q
Turn starting switch connected, engine starts
OFF, connect cable, When terminal B at safety relay outlet and terminal C are
q
and perform trouble- connected, engine starts
shooting with starting Even if terminal B at safety relay outlet and terminal C q
switch at ON are connected, engine does not start
When terminal at safety switch and terminal B at starting
q
motor are connected, engine starts
Replace
Replace

Replace
Replace
Replace
Replace
Correct

Rem-

edy

HB205-1, HB215LC-1 40-523

(01)
Troubleshooting of engine (S-mode)
S-2 Engine does not start

b) Engine cranks but no exhaust smoke comes out Causes

Leakage or clogging of fuel piping or air in the fuel piping

General causes why engine cranks but no exhaust smoke comes out

q Fuel is not being supplied.

Malfunction of overflow valve (does not close)

q Supply of fuel is extremely small.

Clogged air breather hole in fuel tank cap

Seized or prematurely worn feed pump

Defective common rail pressure limiter

q Improper selection of fuel (particularly in winter)

Stuck or seized supply pump plunger

Defective supply pump MPROP
Clogged fuel filter element

Broken supply pump shaft

Insufficient fuel in tank

Defective fuel injector

Use of improper fuel
Check recent repair history
Degree of use of
Questions

Operated for long period EE

machine
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w E
Filters are not replaced as indicated in the Operation and Maintenance Man-
w E Q
ual
When fuel tank is inspected, it is found to be empty w
Air breather hole in fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q E EE
When fuel filter is removed, there is no fuel in it w w
Check items

Fuel is leaking from fuel piping w

No response or heavy resistance is felt when operating the priming pump w Q
Even if air bleeding plug of fuel filter head is removed, fuel
While engine is Q Q w Q
does not flow out
cranked:
If spill hose from injector is disconnected, little fuel spills Q w w w Q
When air bleeding operation for fuel system is performed, air comes out q
Inspect fuel filter directly q
q
Troubleshooting

Inspect feed pump directly

Perform troubleshooting for "Supply pump pressure low error according to
q q
failure code (*1)
Perform troubleshooting for "Supply pump PCV error" according to failure
q
code (*2)
Inspect overflow valve directly q
Engine can be started in cylinder cutout mode q
If pressure limiter return pipe is disconnected, fuel flows out from limiter q
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Add

Remedy

*1: Displayed failure codes [CA559] and [CA2249]

*2: Displayed failure codes [CA271] and [CA272]

40-524 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
S-2 Engine does not start

c) Exhaust smoke comes out but engine does not start (Fuel is being Causes
injected)

Defective coolant temperature sensor or wiring harness

Leakage or clogging of fuel system or air in the fuel
General causes why exhaust smoke comes out but engine does not start

q Lack of cranking force due to defective electrical system

Worn valve system (valve, rocker lever, etc.)

Clogged air breather hole in fuel tank cap

q Insufficient supply of fuel

Stuck or seized supply pump plunger

Clogged injector, or defective spray

Defective intake air heater system

q Insufficient intake of air

Defective or deteriorated battery

Clogged air cleaner element
q Improper selection of fuel

Worn piston ring or cylinder

Use of improper fuel

Clogged fuel filter

Check recent repair history
Degree of use of
Operated for long period E E E
machine
w w Q
Questions

Suddenly failed to start

Fuel other than specified one is used Q Q
Filters are not replaced as indicated in the Operation and Maintenance
w w
Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating moni-
w
tor does not indicate normally
Dust indicator indicates a red zone w
Air breather hole in fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is no fuel in it w
Fuel is leaking from fuel piping w
No response or heavy resistance is felt when operating the priming pump w Q
Starting motor rotates engine slowly w
When engine is cranked, unusual noise is generated around cylinder
w
head
Check items

Even if air bleeding plug of fuel filter head is

Q w
While engine is removed, fuel does not flow out
cranked: If spill hose from injector is disconnected, little fuel
w
spills
When exhaust manifold is touched immediately after starting engine,
w
temperature of some cylinders is low
Inspect air cleaner directly q
Inspect valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

When air bleeding operation for fuel system is performed, air comes out q
Inspect fuel filter directly q
Perform troubleshooting for error "Rail Press Low" or "Rail Press Very
q
Low" (*1) indicated by failure code
Engine can be started cylinder cutout mode q
Specific gravity of electrolyte and voltage of battery are low q
Coolant temperature gauge does not indicate normally q
During pre-heating operation, intake air heater mount is cold q
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Correct
Clean

Clean

Clean

Remedy

*1: Displayed failure codes [CA559] and [CA2249]

HB205-1, HB215LC-1 40-525

(01)
Troubleshooting of engine (S-mode)
S-3 Engine does not pick up smoothly

S-3 Engine does not pick up smoothly 40-526

General causes why engine will not pick up smoothly Causes

Leakage or clogging of fuel piping or air in the fuel piping

q Insufficient intake of air

q Insufficient supply of fuel

q Defective condition of fuel injection

Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat

Seizure or interference at turbocharger

q Improper selection of fuel

Stuck or seized supply pump plunger

Clogged injector, or defective spray
q Controller is controlling engine in derate mode
(limiting injection rate (output) because of an error in electrical system)

Clogged air cleaner element

Worn piston ring or cylinder

Improper valve clearance

Clogged fuel filter

Check recent repair history
Degree of use of
EE E E
Questions

Operated for long period

machine
Engine pick-up suddenly became worse w Q Q Q
Fuel other than specified one is used w w w
Filters are not replaced as indicated in the Operation and Maintenance Manual w w
Oil must be added more frequently w
Dust indicator indicates a red zone w
Air breather hole in fuel tank cap is clogged w
Rust and water are found when fuel tank is drained w
Fuel is leaking from fuel piping w
No response or heavy resistance is felt when operating the priming pump w Q
When exhaust manifold is touched immediately after starting engine, temperature
Q w
of some cylinders is low
Color of exhaust Blue under light load w
Check items

gas Black w Q w w
When engine is cranked, unusual noise is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed is normal, but speed suddenly drops when load is applied Q w
Engine hunts Q Q Q
Blowby gas is excessive w
Inspect air cleaner directly q
When compression pressure is measured, it is found to be low q q
Troubleshooting

Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
When air bleeding operation for fuel system is performed, air comes out q
Inspect fuel filter or strainer directly q
Perform troubleshooting for "Supply pump pressure low error according to failure
q
code (*1)
When a certain cylinder is cut out, engine speed does not change q
Replace

Replace
Replace

Replace
Replace
Correct
Adjust
Clean

Clean

Clean

Remedy

*1: Displayed failure codes [CA559] and [CA2249]

40-526 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
S-4 Engine stops during operations

S-4 Engine stops during operations 40-527

General causes why engine stops during operation Causes

Broken valve system (valve, rocker arm, etc.)

q Internal parts of engine seized

Broken or seized piston or connecting rod

Clogged air breather hole in fuel tank cap

q Insufficient supply of fuel

Stuck or seized supply pump plunger

Broken or seized crankshaft bearing

Leakage or clogging of fuel piping

q Engine overheating

(pump or air compressor, etc.)

Broken or seized feed pump

Broken auxiliary equipment

Broken or seized gear train

Broken supply pump shaft

q Problem in drive devices on installed machine side

Defective hydraulic pump

oPerform troubleshooting at installed equipment side

Insufficient fuel in tank

Clogged fuel filter

Check recent repair history
Degree of use of
Operated for long period E
machine
Unusual noise was heard, it stopped suddenly w w w w Q w Q w w
Questions

Condition when Engine overheated and stopped w Q Q

engine stopped Engine stopped slowly w Q
Engine hunted, then stopped w Q Q Q
Fuel other than specified one is used Q Q Q
Filters are not replaced as indicated in the Operation and Maintenance
w
Manual
Fuel level monitor indicates low level (if monitor is installed) w
When fuel tank is inspected, it is found to be empty w
Air breather hole in fuel tank cap is clogged w
Fuel is leaking from fuel piping w
No response or heavy resistance is felt when operating the priming
w Q
pump
Rust and water are found when fuel tank is drained w
Check items

Metal particles are found when oil is drained from oil pan w w w Q
Does not turn at all w w
When engine is Turns in opposite direction only w
rotated by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine operates, but stops when load is applied to machine w
Inspect valve system directly q
Perform troubleshooting in H-mode

Inspect piston and connecting rod directly q

Inspect crankshaft bearing directly q
Inspect gear train directly q
Troubleshooting

Inspect fuel filter or strainer directly q

Inspect feed pump directly q
Perform troubleshooting for "Supply pump pressure low error accord-
q q
ing to failure code (*1)

Engine operates when auxiliary equipment (hydraulic pump, compres-

q
sor, etc.) is removed
Replace
Replace
Replace
Replace

Replace
Replace
Replace

Replace
Correct
Clean

Clean
Add

Remedy

*1: Displayed failure codes [CA559] and [CA2249]

HB205-1, HB215LC-1 40-527

(01)
Troubleshooting of engine (S-mode)
S-5 Engine does not rotate smoothly

S-5 Engine does not rotate smoothly 40-528

General causes why engine does not rotate smoothly Causes

Leakage or clogging of fuel piping or air in the fuel piping

q Air in fuel system

Clogged injector, or defective spray (dirt in injector)

q Defective engine speed sensor (error at degree that does not generate failure code)

Defective Bkup speed sensor, or wiring harness

Defective Ne speed sensor, or wiring harness
Clogged air breather hole in fuel tank cap
Insufficient fuel in tank

Clogged fuel filter

Check recent repair history
Degree of use of
Operated for long period E
Questions

machine
Occurs at a certain speed range Q Q
Occurs at low idle Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Filters are not replaced as indicated in the Operation and Maintenance Manual w
When fuel tank is inspected, it is found to be empty w
Air breather hole in fuel tank cap is clogged w
Troubleshooting Check items

Rust and water are found when fuel tank is drained Q

Fuel is leaking from fuel piping w
No response or heavy resistance is felt when operating the priming pump w Q

When air bleeding operation for fuel system is performed, air comes out q
Inspect fuel filter or strainer directly q
When a certain cylinder is cut out, engine speed does not change q
Perform troubleshooting for "Eng Ne speed sensor error" according to failure code (*1) q
Perform troubleshooting for "Eng Backup speed sensor error" according to failure code
q
(*2)
Replace
Replace
Replace
Replace
Replace
Clean
Add

Remedy

*1: Displayed failure code [CA689]

*2: Displayed failure code [CA778]

40-528 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
S-6 Engine lacks output (or lacks power)

S-6 Engine lacks output (or lacks power) 40-529

General causes why engine lacks power Causes

q Insufficient intake of air

Clogged injector, or defective spray (dirt in injector)

Defective boost pressure sensor or wiring harness

q Insufficient supply of fuel

Defective installation of boost pressure sensor

Defective injector drive (signal or solenoid)
q

Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat
Improper fuel injection

Seizure or interference at turbocharger

Stuck or seized supply pump plunger

q Improper selection of fuel

Leakage or clogging of fuel piping

Air leakage from air intake piping
q Engine overheating

Clogged air cleaner element

oSee S-14 Coolant temperature becomes too high (overheating).

Worn piston ring or cylinder

Improper valve clearance
q Controller is controlling in derate mode.

Clogged spill piping

(limiting injection rate (power) because of an error in electrical system)

Clogged fuel filter

(air leakage)
Check recent repair history
Degree of use of
Operated for long period E E E E
machine
Questions

Suddenly Q w Q Q Q Q
Power was lost
Gradually Q Q Q Q Q Q
Fuel other than specified one is used Q Q Q
Filters are not replaced as indicated in the Operation and Maintenance Manual w w
Engine oil must be added more frequently Q Q
Dust indicator indicates a red zone w w
Air breather hole in fuel tank cap is clogged w w
Fuel is leaking from fuel piping w
Output power becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine, tempera-
w w
ture of some cylinders is low
Check items

When engine is cranked, interference sound is generated around turbocharger w

When engine is cranked, Unusual noise is generated around cylinder head w
High idle speed is too high Q
High idle speed is normal, but speed suddenly drops when load is applied Q w Q Q
Engine does not pick up smoothly and combustion is irregular w w Q Q w
Engine hunts Q Q Q Q Q
Blowby gas is excessive w w

Inspect air cleaner directly q

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
When compression pressure is measured, it is found to be low q q
q
Troubleshooting

Inspect valve clearance directly

Inspect fuel piping q
Inspect fuel filter or strainer q
Inspect spill port check valve directly q
Perform troubleshooting for "Supply pump pressure low error according to
q
failure code (*1)
When a certain cylinder is cut out, engine speed does not change q q
Inspect boost pressure sensor mount directly q
Perform troubleshooting for Abnormality in boost pressure sensor " according
q
to failure code (*2)
Replace
Replace

Replace

Replace
Replace
Replace
Replace

Replace
Replace
Correct

Correct

Correct
Adjust
Clean

Clean

Remedy

*1: Displayed failure codes [CA559] and [CA2249]

*2: Displayed failure codes [CA122] and [CA123]

HB205-1, HB215LC-1 40-529

(01)
Troubleshooting of engine (S-mode)
S-7 Exhaust gas is black (incomplete combustion)

S-7 Exhaust gas is black (incomplete combustion) 40-530

General causes why exhaust gas is black Causes

Leakage of air between turbocharger and

Defective contact of valve with valve seat

Defective coolant temperature sensor or

q

Seizure or interference at turbocharger

Insufficient intake of air

Stuck or seized supply pump plunger

q Improper fuel injection

Improper fuel injection pressure

Improper fuel injection timing
Clogged air cleaner element
q Improper selection of fuel

Worn piston ring or cylinder

Crushed or clogged muffler

Clogged or seized injector

Improper valve clearance

Abnormally worn injector

q Engine overheating
oSee S-14 Coolant temperature becomes too high (overheating).

wiring harness
cylinder head
q Controller is controlling in derate mode.
(limiting injection rate (power) because of an error in electrical system)

Check recent repair history

Degree of use of
Operated for long period E E E E
machine
Suddenly becomes black w w Q Q Q
Questions

Color of exhaust
Gradually becomes black w Q Q
gas
Blue under light load w
Fuel other than specified one is used Q Q
Oil must be added more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Dust indicator indicates a red zone w
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp worked
w
loose
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine,
Q w
temperature of some cylinder is low
When engine is cranked, interference sound is generated around tur-
w
Check items

bocharger
When engine is cranked, unusual noise is generated around cylinder
w
head
Pump relief speed is high (Fuel is injected excessively) Q
Exhaust sound is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
Blowby gas is excessive w
If spill hose from injector is disconnected, abnormally much fuel spills w
Inspect air cleaner directly q
When turbocharger is rotated by hand, it is found to be heavy q
When compression pressure is measured, it is found to be low q q
Troubleshooting

Inspect valve clearance directly q

When muffler is removed, exhaust sound improves q
Perform troubleshooting for Supply pump pressure low error accord-
q q
ing to failure code (*1)
When a certain cylinder is cut out, engine speed does not change q
Perform troubleshooting for error Coolant Temp Sens High or Cool-
q
ant Temp Sens Low according to failure code (*2)
Check by using monitoring function q q
Replace
Replace

Replace
Replace
Replace
Replace
Replace

Replace
Replace
Correct
Adjust

Adjust
Clean

Rem-
edy

*1: Displayed failure codes [CA559] and [CA2249]

*2: Displayed failure codes [CA144] and [CA145]

40-530 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
S-8 Oil consumption is excessive (or exhaust gas is blue)

S-8 Oil consumption is excessive (or exhaust gas is blue) 40-531

General causes why oil consumption is excessive Causes

q Abnormal combustion of oil

q Long-time operation of engine at low idle or high idle

(Do not run engine at idle for more than 20 minutes continuously)

Turbocharger

Oil leakage from oil pan, cylinder head, etc.

Worn or damaged valve (stem, guide, seal)
q External leakage of oil

q Wear of parts in lubrication system

Clogged breather or breather hose

Dust sucked in from intake system

Worn seal on compressor side

Worn or damaged rear oil seal

Oil leakage from oil drain plug

Worn piston ring or cylinder

Oil leakage from oil cooler

Oil leakage from oil piping

Worn seal on turbine side

Oil leakage from oil filter

Broken piston ring

Broken oil cooler

Check recent repair history
Degree of use of
Questions

Operated for long period EEE E

machine
Oil consumption suddenly increased w Q
Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger outlet pipe on compressor side is dirty with oil w
Inside of turbocharger outlet pipe on turbine side is dirty with oil Q w
Check items

Oil in coolant w
Oil level in damper chamber of installed machine is high w
Exhaust gas is blue under light load w w
Amount of blowby Excessive Q Q w w
gas None w
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty abnor-
q
Troubleshooting

mally
Excessive play of turbocharger shaft q q
Check breather or breather hose directly q
When compression pressure is measured, it is found to be low q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows oil leakage q q
External leakage of oil from engine q q q q
Replace
Replace

Replace
Replace

Replace
Replace
Correct
Correct

Correct

Correct
Correct
Correct
Correct
Clean

Remedy

HB205-1, HB215LC-1 40-531

(01)
Troubleshooting of engine (S-mode)
S-9 Oil becomes contaminated quickly

S-9 Oil becomes contaminated quickly 40-532

General causes why oil becomes contaminated quickly Causes

q Entry of exhaust gas into oil due to internal wear

q Clogging of lubrication passage

Clogged turbo lubrication oil drain tube

Defective seal in turbocharger turbine
q Use of improper fuel

Clogged breather or breather hose

q Use of improper oil

Defective oil filter safety valve

Worn piston ring or cylinder
Worn valve or valve guide

Exhaust gas color is bad

q Operation under excessive load

Clogged oil cooler

Clogged oil filter
Check recent repair history
Questions

Degree of use of machine Operated for long period E E E

Fuel other than specified one is used Q Q
Engine oil must be added more frequently w
Metal particles are found when oil is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check items

Color of exhaust gas

Black w
Excessive Q Q w Q
Amount of blowby gas
None w

Excessive play of turbocharger shaft q

Troubleshooting

When compression pressure is measured, it is found to be low q q

See S-7.
Check breather or breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is stuck or broken q
Inspect turbocharger lubrication oil drain tube directly q
Replace
Replace
Replace

Replace
Replace
Clean
Clean

Clean

Remedy

40-532 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
S-10 Fuel consumption is excessive

S-10 Fuel consumption is excessive 40-53

General causes why fuel consumption is excessive Causes

Defective coolant temperature sensor or wiring harness

q Leakage of fuel

q Improper fuel injection (fuel pressure or injection timing)

q Excessive injection of fuel

Fuel leakage inside cylinder head cover

Fuel leakage from fuel filter, piping, etc.

Defective common rail pressure

Defective supply pump plunger

Defective operation of injector

Improper fuel injection timing
Defective feed pump oil seal

Defective spray by injector

Check recent repair history
Degree of use
Questions

Operated for long period EE E

of machine
More than that on other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of
w
Check items

some cylinders is low

Low idle speed is high Q
Pump relief speed is high Q
Color of exhaust Black Q Q Q Q
gas White Q
Remove and inspect cylinder head cover directly q
Inspect feed pump oil seal directly q
Troubleshooting

Perform troubleshooting for "Supply pump pressure low error according to failure
q
code (*1)
When a certain cylinder is cut out, engine speed does not change q
If spill hose from injector is disconnected, much fuel spills q
Perform troubleshooting for error "Coolant Temp Sens High" or "Coolant Temp Sens
q
Low" according to failure code (*2)
Check by using monitoring function q q
Replace
Replace

Replace
Replace
Replace
Replace
Correct
Correct

Correct

Remedy

*1: Displayed failure codes [CA559] and [CA2249]

*2: Displayed failure codes [CA144] and [CA145]

HB205-1, HB215LC-1 40-533

(01)
Troubleshooting of engine (S-mode)
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)

S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 40-534

General causes why oil is present in coolant Causes

q Internal leakage in lubrication system

Broken cylinder head or cylinder head gasket

q Internal leakage in cooling system

Internal cracks in cylinder block

Broken oil cooler core or O-ring

Holes caused by pitting
Check recent repair history
Degree of use of
Questions

Operated for long period E E

machine
Suddenly increased Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts w
Troubleshooting Check items

Hydraulic oil in installed machine is milky

When hydraulic oil is drained from installed machine, water is found

Pressure-tightness test of cylinder head shows oil leakage q

Check cylinder block and liner directly q q

Pressure-tightness test of oil cooler shows oil leakage q

Replace
Replace
Replace
Replace

Remedy

40-534 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
S-12 Oil pressure drops

S-12 Oil pressure drops 40-535

General causes why oil pressure drops Causes

Defective oil level sensor or wiring harness

Leakage, clogging, or wear on lubrication system

q Defective oil pressure control

Leaking, crushed, clogged oil piping

Clogged or broken pipe in oil pan
q Selection of oil by the temperature etc. specified in the Operation and Maintenance
Manual is not observed.

Clogged strainer in oil pan

Defective regulator valve

q Deterioration of oil due to overheating

Coolant or fuel in oil

Lack of oil in oil pan

Defective oil pump

Clogged oil filter

Worn bearing
Check recent repair history
Degree of use of
Questions

Operated for long period E E E

machine
Oil pressure monitor indicates low oil pressure Q w
Oil other than specified one is used Q Q
Filters are not replaced as indicated in the Operation and Maintenance Manual w
Indicates pressure drop at low idle w
Oil pressure
Indicates pressure drop both at low and high idle Q w w w Q
monitor
Indicates pressure drop on slopes w
(if installed)
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil level drop w w
Oil level in oil pan is low w
External lubrication piping is leaking or crushed w
Troubleshooting Check items

Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found in the oil drained from oil filter w Q
Metal particles are found in oil filter q
Inspect oil pan strainer and pipe directly q q
See S-13

Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of regulator valve are fatigued or damaged q
Inspect oil filter directly q
If oil level sensor is replaced, oil pressure monitor indicates proper oil level q
Replace

Replace
Correct
Adjust
Clean

Clean
Clean

Clean
Add

Remedy

HB205-1, HB215LC-1 40-535

(01)
Troubleshooting of engine (S-mode)
S-13 Oil level rises (coolant or fuel in oil)

S-13 Oil level rises (coolant or fuel in oil) 40-536

General causes why oil level rises Causes

Defective seal of auxiliary equipment (pump, compressor)

q Coolant in oil (milky)

q Fuel in oil (oil smells of diluted diesel fuel)

Broken cylinder head or cylinder head gasket

a If oil is in coolant, perform troubleshooting for S-11 Oil is in coolant.

Broken oil cooler core or O-ring

Worn or damaged rear oil seal
Cracks inside cylinder block

Defects in supply pump

Holes caused by pitting
Broken injector O-ring
Check recent repair history
Questions

Degree of use of
Operated for long period E EE E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
Oil in coolant QQ QQ w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bub-
w Q
Check items

bles appear, or coolant spurts

Exhaust gas is white Q
Oil level in damper chamber of installed machine is low w
Oil level in hydraulic tank of installed machine is low w
When compression pressure is measured, it is found to be low q
Troubleshooting

Remove injector and inspect O-ring q

Inspect cylinder block directly qq
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows oil leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace

Replace
Replace

Replace
Replace
Replace
Correct

Correct

Remedy

40-536 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
S-14 Coolant temperature rises too high (overheating)

S-14 Coolant temperature rises too high (overheating) 40-537

General causes why coolant temperature rises too high Causes

q Lack of cooling air (deformation or damage of fan)

Broken cylinder head or cylinder head gasket

q Drop in heat dissipation efficiency

q Problem in coolant circulation system

Defective radiator cap (pressure valve)

Defective coolant temperature gauge

Slipping fan belt or worn fan pulley
q Hydraulic oil temperature in installed machine is high

Rise in hydraulic oil temperature

Clogged or crushed radiator fins
oPerform troubleshooting on installed machine

Clogged or broken oil cooler

Malfunction of thermostat
Holes caused by pitting

Clogged radiator core

Broken water pump
Lack of coolant
Check recent repair history
Degree of use of
Operated for long period EE EE
machine
Questions

Condition of Suddenly occurred Q w Q

overheating Always tends to overheat Q w w Q
Coolant temper- Rises quickly Q w
ature gauge
Does not go down below red range w
(if installed)
Radiator coolant level monitor indicates drop of coolant level w
Engine oil level rises and oil is milky w Q
Fan belt tension is low w
When fan belt is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts w
When light bulb is held behind radiator core, no light passes through w
Check items

Radiator shroud, inside of underguard on machine are clogged with dirt or

w w
mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Hydraulic oil temperature enters red range faster than engine coolant tem-
w
perature
When compression pressure is measured, it is found to be low q
performed troubleshooting in H-mode

Inspect cylinder directly q

Inspect oil cooler directly q
Temperature difference between upper and lower tanks of radiator is large q
Troubleshooting

When operation test of thermostat is performed, it does not open at crack-

q
ing temperature
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is performed, its cracking pressure is low q
Check fan belt and pulley directly q

When coolant temperature is measured, it is found to be normal q

Replace
Replace
Replace

Replace
Replace

Replace

Replace
Correct
Correct

Correct
Add

Remedy

HB205-1, HB215LC-1 40-537

(01)
Troubleshooting of engine (S-mode)
S-15 Unusual noise is made

S-15 Unusual noise is made 40-538

General causes why unusual noise is heard Causes

Improper fuel injection timing (defect in low coolant temperature

q Abnormality due to defective parts

Deformed cooling fan, loose fan belt, interference of fan belt

Defective inside of muffler (partition board out of position)
q Abnormal combustion

Leakage of air between turbocharger and cylinder head

q Air sucked in from air intake system

a Judge if the noise is an internal noise or an external noise before starting

Broken valve system (valve or rocker arm)

troubleshooting.

Excessively worn piston ring or cylinder

Seizure or interference at turbocharger
a The engine is operated in the low-temperature mode while it is not warmed

sensor or boost temperature sensor)

up sufficiently. Accordingly, the engine sound becomes a little larger. This
does not indicate abnormality, however.

Dislocated or seized bushing

Improper gear train backlash
a When the engine is accelerated, it is operated in the acceleration mode and

Clogged or seized injector

Improper valve clearance
its sound becomes a little larger for up to approximately three seconds. This

Dirt caught in injector

does not indicate abnormality, however.

Check recent repair history

Degree of use of
Operated for long period E
Questions

machine
Condition of Gradually occurred Q Q
unusual noise Suddenly occurred Q Q Q
Fuel other than specified one is used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is heard from turbocharger w
When engine is cranked, unusual noise is generated around cylinder
w w
head
When engine is cranked, beat noise is generated around muffler w
Check items

When exhaust manifold is touched immediately after starting engine, tem-

w Q
perature of some cylinders is low
Color of exhaust Blue under light load w
gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Unusual noise is loud when engine is accelerated Q Q Q Q
Blowby gas is excessive w
When turbocharger is rotated by hand, it is found to be heavy q
Inspect valve system q
When muffler is removed, unusual noise disappears q
Troubleshooting

Inspect valve clearance directly q

When compression pressure is measured, it is found to be low q
Inspect gear train directly q q
Check fan and fan belt directly q
When a certain cylinder is cut out, engine speed does not change q q
Unusual noise is heard only when engine is cranked q
Perform checking by using monitoring function of machine monitor q
Replace
Replace

Replace

Replace
Replace
Replace

Replace
Replace

Replace
Correct

Correct
Adjust

Remedy

40-538 HB205-1, HB215LC-1

(01)
 Troubleshooting of engine (S-mode)
S-16 Vibration is excessive

S-16 Vibration is excessive 40-539

General causes why vibration is excessive Causes

Improper injection timing (defect in coolant or boost temperature sensor)

q Defective parts (premature wear or breakage)

q Misalignment between engine and installed machine

q Abnormal combustion

a If unusual noise is made and vibration is excessive, perform troubleshooting for S-15
Unusual noise is heard, too.

Misalignment between engine and hydraulic pump

Loose engine mounting bolts or broken cushions
Worn main bearing, or connecting rod bearing
Stiff valve system (valve, rocker arm, etc.)

Broken output shaft or damper chamber

Improper gear train backlash
Worn camshaft bushing
Check recent repair history
Degree of use of
Questions

Operated for long period E E E

machine
Condition of vibra- Suddenly increased Q Q
tion Gradually increased Q Q Q
Oil other than specified one is used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items

Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust gas is black w Q

Inspect valve system directly q

q
Troubleshooting

Inspect main bearing and connecting rod bearing directly

Inspect gear train directly q
Inspect camshaft bushing directly q
Inspect by using monitoring function q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Adjust

Remedy

HB205-1, HB215LC-1 40-539

(01)
Troubleshooting hybrid system (Y-mode)
Precautions related to hybrid machine

Troubleshooting hybrid system (Y-mode) 40-540

Precautions related to hybrid machine 40-540

k When testing or adjusting hybrid devices, ensure that you fully understand the following.

1. Disassemble of hybrid devices (motor-generator, capacitor, inverter, electric swing motor etc.) and
high-voltage wiring must be performed by whom finished special education for low-voltage electric
handling.
2. Never disassemble the hybrid devices, even if you are the qualified person for the work. This is from quality
assurance reason.
3. The hybrid devices and high-voltage wirings (wound with orange conduits) must be replaced by the unit.
4. When handling hybrid devices, be sure to discharge the capacitor completely first.
(For details, see Testing and adjusting, Special functions of machine monitor, "Discharge of capacitor".)
a Discharge of capacitor by using machine monitor is only performed when hybrid system is normal.
a When the failure code of "GA ****" appears and hybrid system is abnormal, discharge can not be done
although discharge display appears on the machine monitor. (The condition to consume the electric
charge of capacitor is not established.) Accordingly, use the generator dedicated to discharge capacitor :
796-426-1800. (For details, see Failure code [GA****] hybrid related precautions, common troubleshooting
procedure for high voltage system.)

k Since the items with the above mark are related to handling of the hybrid devices, ensure that you
understand the descriptions of 00-200 Introduction, safety, and basic information, "Handling of hy-
brid devices and high-voltage wiring", before beginning the work on them.
a For the monitoring items applied to troubleshooting for the hybrid devices, see the list in "Separate sheet
1" of failure code [GA****].
a For the check sheet to record the inspection result when any hybrid device is abnormal, see "Separate
sheet 2" of failure code [GA****].

40-540 HB205-1, HB215LC-1

(01)
 Troubleshooting hybrid system (Y-mode)
Precautions related to hybrid machine

Common troubleshooting procedures for high voltage devices 40-541

k Before starting troubleshooting, discharge the capacitor by using capacitor discharge tool (gen-
erator): 796-426-1800 (see previous page).
k After discharging the capacitor, confirm that both capacitor charge LEDs (1) are OFF.
k A voltage not exceeding 30 V will still remain in the capacitor after the discharging process is com-
pleted. Do not work with bare hands. Always wear insulating gloves.
a After disconnecting connector HB01 (at capacitor), cover the connector (both of wiring harness and ca-
pacitor sides) with a plastic bag to prevent entry of foreign matter.
a Perform troubleshooting while the engine is stopped.
a Do not connect the multimeter probe directly to the capacitor side connector (female side of HB01).

1. Capacitor charge LEDs

1) Right and left LEDs are ON: High-voltage output in progress
2) Only right LED is ON: Charged with high voltage
3) Right and left LEDs are OFF: Voltage is under 30 V
q If test results for the failure code indicate a possible problem in the high voltage system, follow the common
troubleshooting procedures 1. to 7. to check by disconnecting the power cable from each device.

HB205-1, HB215LC-1 40-541

(01)
Troubleshooting hybrid system (Y-mode)
Y-1 Hybrid monitor does not go out

Y-1 Hybrid monitor does not go out 40-542

Failure Hybrid monitor does not go out but keeps lighting.

q Hybrid controller switch input can be checked by using monitoring function.
Related infor-
(Code: 09702 hybrid controller switch input)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Criteria and troubleshooting procedure

If capacitor voltage is 150 V or lower, run the engine at low idle for
1 Capacitor voltage drop
more than 5 minutes.
Swing emergency stop
2 Turn swing emergency stop switch OFF.
switch is ON

3 Defective hybrid system If error of user code E09 is displayed, troubleshoot it first.

Defective assembly of swing Operation section and contact section of swing emergency stop
4
emergency stop switch switch may be coupled defectively. Check them directly.
Swing emergency stop switch may have internal defect. Check it
directly.
Probable Defective swing emergency 1. Turn starting switch OFF.
5
causes and cri- stop switch a Turn swing emergency stop switch OFF.
teria Resis-
Between terminals HS01 (11) and HS01(12) Max. 1 z
tance
1. Turn starting switch OFF.
2. Disconnect No.17 in fuse box F01.
3. Disconnect connector HC01 and HC02, then connect T-adapter
Open circuit in wiring har- to female side.
ness Between HS01 (female) (11) and HC01 Resis-
6 Max. 1 z
(wire breakage or defective (female) (5), (11) tance
contact of connector) Resis-
Between HS01 (female) (11) and F01 - 17 Max. 1 z
tance
Resis-
Between HS01 (12) and HC02 (female) (3) Max. 1 z
tance
If no failure is found by check on causes 1 to 6, hybrid controller
Defective inverter (hybrid
7 may be defective. (Since this is an internal defect, troubleshooting
controller)
cannot be performed.)

40-542 HB205-1, HB215LC-1

(01)
 Troubleshooting hybrid system (Y-mode)
Y-1 Hybrid monitor does not go out

Hybrid monitor related circuit diagram 40-543

HB205-1, HB215LC-1 40-543

(01)
Troubleshooting hybrid system (Y-mode)
Y-2 Upper structure does not swing

Y-2 Upper structure does not swing 40-54

Failure (1) Upper structure swings neither to the right nor left
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control Output pressure of swing holding
Malfunction of swing holding
1 lever brake solenoid valve
brake solenoid valve
NEUTRAL 0 MPa {0 kg/cm2}
Swing LEFT/RIGHT 2.9 MPa {30 kg/cm2}
Malfunction of swing holding
2 Swing holding brake may be malfunctioning. Check it directly.
brake
1. Turn starting switch OFF.
2. Turn emergency swing stop switch OFF.
Probable Defective swing emergency Wiring harness between emergency stop Resis-
causes and cri- 3 Max. 1 z
stop switch switch HS01 (11) and (12) tance
teria Wiring harness between emergency stop Resis-
Max. 1 z
switch HS01 (21) and (22) tance
Swing machinery may have internal defect. Check it directly.
4 Defective swing machinery * The defect can be judged by unusual noise, abnormal heat,
metallic powder in drained oil, etc.
Open or short circuit in swing If failure code [DHVAKZ] is displayed, an open or short circuit is
5 RIGHT PPC pressure sen- suspected in the HYB swing right PPC pressure sensor. Perform
sor for hybrid system troubleshooting.
Open or short circuit in swing If failure code [DHVBKZ] is displayed, an open or short circuit is
6 LEFT PPC pressure sensor suspected in the HYB swing left PPC pressure sensor. Perform
for hybrid system troubleshooting.
If no failure is found by check on causes 1 to 6, hybrid controller
7 Defective inverter may be defective. (Since this is an internal defect, troubleshooting
cannot be performed.)

Failure (2) Upper structure does not swing in only one direction.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
PPC valve output pressure
Malfunction of swing PPC lever
1
valve NEUTRAL 0 MPa {0 kg/cm2}
Probable
causes and cri- 2.84 3.43 MPa
Swing LEFT/RIGHT
teria {29 35 kg/cm2}
Open short circuit in swing If failure code [DHVAKZ] is displayed, an open or short circuit is
2 RIGHT PPC pressure sen- suspected in the HYB swing right PPC pressure sensor. Perform
sor for hybrid system troubleshooting.
Open or short circuit in swing If failure code [DHVBKZ] is displayed, an open or short circuit is
3 LEFT PPC pressure sensor suspected in the HYB swing left PPC pressure sensor. Perform
for hybrid system troubleshooting.

40-544 HB205-1, HB215LC-1

(01)
 Troubleshooting hybrid system (Y-mode)
Y-2 Upper structure does not swing

Swing related circuit diagram 40-545

HB205-1, HB215LC-1 40-545

(01)
Troubleshooting hybrid system (Y-mode)
Y-3 Swing acceleration or swing speed is low

Y-3 Swing acceleration or swing speed is low 40-546

Failure (1) Swing acceleration performance is poor or swing speed is slow in both right and left directions.
q Capacitor voltage can be checked by using monitoring function.
Related infor- (Code: 09300 capacitor voltage)
mation q Method of reproducing failure code: Turn starting switch to ON or start the engine. Perform all trou-
bleshooting with the working mode set to the Power Mode (P).

Cause Criteria and troubleshooting procedure

Malfunction of swing holding
1 Swing holding brake may malfunction. Check it directly.
brake
Malfunction of all control LS shuttle valves of all control valves may malfunction. Check
2
valves (LS shuttle valves) them directly.

Probable Swing machinery may have internal defect. Check it directly.

causes and cri- 3 Defective swing machinery * The defect can be judged by unusual noise, abnormal heat,
teria metallic powder in drained oil, etc.
If the capacitor voltage falls far below 200 V when a swing is per-
Lowering of capacitor perfor- formed during work involving usual swings (approx. 90 degrees),
4
mance the capacitor may be deteriorated. (Since this is an internal failure,
troubleshooting cannot be performed.)
If no failure is found by check on causes 1 to 3, hybrid controller
5 Defective inverter may be defective. (Since this is an internal defect, troubleshooting
cannot be performed.)

Failure (2) Swing acceleration performance is poor or swing speed is slow in only one direction.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
PPC valve output pressure
Probable Malfunction of swing PPC lever
1
causes and cri- valve NEUTRAL 0 MPa {0 kg/cm2}
teria 2.84 3.43 MPa
Swing LEFT/RIGHT
{29 35 kg/cm2}
If no failure is found by check on cause 1, hybrid controller may be
2 Defective inverter defective. (Since this is an internal defect, troubleshooting cannot
be performed.)

40-546 HB205-1, HB215LC-1

(01)
 Troubleshooting hybrid system (Y-mode)
Y-4 Upper structure overruns largely when stop swinging

Y-4 Upper structure overruns largely when stop swinging 40-547

Failure (1) Upper structure overruns excessively when stop swinging in both right and left directions.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation

Probable Cause Criteria and troubleshooting procedure

causes and cri-
teria 1 Defective software Check the version number of software.

Failure (2) Upper structure overruns excessively when stop swinging in only one direction.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control Output pressure of swing holding
Malfunction of swing PPC lever brake solenoid valve
1
Probable valve
NEUTRAL 0 MPa {0 kg/cm2}
causes and cri-
teria 2.84 3.43 MPa
Swing LEFT/RIGHT
{29 35 kg/cm2}
Swing PPC slow return valve may malfunction. Check it directly.
Clogged swing PPC slow
2 * Judgment can be made by checking a change of phenomenon
return valve
after exchanging right and left valves.
3 Defective software Check the version number of software.

HB205-1, HB215LC-1 40-547

(01)
Troubleshooting hybrid system (Y-mode)
Y-5 Large shock is made when upper structure stops swinging

Y-5 Large shock is made when upper structure stops swinging 40-548

Failure q Large shock is caused when upper structure stops swinging.

Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control Output pressure of swing holding
Probable Malfunction of swing PPC lever brake solenoid valve
1
valve
causes and cri- NEUTRAL 0 MPa {0 kg/cm2}
teria
2.84 3.43 MPa
Swing LEFT/RIGHT
{29 35 kg/cm2}
Swing PPC slow return valve may malfunction. Check it directly.
Clogged swing PPC slow
2 * Judgment can be made by checking a change of phenomenon
return valve
after exchanging right and left valves.

Y-6 Large unusual noise is made when upper structure stops swinging 40-548

Failure q Large unusual noise is made when upper structure stops swinging in both directions.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation

Cause Criteria and troubleshooting procedure

Probable
causes and cri- Swing machinery may have internal defect. Check it directly.
teria 1 Defective swing machinery * The defect can be judged by unusual noise, abnormal heat,
metallic powder in drained oil, etc.

40-548 HB205-1, HB215LC-1

(01)
 Troubleshooting hybrid system (Y-mode)
Y-7 Swing drift on a slope is large

Y-7 Swing drift on a slope is large 40-549

Failure (1) Swing drift on a slope is large (when swing holding brake is being applied)
q If swing lock switch is ON or swing brake cancel switch is in normal position, swing holding brake
Related infor-
operates and upper structure is fixed by disc brake.
mation
q Perform all troubleshooting with working mode in power mode (P).

Cause Criteria and troubleshooting procedure

a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control Output pressure of swing holding
Probable Malfunction of swing holding
1 lever brake solenoid valve
causes and cri- brake solenoid valve
teria NEUTRAL 0 MPa {0 kg/cm2}
Swing LEFT/RIGHT 2.9 MPa {30 kg/cm2}

2 Malfunction of swing brake Swing brake may malfunction. Check it directly.

Failure (2) Swing drift on a slope is large (when swing brake is being released).
q If swing lock switch is ON or swing brake cancel switch is in normal position, swing holding brake
Related infor-
operates and upper structure is fixed by disc brake.
mation
q Perform all troubleshooting with working mode in power mode (P).

Cause Criteria and troubleshooting procedure

Probable 1 Defective swing motor The swing motor may be defective. Check it directly.
causes and cri-
Hybrid controller may be defective.
teria
2 Defective inverter (Since this is an internal defect, troubleshooting cannot be per-
formed.)

HB205-1, HB215LC-1 40-549

(01)
Troubleshooting hybrid system (Y-mode)
Y-8 Electric swing motor temperature increases abnormally

Y-8 Electric swing motor temperature increases abnormally 40-5 0

Failure q Electric swing motor overheats and failure code [GA70NS] is displayed.
q Electric swing motor coil temperature can be checked with monitoring function.
Related infor-
(Code: 09101 electric swing motor coil temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start the engine.

Cause Criteria and troubleshooting procedure

Overcharging and over dis-
Confirm if swing and swing stop operations have been exclusively
1 charging of capacitor (when
repeated or not.
system is normal)
Ground fault in electric swing
motor coil temperature sen-
2 See failure code [GA70NS], [GA71KZ].
sor harness
(contact with ground circuit)
Lack of cooling (lubricating)
3 Check the oil level with the dipstick. Add oil if necessary.
oil
Deteriorated cooling (lubri- The cooling (lubricating) oil may be contaminated with water or
4
cating) oil metallic powder. Check oil directly.
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Defective lubricating oil pas- Max. 0.3
5 Place all control levers in NEUTRAL and
sage in electric swing motor MPa
take measurements at pressure inspection Pressure
plugs. {3.1 kg/cm2}
Clogging of cooling (lubricat-
6 Inspect the filter and clean as necessary.
ing) oil filter
Lubrication pump may have malfunction or internal defects. Check it
by following method.
Probable
causes and cri- 1. Disconnect the hose at the cooling (lubricating) oil inlet of the
7 Defective lubrication pump
electric swing motor.
teria
2. Crank (manually rotate) the engine at the flywheel.
3. It is normal if oil flows out from the disconnected hose.
Overheating of coolant in the radiator is suspected. Perform trouble-
Overheating of coolant in
8 shooting for S mode S-14 Coolant temperature becomes too high
radiator
(overheating).
If the radiator coolant level monitor indicates a drop of coolant level,
9 Lowering of coolant level
add coolant to the hybrid radiator directly.
Defective wiring or open cir-
10 See failure code [GA1TNS].
cuit in water pump
Defective water pump impel-
11 Unusual noise or vibration arises from water pump.
ler
Air may be stagnating in the suction side of the water pump. Check it
by following method.
1. Open the hybrid radiator cap.
Air accumulated in suction
12 2. Turn the starting switch to ON position and operate water pump.
side of water pump
3. It is normal if no unusual noise or vibration is generated from the
water pump and coolant flow is observed in the radiator upper
tank.
Clogged or crushed hybrid
13 Inspect the hybrid radiator fins directly.
radiator fins
14 Clogged radiator core Inspect the hybrid radiator core directly.

40-550 HB205-1, HB215LC-1

(01)
 Troubleshooting hybrid system (Y-mode)
Y-8 Electric swing motor temperature increases abnormally

Cause Criteria and troubleshooting procedure

Defective hybrid radiator cap If coolant flows out from hybrid radiator overflow hose, inspect the
15
(pressure valve) hybrid radiator cap directly.
Probable Slipping fan belt or worn fan If radiator shroud and inside of underguard are not clogged with dirt
causes and cri- 16 pulley or mud, inspect fan belt and fan pulley directly.
teria Defective electric swing
17
motor Since this is an internal defect, troubleshooting cannot be per-
Defective inverter (hybrid formed.
18
controller)

HB205-1, HB215LC-1 40-551

(01)
Troubleshooting hybrid system (Y-mode)
Y-9 Motor-generator temperature increases abnormally

Y-9 Motor-generator temperature increases abnormally 40-5 2

Failure q Motor-generator overheats and failure code [GA61NS] is displayed.

q Motor-generator temperature can be checked with monitoring function.
Related infor-
(Code: 09600 motor generator temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start the engine.

Cause Criteria and troubleshooting procedure

Overcharging and overdis-
Confirm if swing and swing stop operations have been exclusively
1 charging of capacitor (when
repeated or not.
system is normal)
Ground fault in motor-gener-
ator temperature sensor har-
2 See failure code [GA61KZ], [GA61NS].
ness
(contact with ground circuit)
Lack of cooling (lubricating)
3 Check the oil level with the dipstick. Add oil if necessary.
oil
Deteriorated cooling (lubri- The cooling (lubricating) oil may be contaminated with water or
4
cating) oil metallic powder. Check oil directly.
a Be ready with engine stopped, then troubleshoot with engine at
full speed.
Defective lubricating oil pas- Below 0.6
Probable 5 Place all control levers in NEUTRAL and
sage in motor-generator MPa
causes and cri- take measurements at pressure inspection Pressure
teria plugs. {6.1 kg/cm2}
Clogging of cooling (lubricat-
6 Inspect the filter directly and clean as necessary.
ing) oil filter
Lubrication pump may have malfunction or internal defects. Check it
by following method.
1. Disconnect the hose at the cooling (lubricating) oil inlet of the
7 Defective lubrication pump
motor-generator.
2. Crank (manually rotate) the engine at the flywheel.
3. It is normal if oil flows out from the disconnected hose.
Overheating of coolant in the radiator is suspected. Perform trouble-
Overheating of coolant in
8 shooting for S mode "S-14 Coolant temperature becomes too high
radiator
(overheating)".
9 Defective motor-generator
Since this is an internal defect, troubleshooting cannot be per-
Defective inverter (hybrid formed.
10
controller)

40-552 HB205-1, HB215LC-1

(01)
 Troubleshooting hybrid system (Y-mode)
Y-10 Inverter overheats

Y-10 Inverter overheats 40-5 3

Failure q Inverter overheats and failure code(s) [GA1ZNS] and/or [GA1YNS] displayed.
q Inverter booster IGBT temperature and booster inductor temperature can be checked with monitor-
Related infor- ing function.
mation (Code: 09401 booster IGBT temperature, code: 09042 booster inductor temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start the engine.

Cause Criteria and troubleshooting procedure

Overcharging and overdis-
Confirm if swing and swing stop operations have been exclusively
1 charging of capacitor (when
repeated or not.
system is normal)
If the radiator coolant level monitor indicates a drop of coolant level,
2 Lowering of coolant level
add coolant to the hybrid radiator directly.
Defective wiring or open cir-
3 See failure code [GA1TNS].
cuit in water pump
Defective water pump impel-
4 No unusual noise or vibration arises from water pump.
ler
Air may be stagnating in the suction side of the water pump. Check
it by following method.
Probable
1. Open the hybrid radiator cap.
causes and cri- Air accumulated in suction
5 2. Turn the starting switch to ON and operate water pump.
teria side of water pump
3. It is normal if no unusual noise or vibration is generated from the
water pump and coolant flow is observed in the radiator upper
tank.
Clogged or crushed hybrid
6 Inspect the hybrid radiator fins directly.
radiator fins
7 Clogged radiator core Inspect the hybrid radiator core directly.
Defective hybrid radiator cap If coolant flows out from hybrid radiator overflow hose, inspect the
8
(pressure valve) hybrid radiator cap directly.
Slipping fan belt or worn fan If radiator shroud and inside of underguard are not clogged with dirt
9
pulley or mud, inspect fan belt and fan pulley directly.
Defective inverter (hybrid Since trouble is in high-voltage section, testing/troubleshooting can-
10
controller) not be performed.

HB205-1, HB215LC-1 40-553

(01)
Troubleshooting hybrid system (Y-mode)
Y-11 Capacitor overheats

Y-11 Capacitor overheats 40-5 4

Failure q Capacitor overheats and failure code [GA1TNS] is displayed.

q Capacitor cell center temperature and capacitor base temperature can be checked with monitoring
function.
Related infor- (Code: 09306 capacitor cell temperature, code: 09304 capacitor base temperature)
mation q Capacitor cell center temperature is an estimated value which is calculated from capacitor base
temperature.
q Method of reproducing failure code: Turn starting switch to ON position or start the engine.

Cause Criteria and troubleshooting procedure

Overcharging and overdis-
Confirm if swing and swing stop operations have been exclusively
1 charging of capacitor (when
repeated or not.
system is normal)
Ground fault in capacitor
base temperature sensor
2 See failure code [GA1TNS].
harness
(contact with ground circuit)
If the radiator coolant level monitor indicates a drop of coolant level,
3 Lowering of coolant level
add coolant to the hybrid radiator directly.
Defective wiring or open cir-
4 See failure code [GA1TNS].
cuit in water pump
Defective water pump impel-
5 Unusual noise or vibration arises from water pump.
ler
Probable
Air may be stagnating in the suction side of the water pump. Check
causes and cri-
it by following method.
teria
1. Open the hybrid radiator cap.
Air accumulated in suction
6 2. Turn the starting switch to ON and operate water pump.
side of water pump
3. It is normal if no unusual noise or vibration is generated from the
water pump and coolant flow is observed in the radiator upper
tank.
Clogged or crushed hybrid
7 Inspect the hybrid radiator fins directly.
radiator fins
8 Clogged radiator core Inspect the hybrid radiator core directly.
Defective hybrid radiator cap If coolant flows out from hybrid radiator overflow hose, inspect the
9
(pressure valve) hybrid radiator cap directly.
Slipping fan belt or worn fan If radiator shroud and inside of underguard are not clogged with dirt
10
pulley or mud, inspect fan belt and fan pulley directly.
Perform 1. of common troubleshooting procedures for high voltage
11 Defective capacitor
systems.

40-554 HB205-1, HB215LC-1

(01)
SEN0537731-00 50-1

HB205-1, HB205LC-1

HYDRAULIC EXCAVATOR
Shop Manual 5-01

HB205-1
HB215LC-1

Machine model Serial number

HB205-1 1001 and up
HB215LC-1 1001 and up

50 Disassembly and assembly 50-1

HB205-1, HB205LC-1 50-1

(01)
Contents

Contents 50-2
50 Disassembly and assembly
General information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4
Precautions related to hybrid machine................................................................................. 50- 6
Coating materials list............................................................................................................ 50- 7
Special tools list ................................................................................................................... 50- 10
Sketches of special tools ..................................................................................................... 50- 15
Engine and cooling system ..................................................................................................... 50- 20
Removal and installation of fuel supply pump assembly ..................................................... 50- 20
Removal and installation of fuel injector assembly .............................................................. 50- 25
Removal and installation of cylinder head assembly ........................................................... 50- 32
Removal and installation of radiator assembly .................................................................... 50- 55
Removal and installation of hydraulic oil cooler assembly................................................... 50- 57
Removal and installation of aftercooler assembly................................................................ 50- 59
Removal and installation of engine front seal ...................................................................... 50- 62
Removal and installation of engine rear seal ....................................................................... 50- 64
Removal and installation of fuel cooler assembly ................................................................ 50- 68
Removal (and installation) of engine, motor generator, and main pump assembly ............. 50- 70
Removal and installation of fuel tank assembly ................................................................... 50- 86
Hybrid...................................................................................................................................... 50- 89
Draining adding coolant and bleeding air for hybrid system ................................................ 50- 89
Removal and installation of hybrid radiator assembly.......................................................... 50- 93
Removal and installation of water pump assembly for hybrid system ................................. 50- 96
Removal and installation of inverter assembly..................................................................... 50- 99
Removal and installation of inverter and capacitor assembly .............................................. 50- 103
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.............................................................................................................................. 50- 129
Removal and installation of final drive assembly ................................................................. 50- 129
Disassembly and assembly of final drive ............................................................................. 50- 131
Removal and installation of sprocket ................................................................................... 50- 140
Removal and installation of swing motor and swing machinery assembly .......................... 50- 141
Disassembly and assembly of swing machinery assembly ................................................. 50- 145
Removal and installation of swing circle assembly .............................................................. 50- 160
Undercarriage and frame ........................................................................................................ 50- 161
Separation and connection of track shoe assembly ............................................................ 50- 161
Disassembly and assembly of idler...................................................................................... 50- 164
Disassembly and assembly of idler cushion assembly ........................................................ 50- 167
Disassembly and assembly of track roller............................................................................ 50- 169
Disassembly and assembly of carrier roller ......................................................................... 50- 171
Removal and installation of revolving frame assembly ........................................................ 50- 175
Removal and installation of counterweight assembly .......................................................... 50- 177
Hydraulic system..................................................................................................................... 50- 179
Removal and installation of center swivel joint assembly .................................................... 50- 179
Disassembly and assembly of center swivel joint assembly................................................ 50- 181
Removal and installation of hydraulic tank assembly .......................................................... 50- 183
Removal and installation of main pump assembly............................................................... 50- 188
Removal and installation of main pump input shaft oil seal ................................................. 50- 193
Removal and installation of control valve assembly ............................................................ 50- 194

50-2 HB205-1, HB205LC-1

(01)
 Contents

Disassembly and assembly of control valve ........................................................................ 50- 199

Disassembly and assembly of work equipment PPC valve assembly ................................. 50- 203
Disassembly and assembly of travel PPC valve.................................................................. 50- 205
Work equipment...................................................................................................................... 50- 208
Removal and installation of work equipment assembly ....................................................... 50- 208
Disassembly and assembly of work equipment cylinder assembly ..................................... 50- 211
Cab and its attachments ......................................................................................................... 50- 217
Removal and installation of operator's cab assembly.......................................................... 50- 217
Removal and installation of operator's cab glass (adhered window glass).......................... 50- 221
Removal and installation of front window assembly ............................................................ 50- 231
Removal and installation of floor frame assembly ............................................................... 50- 238
Removal and installation of air conditioner unit assembly ................................................... 50- 243
Electrical system ..................................................................................................................... 50- 246
Removal and installation of engine controller assembly...................................................... 50- 246
Removal and installation of pump controller assembly........................................................ 50- 248
Removal and installation of machine monitor assembly...................................................... 50- 251
Removal and installation of KOMTRAX terminal assembly ................................................. 50- 253

HB205-1, HB205LC-1 50-3

(01)
General information on disassembly and assembly
How to read Disassembly and Assembly

General information on disassembly and assembly 50-4

How to read Disassembly and Assembly 50-4
(Rev. 2009. 01)
1. Removal (and installation) of TTTT assembly 50-4

Special tools 50-4 [*1] : This mark shows that instructions or

q Special tools which are necessary for removal or
installation of parts are described as A1 X1
etc. and their part numbers, part names and
quantities are described in the special tool list.
q The following information is described in the
special tool list as well.
1) Necessity
t: Special tools that cannot be substituted
and should always be used.
q: Special tools that will be useful if available
and are substitutable with tools available
on the market.
2) New/redesign
N : Tools newly developed for this model.
They have a new part number respec-
tively.
R : Tools made available by redesigning
the existing tools which were devel-
oped for other models. Each of them
has a new part number assigned by
setting forward the part number of the
existing tool.
Blank :Tools already available for other
models. They can be used without any
modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
ed in the section of Sketches of special
tools.
q Part numbers of special tools starting with
part number 79*T-***-****indicate that
they are not available from Komatsu Ltd.
(i.e. tools to be made locally).
precautions for parts installation work are
given in Installation section.
6 : This mark shows the amount of oil or
coolant to be drained
4 : This mark shows the weight of a part
or a component.
Installation 50-4
q Unless otherwise instructed, installation of parts
is to be done in the reverse order to removal.
q Instructions and precautions for parts installation
are shown with the mark ([*1], [*2]...) which cor-
responds to the mark in Removal section.
q Common tools that are necessary for installation
are described as [1], [2] etc. and their part
numbers, part names and quantities are not de-
scribed.
q Marks shown in the "Installation" section stand
for the following.
k : Precautions related to work safety are
described.
a : Know-how or precautions for work are de-
scribed.
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replen-
ished
Sketches of special tools 50-4
q Various special tools are illustrated for the local
manufacture.

Removal 50-4
q In Removal section, the work procedures, pre-
cautions and know-how to do the work, and the
amount of oil and coolant to be drained are de-
scribed.
q Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not de-
scribed.
q Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety are
described.
a : Know-how or precautions for work are de-
scribed.

50-4 HB205-1, HB205LC-1

(01)
 General information on disassembly and assembly
How to read Disassembly and Assembly

2. Disassembly (and assembly) of TTTT assembly 50-5

Special tools
q Special tools which are necessary for disassem-
bly and assembly of parts are described as
A1X1 etc. and their part numbers, part names
and quantities are described in the special tool
list.
q The following information is described in the
special tool list as well.
1) Necessity
t: Special tools that cannot be substituted
and should always be used.
q: Special tools that will be useful if available
and are substitutable with tools available
on the market.
2) New/redesign
N : Tools newly developed for this model.
They have a new part number respec-
tively.
R : Tools made available by redesigning
the existing tools which were devel-
oped for other models. Each of them
has a new part number assigned by
setting forward the part number of the
existing tool.
Blank :Tools already available for other
models. They can be used without any
modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
ed in the section of Sketches of special
tools.
q Part No. of special tools starting with
79*T-***-****: means that they are not
available from Komatsu Ltd. (i.e. tools to
be made locally).
50-5 Assembly 50-5
q In Assembly section, the work procedures, pre-
cautions and know-how to do the work, and the
amount of oil and coolant to be replenished are
described.
q Common tools that are necessary for assembly
are described as [1], [2] etc. and their part
numbers, part names and quantities are not de-
scribed.
q The meanings of the symbols used in "Assem-
bly" section are as follows.
k : Precautions related to work safety are
described.
a : Know-how or precautions for work are de-
scribed.
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replen-
ished
Sketches of special tools 50-5
q Various special tools are illustrated for the local
manufacture.

Disassembly 50-5
q In Disassembly section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q Common tools that are necessary for disassem-
bly are described as [1], [2] etc. and their part
numbers, part names and quantities are not de-
scribed.
q The meanings of the symbols used in "Disas-
sembly" section are as follows.
k : Precautions related to work safety are
described.
a : Know-how or precautions for work are de-
scribed.
6 : Amount of oil or coolant drained.

HB205-1, HB205LC-1 50-5

(01)
General information on disassembly and assembly
Precautions related to hybrid machine

Precautions related to hybrid machine 50-6

k When removing and installing the hybrid de-

vices, fully understand the following items.

1. Even a qualified person must not disassemble

the above devices for quality assurance.
2. The hybrid devices and high-voltage wirings
(wound with orange conduits) must be replaced
by the unit.
3. When removing and installing the hybrid
devices, handle them with extreme care not to
lose the safety or damage their quality.
4. When removing the hybrid devices, be sure to
discharge the capacitor completely first. (For
details, see 00-200 Introduction, safety, and
basic information, "Handling of hybrid devices
and high-voltage wirings", "Discharge procedure
for capacitor" or 30-102 Testing and adjusting
(Part 2), Special functions of machine monitor,
"Discharge of capacitor".)
Depending on the type of error occurred, the
capacitor cannot be discharged by using the
machine monitor in some cases.

k Since the items having the above mark are

related to handling of the hybrid devices, un-
derstand the contents of 00-200 Introduction,
safety, and basic information, "Safety pre-
cautions 1. Precautions peculiar to hybrid
machine" and "Handling of hybrid devices
and high-voltage wirings" before working on
them.

50-6 HB205-1, HB205LC-1

(01)
 General information on disassembly and assembly
Coating materials list

Coating materials list 50-7

(Rev. 2009. 08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassem-
bly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate-
Komatsu code Part No. Capacity Container Main features and applications
gory
q Use to prevent rubber gaskets, rubber cushions,
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropyl-
20 g Polyethyl-
ene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050 (2 pcs. ene con-
ber, metal, and non-metal parts which require
contained ) tainer
immediate and strong adhesion.
Polyethyl-
q Features: Resistance to heat and chemicals
LT-2 09940-00030 50 g ene con-
q Use to fix and seal bolts and plugs.
tainer
Adhesive:
790-129-9060
1 kg
LT-3 (Set of adhesive Can q Use to bond and seal metal, glass and plastics.
Hardener:
and hardener)
500 g
Adhesive

Polyethyl-
LT-4 790-129-9040 250 g ene con- q Use to seal plugs for blank holes.
tainer
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines
MH 705
q Instanetaneous adhesive
Polyethyl-
ThreeBond q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g ene con-
1735 q Use mainly to bond metals, rubbers, plastics, and
tainer
woods.
q Instanetaneous adhesive
Polyethyl-
q Quick-curing type (max. strength is obtained after
Aron-alpha 201 790-129-9130 2g ene con-
30 minutes)
tainer
q Use mainly to bond rubbers, plastics, and metals.
Polyethyl-
q Features: Resistance to heat and chemicals
Loctite 648-50 79A-129-9110 50 cc ene con-
q Use for fitted portions used at high temperatures.
tainer
q Use to seal various threaded portions, pipejoints,
Polyethyl-
and flanges.
LG-5 790-129-9080 1 kg ene con-
q Use to seal taper plugs, elbows, and nipples for
tainer
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal threaded portions on flange surface
q Use to seal oil pan, final drive case, etc.
Liquid gasket

q Features: Silicon-based quick-curing sealant

LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.

LG-8 q Features: Silicon-based, heat and cold-resistant,

ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the
ThreeBond 790-129-9310 200 g Tube
weld which must be caulked, etc.
1206D
q Can be coated with paint.

HB205-1, HB205LC-1 50-7

(01)
General information on disassembly and assembly
Coating materials list

Cate-
Komatsu code Part No. Capacity Container Main features and applications
gory
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket

1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulphide

portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
lubricant

q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on
09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound

q Feature: Seizure and galling prevention com-

pound with metallic super-fine-grain, etc.
Seizure

LC-G
Can q Use for the mounting bolt in the high temperature
NEVER-SEEZ
area of the exhaust manifold and the turbocharg-
er, etc.

SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold dis- brication performance, general purpose type.
SYG0-400LI-A
trict
(*)
SYG0-16CNLI
(*)
q Use for parts under heavy load.
Bel- Caution:
Molybdenum
SYG2-400M 400 g x 10 lows-type q Do not use this grease for rolling bearings like
disulphide
SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
grease
SYGA-16CNM 16 kg q Use this grease for work equipment pins only
LM-G (G2-M)
Can when installing them, but do not use it after-
ward.
Grease

SYG2-400T-A
Hyper White
SYG2-16CNT Bel- q Seizure resistance, heat resistance and water re-
G2-T
SYG0-400T-A 400 g lows-type sistance higher than molybdenum disulphide
G0-T (*)
(*) 16 kg container grease.
*: For cold dis-
SYG0-16CNT Can q Not conspicuous on machine since color is white.
trict
(*)
Biogrease
SYG2-400B
G2-B
SYGA-16CNB Bel-
G2-BT (*) q Since this grease is biodegradable in short period,
SYG2-400BT 400 g lows-type
*: For use at it has less impact on microorganisms, animals,
(*) 16 kg container
high tempera- and plants.
SYGA-16CNBT Can
ture and under
(*)
high load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.

50-8 HB205-1, HB205LC-1

(01)
 General information on disassembly and assembly
Coating materials list

Cate-
Komatsu code Part No. Capacity Container Main features and applications
gory
q Feature: Urea (organic system) grease with heat
resistance and long life, can be packed into the
Grease

G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER580 tainer (Effective period: four months after date of
SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of

For adhered window glass

PRIMER 580 tainer
manufacture)
SUPER
q Use as primer for painted cab sheet metal
SUNSTAR
Glass con- surface.
Primer

PAINT PRIMER 22M-54-27230 20 ml

tainer (Effective period: four months after date of
435-95
manufacture)
q Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbon-
GLASS
22M-54-27240 150 ml Can ate-coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
q Use as primer for sash (anodized aluminum
SUNSTAR
Glass con- surface).
SASH PRIMER 22M-54-27250 20 ml
tainer (Effective period: four months after date of
GP-402
manufacture)
SUNSTAR q Use S" in high-temperature season and W"
PENGUINE Polyethyl- in low-temperature season as adhesive for
SEAL580 417-926-3910 320 ml ene con- glass.
SUPER S" or tainer (Effective period: four months after date of
Adhesive

W" manufacture)
Polyethyl- q Use as adhesive for glass.
Sika Japan,
For adhered window glass

20Y-54-39850 310 ml ene con- (Effective period: six months after date of
Sikaflex 256HV
tainer manufacture)
SUNSTAR Ecocart q Use as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Effective period: six months after date of
SUPER 560 container) manufacture)
SUNSTAR Polyethyl- q Use to seal glass-to-glass joints.
PENGUINE 417-926-3920 320 ml ene con- (Effective period: four months after date of
Caulking material

SEAL No. 2505 tainer manufacture)

SEKISUI SILI- Polyethyl- q Use to seal front window.
CONE SEAL- 20Y-54-55130 333 ml ene con- (Effective period: six months after date of
ANT tainer manufacture)
q Use to seal glass-to-glass joint. Translucent
GE TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL381
manufacture)

HB205-1, HB205LC-1 50-9

(01)
General information on disassembly and assembly
Special tools list

Special tools list 50-10

a Part Nos. of special tools starting with 79*T-***-**** mean that they are not available from Komatsu Ltd.
(i.e. tools to be made locally).
a Necessity:
t:Special tools that cannot be substituted and should always be used.
q:Special tools that will be useful if available and are substitutable with tools available on the market.
a New/redesign:
N: Tools newly developed for this model, newly assigned with unique part numbers.
R: Tools made available by redesigning the existing tools which were developed for other models. Each
of them has a new part number assigned by setting forward the part number of the existing tool.
BlankTools already available for other models, can be used without any modification
a Tools marked with Q in the sketch column are presented in the sketches of the special tools. (See "Sketch-
es of special tools")

New/redesign
Necessity

Sketch
Q'ty
Work Symbol Part number Part name Nature of work, remarks

Adjustment of valve clear-

1 795-799-1131 Gear t 1
ance
Cylinder head
assembly and fuel 2 795-799-8150 Remover q 1 Removal of inlet connector
injector assembly
3 795-799-6700 Puller t 1 Removal of fuel injector
Installation of engine front
Engine front seal 4 795-799-6400 Seal puller t 1
seal
Installation of engine rear
Engine rear seal 5 795-799-6500 Seal puller t 1
seal
Wrench
6 790-331-1120 q 1 Angle tightening of bolt
Cylinder head (Angle)
assembly Judgment of cylinder head
A 7 795-790-4510 Gauge q 1
bolt length
Engine, motor-gen- 8 796T-401-1110 Plate q 1 Q Engine, motor-generator
erator, and main Removal and installation
9 795-790-9300 Lifting tool q 1
pump assembly of main pump assembly

10 796-460-1210 Oil stopper q 1

Main pump assem-
bly, engine, control Stopping oil spill
valve assembly, 11 796-770-1320 Adapter q 1
and center swivel
joint assembly Commercially Measurement of
12 Megaohm tester t 1 N
available motor-generator insulation
Fuel supply pump Removal (and installation)
13 795-799-6130 Support t 1
assembly of gear
1 796T-401-1210 stand q 1 N Q
2 796T-401-1220 Plate q 1 N Q
1 3 01010-81690 Bolt q 2
4 01580-11613 Nut q 2
5 01643-31645 Washer q 4 Removal and installation
Motor-generator
B 1 796-410-1000 Guide t 1 N of motor-generator hous-
housing assembly
2 796-410-1040 Bar t 1 N ing assembly
3 796-410-1050 Plate t 1 N
2
4 01010-81030 Bolt t 2
5 01643-31032 Washer t 6
6 01010-81035 Bolt t 4

50-10 HB205-1, HB205LC-1

(01)
 General information on disassembly and assembly
Special tools list

New/redesign
Necessity

Sketch
Q'ty
Work Symbol Part number Part name Nature of work, remarks

Inverter and capac- Positioning of inverter and

B 3 796T-426-1110 Assembling jig t 1 N Q
itor assembly capacitor assembly
796T-426-1130 Plate t 1 Q
1 790-101-5421 Grip t 1 Press fit of oil seal
01010-81240 Bolt t 1
2 796-426-1120 Push tool t 1 Press fit of sub bearing
Swing electric Press fitting of main bear-
motor and swing 3 796T-426-1410 Push tool t 1 Q
F ing
machinery assem- Removal and installation
bly 4 01124-51490 Guide bolt t 1 N of swing electric motor
assembly
1 796-426-1710 Collet t 1 N
Assembly of swing
5 2 796-426-1720 Tapered cone t 1 N
machinery
3 796-426-1730 Collar t 1 N
796-427-1400 Wrench assembly t 1 N
796-427-1410 q Wrench 1 N Removal and installation
1
796-427-1140 q Pin 3 of nut
01314-20612 q Screw 3
796T-427-1510 Push tool t 1 N Q
790-101-2510 Block t 1
790-101-3310 Block t 1
790-101-2610 Rod t 2
790-101-2730 Adapter t 2
2 Installation of bearing
01580-11613 Nut t 2
790-101-2570 Plate t 2
01643-31645 Washer t 2
Disassembly and 790-101-2102 Puller (294 kN {30 ton}) t 1
assembly of final J 790-101-1102 Pump t 1
drive assembly
3 796-427-1520 Installer t 1 N Installation of floating seal
Removal and installation
4 796-427-1200 Wrench t 1
of nut
5 791-545-1510 Installer t 1 Installation of floating seal
796T-427-1220 Push tool t 1 Q
790-101-2510 Block t 1
792-104-3940 Bolt t 1
6 05180-11610 Nut t 2 Installation of bearing
01613-31645 Washer t 2
790-105-2100 Jack t 2
790-101-1102 Hydraulic pump t 1
7 790-331-1110 Wrench t 1 Angle tightening of bolt
Disassembly and
assembly of carrier 1 790-434-1660 Installer t 1
roller assembly
Disassembly and
assembly of track L 2 796-670-1020 Installer t 1 Installation of floating seal
roller assembly
Disassembly and
assembly of ldler 3 791-530-1510 Installer t 1
assembly

HB205-1, HB205LC-1 50-11

(04)
General information on disassembly and assembly
Special tools list

New/redesign
Necessity

Sketch
Q'ty
Work Symbol Part number Part name Nature of work, remarks

791-600-2001 Compressor (A) t 1

or
791-685-8006 Compressor (B) t 1
790-201-2780 Spacer
1 791-635-3160 Extension t 1
Cylinder
790-101-1600 t 1
(686 N {70 ton})
790-101-1102 Pump t 1 Disassembly and assem-
Idler cushion 790-640-2180 Guide bolt t 1
M bly of idler cushion assem-
assembly
790-101-5201 Push tool kit (B) q 1 bly
790-101-5241 q Plate 1
2
790-101-5221 q Grip 1
01010-51225 q Bolt 2
790-201-1500 Push tool kit q 1
790-201-1620 q Plate 1
3
790-101-5021 q Grip 1
01010-50816 q Bolt 1
791-630-3000 Remover and installer t 1
Separation and Separation and connec-
Cylinder
connection of track R 790-101-1300 t 1 tion of track shoe assem-
(980 kN {100 ton})
shoe assembly bly
790-101-1102 Pump t 1
Main pump assem- Press fit of input shaft oil
S 796T-467-2410 Push tool t 1 N Q
bly seal
790-101-2501 Push-puller q 1
790-101-2510 q Block 1
790-101-2520 q Screw 1
Disassembly and 791-112-1180 q Nut 1 Disassembly and assem-
assembly of center
T 1 790-101-2540 q Washer 1 bly of center swivel joint
swivel joint assem-
790-101-2630 q Leg 2 assembly
bly
790-101-2570 q Plate 4
790-101-2560 q Nut 2
790-101-2650 q Adapter 2

50-12 HB205-1, HB205LC-1

(04)
 General information on disassembly and assembly
Special tools list

New/redesign
Necessity

Sketch
Q'ty
Work Symbol Part number Part name Nature of work, remarks

796-946-1310 Guide f21.8

t 1
(For 723-46-40100)
796-946-1610 Guide f21.4
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2
2 t 1
(For 723-46-43100 and 723-46-43400)
796-946-1910 Guide f21.0
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2210 Guide f20.6
t 1
(For 723-46-45100 and 723-46-45700)
796-946-1320 Guide f21.8
t 1
(For 723-46-40100)
796-946-1620 Guide f21.4
t 1
(For 723-46-41100)
796-946-1820 Guide f21.2
t 1
(For 723-46-43100 and 723-46-43400)
Disassembly and 3
796-946-1920 Guide f21.0 Replacement of pressure
assembly of con- T t 1
(For 723-46-46101 and 723-46-46300) compensation valve seal
trol valve assembly
796-946-2220 Guide f20.6
t 1
(For 723-46-45100)
796-946-1420 Guide f21.6
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
t 1
(For 723-46-43100 and 723-46-43400)
4
796-946-1930 Sleeve
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)

HB205-1, HB205LC-1 50-13

(01)
General information on disassembly and assembly
Special tools list

New/redesign
Necessity

Sketch
Q'ty
Work Symbol Part number Part name Nature of work, remarks

790-502-1003 Cylinder repair stand q 1 Disassembly and assem-

1 bly of work equipment cyl-
790-101-1102 Pump q 1
inder assembly
790-102-4300 Wrench assembly t 1 Removal and installation
2
790-102-4310 Pin t 2 of piston assembly
3 790-720-1000 Expander q 1
Rubber band
796-720-1670 q 1
(for boom and arm)
07281-01279 Clamp q 1 Installation of piston ring
4
Rubber band
796-720-1660 q 1
(for bucket)
07281-01159 Clamp q 1
790-201-1702 Push tool kit t 1
q Push tool
790-201-1831 1
(for bucket)
Work equipment q Push tool
U 790-201-1930 1
cylinder assembly 5 (For arm) Press fit of bushing
q Push tool
790-201-1940 1
(for boom)
790-101-5021 q Grip 1
01010-50816 q Bolt 1
q Push tool kit
790-201-1500 q 1
(for bucket)
790-201-1640 q Push tool 1
790-101-5021 q Grip 1
01010-50816 q Bolt 1
6 Plate Press fit of dust seal
790-201-1980 q 1
(for boom)
Plate
790-201-1990 q 1
(For arm)
790-101-5021 Grip q 1
01010-50816 Bolt q 1
796-900-1200 Remover t 1
796-900-1210 q Sleeve 1
792-900-1520 q Plate 1
Removal and 799-900-1230 q Screw 1
installation of work 796-900-1240 q Adapter 1
V Removal of foot pin
equipment assem- 01643-33080 q Washer 1
bly
01803-13034 q Nut 1
Puller
790-101-4000 t 1
(490 kN {50 ton}, long)
790-101-1102 Pump (294 kN {30 t}) t 1
2 793-498-1210 Lifter (Suction cup) t 2
Operators cab Installation of operator cab
X
glass (stuck glass) glass (stuck glass)
3 20Y-54-13180 Stopper rubber t 2
Commercially
Impact wrench q 1 Removal and installation
Counterweight available
Z of counterweight mount-
assembly Commercially Socket wrench
q 1 ing bolt
available (Width across flats : 46 mm)

50-14 HB205-1, HB205LC-1

(01)
 General information on disassembly and assembly
Sketches of special tools

Sketches of special tools 50-15

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A8 Plate 50-15

B1-1 Stand 50-15

HB205-1, HB205LC-1 50-15

(01)
General information on disassembly and assembly
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B1-2 Plate 50-16

B3 Assembling jig 50-16

50-16 HB205-1, HB205LC-1

(01)
 General information on disassembly and assembly
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
F1 Plate 50-17

F3 Push tool 50-17

HB205-1, HB205LC-1 50-17

(01)
General information on disassembly and assembly
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
J2 Push tool 50-18

J6 Push tool 50-18

50-18 HB205-1, HB205LC-1

(01)
 General information on disassembly and assembly
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
S Push tool 50-19

HB205-1, HB205LC-1 50-19

(01)
Engine and cooling system
Removal and installation of fuel supply pump assembly

Engine and cooling system 50-20

Removal and installation of fuel supply pump assembly 50-20

Special tools 50-20 3. Open engine hood (4).

New/redesign
Necessity

Sketch
Q'ty
Symbol Part number Part name

A 13 795-799-6130 Support t 1

Removal 50-20
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Close fuel stop valve (1). 4. Remove counterweight maintenance cover (5).

2. If the fuel level is above the hose adapter (supply
pump portion) going to the fuel cooler, open right
inspection cover (2) and open fuel drain valve (3)
to drain the fuel until the fuel level lowers below
the hose adapter going to the fuel cooler.
5. Disconnect the wiring and hoses from the fuel
supply pump as follows. [*1]
a Remove mud from the joints in advance.
(since locks (L) may become hard because of
mud)
a While pressing lock (L) from both sides, pull
out each hose.
a When disconnecting the hoses, fuel will flow
out. Plug the fittings, to prevent fuel from
flowing out.
a Do not use a wooden plug because wooden
chips may enter the fuel line.
a Record the disconnected and clamped por-
tions of each hose.
a Cover the ends of the disconnected hoses
and high pressure pipes with cloths.

50-20 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of fuel supply pump assembly

1) Disconnect connector PUMP (6). 7. Remove high-pressure pipe clamps (13) and
2) Disconnect quick couplers (8) and (9) of the (14). [*7]
fuel return tubes. [*2]
3) Disconnect quick coupler (9) of the hose
coming from the fuel filter. [*3]

8. Remove high-pressure pipe mounting nuts (15)

from the supply pump side and common rail side
and then remove high-pressure pipe (16). [*8]
4) Disconnect quick coupler of the hose (10)
going to the fuel filter. [*4]
5) Remove the joint bolt and disconnect hose
(11) coming from the prefilter. [*5]

9. Remove three mounting nuts (17) (parts A) and

remove fuel supply pump assembly (18). [*9]

6. Remove boots (12) from the supply pump and

common rail. [*6]

HB205-1, HB205LC-1 50-21

(01)
Engine and cooling system
Removal and installation of fuel supply pump assembly

(Parts A: Indicate the pump mounting positions.) 3) Install puller [3] on puller [2] and the shaft.
4) Turn center bolt [4] until the gear comes off
the shaft.
5) Remove pullers [2] and [3].

10. When removing the gear from the fuel supply

pump, follow the procedure described below.
[*10]
1) While locking the gear by using support A13 6) Remove nut (21), lock washer (23), and gear
and 1/2-inch spin handle [1], loosen nut (19). (22) from shaft (24).
a Do not remove nut (19) from the shaft.

2) Install puller [2] between the flange and gear

(20).

50-22 HB205-1, HB205LC-1

(01)

Installation 50-23
q Perform installation in the reverse order to re-
moval.
[*1]
a When installing the fuel hoses and hose clamps,
ensure their removed positions.
[*2], [*3], [*4]
q When installing a connector of quick coupler
type, observe the following points.
a The internal parts of the fitting may be dam-
aged when the hose or tube is removed. Ac-
cordingly, do not reuse the hose or tube.
When installing, replace it with a new one.
a Ensure that mud or dirt is not sticking to the
hose joint portions in advance.
a Push the connector straight (in the direction
of (b)). Do not pry it in or wobble it.
If it is difficult to insert the connector, do not
push it in forcibly but pull it out. Then, check
the male and female couplings for damage
and sticking mud.
[*5]
3 Joint bolt:
19.6 29.4 Nm {2.0 3.0 kgm}
[*6]
a Install the boots with the slits out and down.
a The boots are installed so that fuel does not
spout over the hot parts of the engine and catch
fire when it leaks for some reason.
3 High-pressure pipe mounting bolt:
24 4 Nm {2.45 0.4 kgm}
HB205-1, HB205LC-1
(01)
Engine and cooling system
Removal and installation of fuel supply pump assembly
[*7], [*8]
q Install the fuel high-pressure pipe according to
the following procedure.
1. Temporarily tighten the sleeve nuts on the
common rail side and supply pump side.
2. Ensure that the high-pressure pipe is not
installed forcibly and then alternately tighten the
sleeve nuts on the common rail side and supply
pump side.
3 Sleeve nut:
35 3.5 Nm {3.6 0.36 kgm}
3. Install the high-pressure pipe clamp.
3 High-pressure pipe mounting bolt:
24 4 Nm {2.45 0.4 kgm}
[*9]
a If supply pump mounting stud bolt (21) on the
gear housing was removed, apply adhesive to
the bolt hole before installing the stud bolt.
a If grease is applied too much to O-ring (22) when
the supply pump is installed, it oozes out during
operation. Accordingly, do not apply grease too
much.
(Apply grease to O-ring groove area (B).)
2 Stud bolt (21):
Adhesive (LT-2)
3 Stud bolt (21):
12 2 Nm {1.22 0.2 kgm}
3 Mounting bolt of fuel supply pump (23):
24 4 Nm {2.45 0.41 kgm}
50-23
Engine and cooling system
Removal and installation of fuel supply pump assembly

[*13]
q Install gear (20) according to the following proce-
dure.

a Clean and dry the mating surfaces on shaft (21)

and gear (20) so that the surfaces are free of dirt
and foreign material.

1. Install gear (20) to shaft (21).

2. Install lock washer (22) and nut (19) and

finger-tighten the nut.

3. While locking the gear by using support A13 and

1/2-inch spin handle [1], tighten nut (19) to the
specified torque.
3 Fuel supply pump gear mounting nut:
105 5 Nm {10.7 0.51 kgm}

q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".

50-24 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of fuel injector assembly

Removal and installation of fuel injector assembly 50-25

Special tools 50-25 3. Open engine hood (4).

New/redesign
Necessity

Sketch
Q'ty
Symbol Part number Part name

1 795-799-1131 Gear t 1
A 2 795-799-8150 Remover q 1
3 795-799-6700 Puller t 1

Removal
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.
1. Close fuel stop valve (1).
50-25
4. Remove the fuel injection pipe according to the
following procedure. [*1]
1) Disconnect wiring connector (5).
(This is not necessary when removing only
the No. 4 cylinder injector assembly.)
a Since you cannot hold each connector,
disconnect it by using 2 flat-head screw-
drivers according to the following proce-
dure.
1] Keep pressing lock (a) of the connector
with flat-head screwdriver [1].
2] Insert flat-head screwdriver [2] in the
clearance between the connectors on the
right and left sides of lock (a) and move it
to the right and left to pry out the
connector gradually.

2. If the fuel level is above the hose adapter (supply

pump portion) going to the fuel cooler, open right
inspection cover (2) and open fuel drain valve (3)
to drain the fuel until the fuel level lowers below
the hose adapter going to the fuel cooler.

HB205-1, HB205LC-1 50-25

(01)
Engine and cooling system
Removal and installation of fuel injector assembly

2) Remove boot (6) from the common rail and 6. Remove mounting bolts (13) and blow-by duct
cylinder head. (14). [*3]

7. Remove cylinder head cover (15). [*4]

3) Loosen sleeve nuts (7) on the common rail

side and cylinder head side and remove fuel
injection pipe (8).
4) Disconnect wiring connector (10) of fuel
pressure sensor (9).
a While pressing lock (b), pull out connec-
tor (10) in the direction of the arrow.
a Do not remove the fuel pressure sensor
for any other purpose than replacement.
[*2] 8. Remove retaining nut (26) and inlet connector
(27).
a Remove mud sticking around the inlet con-
nector so that it does not enter the connector
hole.
a Tool A2 is set for removing inlet connector
(27). (See the special tools table)

5. Loosen bolt (11) and remove bracket (12).

(When removing the No. 1 cylinder injector
assembly.)

50-26 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of fuel injector assembly

9. Disconnect wiring (28). 13. Remove mounting bolts (34) of the fuel injector
assembly.
10. Loosen locknut (29) and loosen adjustment
screw (30) thoroughly.

11. Remove rocker arm mounting bolts (31) and

rocker arms (32).

14. Using tool A3, remove fuel injector assembly

(35).
a After removing the fuel injector assembly,
cover the fuel injector sleeve with cloths to
prevent dirt from entering it.
12. Remove crossheads (33).
a Record the installed position and direction
(shapes of holes (a) and (b)) of each cross-
head. (For reinstallation in the same direc-
tion)

HB205-1, HB205LC-1 50-27

(01)
Engine and cooling system
Removal and installation of fuel injector assembly
Installation 50-28
1. Fuel injector assembly
a When replacing the fuel injector assembly
with a new one, be sure to replace the inlet
connector as well.
a Check that fuel injector sleeve (36) is free
from flaw and dirt.
1) Fit O-ring (38) and gasket (39) to fuel injector
(37).
a Replace the O-ring and gasket with new
ones.
2) Apply engine oil to O-ring (38) of fuel injector
(37) and to the fuel injector sleeve.
2 O-ring (38) and fuel injector sleeve:
Engine oil (For details, see "List of
lubricant and water".)
3) While matching concave and convex (A),
install holder (40) to fuel injector (37).
50-28
4) When installing, direct the fuel inlet hole (inlet
connector mounting hole) toward the air
intake manifold.
5) Install fuel injector assembly (35) to the fuel
injector sleeve and tighten mounting bolts
(34) at least three - four turns.
6) Apply engine oil to O-ring (41) of inlet
connector (27) and to the inlet connector
mounting hole (on the cylinder head side).
a Check the inlet connector visually for the
following defects. If it has any of those de-
fects, replace it and fuel injector assembly
with new ones.
q Front end (a) or rear end (b) of the inlet
connector is burred or worn.
q Foreign material is collected in the edge
filter at rear end (c) of the inlet connector.
q Cracks or deterioration is recognizable in
O-ring of the inlet connector upper (d)
portion.
q Sealing surface (e) on the edge of the in-
let connector is worn or has uneven con-
tact pattern.
a If high-pressure fuel leaks through the
inlet connector, the sealing surface
has fine streaks or cracks.
HB205-1, HB205LC-1
(01)
 Engine and cooling system
Removal and installation of fuel injector assembly

7) While setting part (B) of inlet connector (27) 8) Install the inlet connector and tighten
to the groove (upper side) on the head, insert retaining nut (26) temporarily.
the inlet connector completely. 3 Retaining nut:
2 O-ring (41) and inlet connector 15 5 Nm {1.5 0.5 kgm}
mounting bore: Engine oil (For de-
tails, see "List of lubricant and wa-
ter".)

9) Tighten mounting bolts (34) of fuel injector

assembly (35) alternately.
3 Fuel injector mounting bolt (34):
8 0.8 Nm {0.8 0.08 kgm}
10)Tighten retaining nut (26) to the specified
torque.
3 Retaining nut (26):
50 5 Nm {5.1 0.51 kgm}

HB205-1, HB205LC-1 50-29

(01)
Engine and cooling system
Removal and installation of fuel injector assembly

2. Rocker arm assembly 2) Install rocker arm assembly (32) and tighten
1) Install crosshead (33). mounting bolts (31).
a Install each crosshead in the position and a Ensure that adjustment screws (30) are
direction (the shape of parts (a)) and (b)) thoroughly loosened.
recorded when removed. a Check that the ball of adjustment screw
(30) is fitted in the push rod socket se-
curely, and then tighten mounting bolt
(31).
3 Rocker arm mounting bolt (31):
36 5 Nm {3.7 0.51 kgm}
3) Adjust the valve clearance. For details, see
Testing and adjusting, Adjusting valve clear-
ance.
a Use tool A1 to rotate the engine.
4) After adjusting the valve clearance, ensure
that locknut (12) is tighten to the specified
torque.
3 Locknut (29):
24 4 Nm {2.4 0.4 kgm}
5) Install wirings (28) and wiring nuts.
a Check that the wirings do not interfere
with the rocker arm.
a Mounted position of wirings
Cable color Cylinder No.
White 1, 3
Black 2, 4

3 Wiring mounting nut:

1.5 0.25 Nm {0.15 0.03 kgm}

50-30 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of fuel injector assembly

[*1] [*2]
a Precautions for installing fuel injection pipe a If injector harness connector (IHC) is removed,
k Do not reuse the fuel injection pipe by apply liquid gasket LG-7 to O-ring (o) and flange
bending it. ((p) of the connector.
k Be sure to use genuine fuel injection pipe Apply a bead of LG-7 f3 mm in diameter to the
clamps and tighten them to the specified O-ring so that the ring groove is completely
torque. sealed.
k After installing the fuel injection pipe, be If the O-ring is damaged, replace it and the
sure to install the boot to the sleeve nut. harness assembly as a unit.
k When installing the boot, direct it out 3 Connector flange mounting bolt (45):
down. 10 2 Nm {1 0.2 kgm}
a Before installing the fuel injection pipe, check the
following.
q If the fuel injection pipe has a fault, it may
leak the fuel. Accordingly, replace it with a
new one.
q Taper seal section (j): Check that there is no
visible streaky slits (k) and spotty dimples (l)
in the 2 mm distance area from the end.
q Portion (m): Check that there is no steps (de-
formation) that your nail can feel in the 2 mm
distance area from the end of the taper seal
section.
3 Sleeve nut:
35 3.5 Nm {3.57 0.36 kgm}
[*3]
a When installing the blowby duct, check that the
O-ring is fitted.
3 Blowby duct mounting bolt:
7 2 Nm {0.71 0.2 kgm}

[*4]
3 Cylinder head cover mounting nut:
24 4 Nm {2.4 0.4 kgm}

a If the stud bolt is removed, install it and tighten to

the following torque.
3 Stud bolt:
24 4 Nm {2.4 0.4 kgm}

q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".

HB205-1, HB205LC-1 50-31

(01)
Engine and cooling system
Removal and installation of cylinder head assembly

Removal and installation of cylinder head assembly 50-32

Special tools 50-32

New/redesign
Necessity
Symbol Part number Part name

Q'ty
1 795-799-1131 Gear t 1
2 795-799-8150 Remover q 1
3 795-799-6700 Puller t 1
A
Wrench
6 790-331-1120 q 1
(Angle)
7 795-790-4510 Gauge q 1

Removal 50-32
k Park the machine on a level place, lower the
work equipment to the ground completely, 4. Open engine hood (4).
and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Loosen the radiator drain valve to drain the

coolant.
6 Radiator:
17.3 l

2. Close fuel stop valve (1).

5. Remove counterweight maintenance cover (5).

3. If the fuel level is above the hose adapter (supply

pump portion) going to the fuel cooler, open right
inspection cover (2) and open fuel drain valve (3)
to drain the fuel until the fuel level lowers below
the hose adapter going to the fuel cooler.

50-32 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of cylinder head assembly

6. Disconnect and move the air conditioner

compressor so that it is not an obstacle
according to the following procedure.
1) Remove fan guard (6).

2) Disconnect wiring connector AC02 (7).

3) Disconnect wiring clamps (8) and (9).
4) Disconnect wiring clamp (10).
5) Remove bracket (11).

7. Remove air hose (16). [*3]

a Make marks at the hose end and tube to indi-
cate their inserted positions.

6) Loosen air conditioner compressor fixing bolt

(12) and belt tension adjustment bolt (13),
and remove air conditioner compressor drive
belt (14). [*1]
a Do not loosen air conditioner compressor
mounting bolts (MB). [*2]
7) Remove air conditioner compressor fixing
bolt (12) and belt tension adjustment bolt (13)
and disconnect air conditioner compressor
assembly (15).

HB205-1, HB205LC-1 50-33

(01)
Engine and cooling system
Removal and installation of cylinder head assembly

8. Remove the air conditioner compressor mount

bracket according to the following procedure.
1) Disconnect ribbon heater wiring E01 (17).
2) Disconnect wiring clamps (18) and (19).
3) Remove three bolts (20).

4) Remove two bolts (21) and brackets (22) and

(23) together.

3) Remove fuel injection pipe mounting sleeve

nuts (26) from the common rail and cylinder
head and remove fuel injection pipe (27).[*5]
4) Disconnect wiring connector (29) for fuel
pressure sensor (28).
a While pressing lock (b), pull out connec-
tor (29) in the direction of the arrow.
a Do not remove fuel pressure sensor (28)
9. Remove the fuel injection pipe and fuel for any other purpose than replacement.
high-pressure pipe according to the following
procedure. [*4]
1) Disconnect connector (24).
a Since you cannot hold connector (24),
disconnect it by using 2 flat-head screw-
drivers according to the following proce-
dure.
1] Keep pressing lock (a) of the connector
with flat-head screwdriver [1].
2] Insert flat-head screwdriver [2] in the
clearance between the connectors on the
right and left sides of lock (a) and move it
to the right and left to pry out the
connector gradually.
2) Remove boots (25) from the common rail and
cylinder head.

50-34 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of cylinder head assembly

5) Similarly, remove fuel injection pipes (30), 9) Remove fuel high-pressure pipe mounting
(31), and (32) in the order of the No. 3, No. 2, sleeve nuts (39) from the supply pump and
and No. 1 cylinders. common rail and remove high-pressure pipe
(40).

6) Disconnect quick couplers (33), (34), and

(35) of the fuel return tube. [*6] 10)Remove four mounting bolts (41) and
7) Remove boots (36) from the common rail and common rail assembly (42). [*7]
fuel supply pump.

10. Remove the muffler and turbocharger assembly

8) Remove fuel high-pressure pipe clamps (37) according to the following procedure.
and (38). 1) Remove plate (43).

HB205-1, HB205LC-1 50-35

(01)
Engine and cooling system
Removal and installation of cylinder head assembly
2) Remove muffler drain pipe clamp (44).
3) Remove muffler drain pipe (45).
4) Remove cover (46).
5) Remove band clamp (47).
a Be sure to remove the band clamp.
6) Loosen U-bolt tightening nut (48).
7) Loosen U-bolt (49).
8) Loosen muffler bracket (50).
50-36
9) Remove cover (51).
10)Remove turbocharger outlet V clamp (52).
11)Disconnect turbocharger cooling hose
connector (53) from the turbocharger.
12)Disconnect turbocharger cooling tubes (54)
and (55) from the turbocharger.
13)Disconnect hose (56) between the turbo-
charger and air cleaner from the turbo-
charger. [*8]
14)Disconnect hose (57) under the aftercooler
from the connector on the turbocharger side.
[*9]
15)Disconnect muffler and exhaust pipe (58).
16)Slant muffler assembly (59) outward.
HB205-1, HB205LC-1
(01)
 Engine and cooling system
Removal and installation of cylinder head assembly

17)Loosen sleeve nut (60) and disconnect inlet 12. Remove eight exhaust manifold mounting bolts
hose (61) of the turbocharger lubricating oil. (69a) and remove exhaust manifold assembly
[*10] (69). [*13]
a Fix connector (62) on the turbocharger
side by using a wrench to prevent it from
being dragged.
18)Remove turbocharger mounting nut (63) and
place the turbocharger on stud bolt (64).
[*11]
19)Remove two hexagon socket head bolts (65)
and disconnect outlet tube (66) of the turbo-
charger lubricating oil. [*12]
20)Remove turbocharger (67).

13. Disconnect clamp (70) and disconnect radiator

upper hose (70) from the water pump. [*14]
a Make marks at the hose end and tube to indi-
cate their inserted positions.

14. Disconnect clamp (71) and disconnect coolant

bypass hoses (73) and (74).

15. Disconnect coolant temperature sensor

connector (75).

11. Remove heat insulation plate (68).

HB205-1, HB205LC-1 50-37

(01)
Engine and cooling system
Removal and installation of cylinder head assembly

16. Remove fan guards (76) and (77). 4) Remove the alternator mounting bolts and
disconnect alternator assembly (83).

17. Remove radiator fan (78).

a Lower the radiator fan.

19. Disconnect turbocharger cooling tube (84).

18. Remove the alternator assembly according to 20. Remove two bolts (85) and blow-by duct (86).
the following procedure. [*15] [*16]
1) Disconnect wiring (79) and (80).
2) Insert wrench [1] in hole (A) (width across 21. Remove joint bolt (87a) and disconnect fuel
flats: T12.7 mm) of tensioner assembly (81) return tube (87). [*17]
and rotate it counterclockwise (R), seeing
from the front of the engine, to loosen fan belt 22. Remove clamp (87b) of the fuel return tube.
(82).
3) Remove fan belt (82) from alternator 23. Remove cylinder head cover (88). [*18]
assembly (83).
k Set wrench [1] securely to hole (A) of
the tensioner assembly before rotating
the tensioner assembly. (The spring of
the tensioner assembly is strong. If
wrench [1] is set incompletely and ro-
tated, it comes off and that is very dan-
gerous.))
k Rotate the tensioner assembly. While
rotating, take care that wrench [1] will
not come off.
k After removing fan belt (82), loosen
wrench [1] slowly and carefully.
k Take care not to catch your finger be-
24. Remove the fuel injector and rocker arm housing
tween the pulley and fan belt during according to the following procedure.
the work. 1) Disconnect wiring (89) from the fuel injector.

50-38 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of cylinder head assembly

2) Loosen retainer (90) and remove inlet

connector (91). 6) Remove two mounting bolts (98) of the fuel
a Remove mud sticking around the inlet injector assembly.
connector so that it does not enter the
connector hole.
a Tool A2 is prepared for removal of inlet
connector. (See Special Tools List.)
3) Remove rocker arm mounting bolts (92),
rocker arms (93), and seats.
a Loosen locknuts (94) and loosen adjust-
ment screw (95) thoroughly.

7) Using tool A3, remove fuel injector assembly

(99).
8) Remove five rocker housing mounting bolts
(100) and remove rocker housing assembly
(101).

4) Remove crossheads (96).

a Record the installed position and direc-
tion (shapes of holes (a) and (b)) of each
crosshead.
(For reinstallation in the same direction)
5) Remove push rods (97).

HB205-1, HB205LC-1 50-39

(01)
Engine and cooling system
Removal and installation of cylinder head assembly

25. Remove eighteen mounting bolts (102) of the Installation 50-40

cylinder head and lift off cylinder head assembly 1. Install the cylinder head assembly according to
(103). the following procedure.
4 Cylinder head assembly: 1) Using tool A7, measure stem length (a) of
50 kg each cylinder head mounting bolt and check
that it is shorter than the using limit. (See
26. Remove cylinder head gasket (104). Special Tools List.)
q Service limit length of bolt: Less than
132.1 mm
a If the stem length of a bolt is longer than
the service limit, do not reuse that bolt but
replace it with a new one.

2) Set cylinder head gasket (104).

a Check that the cylinder head mounting
face and inside of the cylinders are free
from dirt and foreign matter.
a Use new cylinder head gasket (104).
3) Set cylinder head assembly (103).
4 Cylinder head assembly:
50 kg
a Check that the holes in cylinder head gas-
ket (104) are aligned with the holes in the
cylinder head.
4) Tighten eighteen mounting bolts (102) at
least two to three turns with the fingers and
then tighten them in the following procedure.
a Apply engine oil to the threaded part and
seat surface of bolt.
2 Threaded part and seat surface:
Engine oil (For details, see "List of
lubricant and water")

q Tightening procedure for mounting bolts

(102)
(When using angle tightening tool A6
(See the Special Tools List.))
a Tighten the bolts in order of [1] [18]
in 3 times.
3 Mounting bolt:
1] 90 3 Nm {9.2 0.3 kgm}
2] 90 3 Nm{9.2 0.3 kgm}
3] 90 3 deg.(Tighten with tool A6)

50-40 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of cylinder head assembly

2. Install the rocker housing assembly according to

the following procedure.
1) Install rocker housing assembly (101) and
tighten five rocker housing mounting bolts
(100).
a Replace the gasket with new one.
3 Mounting bolt:
24 4 Nm {2.4 0.4 kgm}
2) Install push rod (97).

3. Install the fuel injector according to the following

procedure.
a When replacing the fuel injector assembly
with a new one, be sure to replace the inlet
connector as well.
(When not using angle tightening
a Check that fuel injector mounting bore (105)
tool A6)
is free from dirt or other particles.
4] After performing steps 1] - 2]
above, make marks on the cylinder
head mounting bolts with a marker
pen.
5] Retighten 90 5 deg.

HB205-1, HB205LC-1 50-41

(01)
Engine and cooling system
Removal and installation of cylinder head assembly
1) Install O-ring (107) and gasket (108) to fuel
injector (106).
a Replace the O-ring and gasket with new
ones.
2) Apply engine oil to O-ring (107) of fuel
injector (106) and the fuel injector mounting
bore.
2 O-ring (107) and fuel injector
sleeve: Engine oil (For details, see
"List of lubricant and water".)
3) Engage the male and female parts at (A) to
install holder (109) to fuel injector (106).
4) When installing, direct the fuel inlet hole (inlet
connector mounting hole) toward the air
intake manifold.
5) Install fuel injector assembly (99) to fuel
injector sleeve. Finger tighten mounting bolts
(98) at least three or four turns.
50-42
6) Apply engine oil to O-ring (91a) of inlet
connector (91) and the inlet connector
mounting hole (on the cylinder head side).
a Check the inlet connector visually. If it
has any of the following faults, replace it
and fuel injector assembly together.
q There is a burr or a worn part at front end
(a) or rear end (b) of the inlet connector.
q Foreign material is collected in the edge
filter at rear end (c) of the inlet connector.
q Cracks or deterioration is recognizable in
O-ring of the inlet connector upper (d)
portion.
q Sealing surface (e) on the edge of the in-
let connector is worn or has uneven con-
tact pattern.
a If high-pressure fuel leaks through the in-
let connector, the sealing surface has fine
streaks or cracks.
7) Insert inlet connector (91) completely, while
matching its part (b) with the groove (upper)
on the head side.
2 O-ring (91a) and inlet connector
mounting bore: Engine oil (For de-
tails, see "List of lubricant and wa-
ter".)
HB205-1, HB205LC-1
(01)
 Engine and cooling system
Removal and installation of cylinder head assembly

4. Install the rocker arm assembly according to the

following procedure.
1) Install push rod (97).
2) Install crosshead (96).
a Install each crosshead in the position and
direction (the shape of parts (a) and (b))
recorded when removed.

8) Install retainer (90) and tighten it temporarily.

3 Inlet connector retainer :
15 5 Nm {1.5 0.5 kgm}

9) Alternately tighten mounting bolts (98) of fuel

injector assembly (99).
3 Fuel injector mounting bolt:
8 0.8 Nm {0.8 0.08 kgm} 3) Install rocker arm (93) and tighten mounting
10)Tighten retainer (90) to the specified torque. bolt (92).
3 Retainer (90): a Ensure that adjustment screw (95) is suf-
50 5 Nm {5.1 0.51 kgm} ficiently loose.
3 Rocker arm mounting bolt (92):
36 5 Nm {3.7 0.51 kgm}
4) Adjust the valve clearance. For details, see
Testing and adjusting, Adjusting valve clear-
ance.
a Use tool A1 to rotate the engine.
5) After valve clearance adjustment, ensure
that lock nut (94) is tightened to the specified
torque.
3 Lock nut (94):
24 4 Nm {2.4 0.4 kgm}

HB205-1, HB205LC-1 50-43

(01)
Engine and cooling system
Removal and installation of cylinder head assembly
6) Install the wirings and tighten them with the
nuts.
a Check that the wirings do not interfere
with the rocker arm.
a Installed positions of wires
Cable color Cylinder No.
White 1, 3
Black 2, 4
3 Wiring mounting nut (89):
1.5 0.25 Nm {0.15 0.03 kgm}
5. Install cylinder head cover (88).
3 Cylinder head cover mounting nut:
24 4 Nm {2.4 0.4 kgm}
a If the stud bolt is removed, install it and tight-
en to the following torque.
3 Stud bolt:
24 4 Nm {2.4 0.4 kgm}
6. Install clamp (87b) of the fuel return tube.
7. Install joint bolt (87a) and fuel return tube (87).
3 Joint bolt:
19.6 29.4 Nm {2.0 3.0 kgm}
8. Install two bolts (85) and blow-by duct (86).
a When installing the blow-by duct, check that
the two O-rings are fitted.
3 Blowby duct mounting bolt:
7 2 Nm {0.71 0.2 kgm}
50-44
9. Connect turbocharger cooling tube (84).
10. Install the alternator assembly according to the
following procedure.
q Install fan belt (82) to alternator (83) accord-
ing to the following procedure.
1) Install fan belt (82) on each of the pulleys.
2) Insert wrench [1] in hole (A) (width across
flats: T12.7 mm) of tensioner assembly (81)
and rotate it counterclockwise (R), seeing
from the front of the engine, to decrease the
tension of the tensioner assembly, and install
the fan belt.
3) Install wiring (79) and (80).
k Set wrench [1] securely to hole (A) of the
tensioner assembly before rotating the
tensioner assembly. (The spring of the
tensioner assembly is strong. If wrench
[1] is set incompletely and rotated, it
comes off and that is very dangerous.))
k Rotate the tensioner assembly. While ro-
tating, take care that wrench [1] will not
come off.
k After installing fan belt (82), loosen
wrench [1] slowly and carefully.
k Take care not to catch your finger be-
tween the pulley and fan belt during the
work.
HB205-1, HB205LC-1
(01)
 Engine and cooling system
Removal and installation of cylinder head assembly

11. Install radiator fan (78).

16. Install exhaust manifold assembly (69) and eight

12. Install fan guards (76) and (77).
exhaust manifold mounting bolts (69a).
a Tighten the exhaust manifold according to
the following procedure.
1) Tighten to 24 4 Nm {2.4 0.4 kgm} in the
order [1] to [8] shown in the figure.
2) Tighten to 53 5 Nm {5.4 0.51 kgm} in the
order [1] to [8] shown in the figure.
3) Tighten only [1] to [4] in the figure again to 53
5 Nm{ 5.4 0.51 kgm}.

13. Install coolant temperature sensor connector

(75).

14. Install coolant bypass hoses (73) and (74) and

secure with clamp (71).

15. Install radiator upper hose (72) to water pump

and secure it with clamp (70).
(Radiator hose insertion length)
Engine side: 49 mm
Radiator side: 45 mm
3 Radiator hose clamp mounting bolt:
10.8 11.8 Nm {1.1 1.2 kgm}

HB205-1, HB205LC-1 50-45

(01)
Engine and cooling system
Removal and installation of cylinder head assembly

17. Install heat insulation plate (68).

18. Install the muffler and turbocharger assembly

according to the following procedure.
1) Install two hexagon socket head bolts (65)
and outlet tube (66) of the turbocharger lubri-
cating oil.
3 Mounting bolt of lubricating oil re-
turn tube for turbocharger:
10 2 Nm {1.0 0.2 kgm}
(Hexagonal head bolt M6x1.0)
2) Install turbocharger (67) and fix with turbo-
charger mounting nuts (63).
3 Turbocharger mounting nut:
24 4 Nm {2.4 0.4 kgm} 4) Remove band clamp and remove the old
a If the stud bolt is removed, install it and heat cure sealant from exhaust pipe (58).
tighten to the following torque. a Do not reuse the band clamp.
3 Stud bolt:
5) Temporarily assemble muffler bracket (50),
10 2 Nm {1.0 0.2 kgm} muffler assembly (59), and exhaust pipe
3) Install turbocharger lubricating oil inlet hose (58).
(61) according to the following procedure and Apply heat cure sealant to exhaust pipe (58)
tighten sleeve nut (60).
3 Mounting nut of lubricating oil inlet
at where it is inserted to the muffler, and
install muffler assembly (59).
2 Entire periphery of part E:
hose for turbocharger
35 3.5 Nm {3.57 0.36 kgm} Heat cure sealant
a When tightening the hose mounting nut, (Holts FIREGUM or equivalent)
fix the connector on the turbocharger side
securely by using a wrench since its tight-
ening is low.
a If the connector is loosened, tighten it to
the following torque.
9.8 - 12.7 Nm {1.0 - 1.3 kgm}

50-46 HB205-1, HB205LC-1

(01)

Removal and installation of cylinder head assembly
6) Temporarily set the above-mentioned
assembly to turbocharger (67) and place it on
muffler bracket (50) to adjust the position.
12)Install aftercooler lower hose (57) to the
7) Adjust the position of the muffler so that the
centerlines of turbocharger (67) and muffler
assembly (59) are aligned. (Position parts
while muffler bracket mounting bolt and
U-clamp are loose.)
8) Tighten turbocharger outlet V clamp (52).
3 Clamp bolt:
6.9 8.8 Nm {0.7 0.9 kgm}
(Desirable to replace V-clamp with
a new part.)
9) Tighten U-bolts (49).
3 U-bolt tightening nut (48):
22.0 38.0 Nm {2.24 3.87 kgm}
10)Tighten muffler bracket (50).
11)Tighten new band clamp (47).
3 Clamp bolt:
1st time: 39.2 49.0 Nm {4 5 kgm}
2nd time: 68.6 122.5 Nm {7 12.4
kgm}
k Be sure to replace the band clamp with
a new one. Also, install it last.
HB205-1, HB205LC-1
(01)
Engine and cooling system
connector on the turbocharger side.
q If a hose is equipped with a MIKALOR
clamp, install it according to the following
procedure.
a Use a new MIKALOR clamp.
1] Set the hose to the original position
(marked when the hose was
removed).
(Hose insertion depth)
Part (z) of hose (57) between after-
cooler and turbocharger: 80 mm
2] Place bridge (BR) under the clamp
bolt and set overlap (b) between
bridge (BR) and band to the following
dimension.
Dimension (b): Min. 5 mm
3 Clamp bolt thread portion (BC):
Lubricant (THREEBOND PAN-
DO 18B)
a Do not use an impact wrench.
q When reusing the hose
50-47
Engine and cooling system
Removal and installation of cylinder head assembly

3] Install the clamp to the clamp mark 16)Install covers (46) and (51).
made on the hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
q When using a new hose
4] Tighten until dimension BDG
becomes as follows.
Part (z):7 10 mm

17)Install muffler drain pipe (45) and tighten

clamp (44).

13)Install hose (56) between the turbocharger

and air cleaner to the turbocharger.
3 Clamp bolt:
10.0 11.0 Nm {1.02 1.12 kgm}
14)Install turbocharger cooling tubes (54) and
(55) to the turbocharger.
15)Install connector (53) of turbocharger cooling
hose to the turbocharger.

18)Install plate (43).

50-48 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of cylinder head assembly

19. Install the fuel injection pipe and fuel high-pres- a The common rail assembly is finally tight-
sure pipe according to the following procedure. ened after step 6).
[*4], [*5], [*7]
a Do not reuse the fuel injection pipe or fuel
high-pressure pipe by bending it.
k Be sure to use genuine fuel injection
pipe clamps and tighten them to the
specified torque.
k Be sure to use genuine fuel injection
pipe clamps and tighten them to the
specified torque.
k After installing the fuel injection pipe
or fuel high-pressure pipe, be sure to
install the boot to the sleeve nut.
k When installing the boot, direct it out
down.
a Before installing the fuel injection pipe or fuel 2) Install the fuel injection pipe between the
high-pressure pipe, check the following. common rail and cylinder head and tighten it
q If the fuel injection pipe has a fault, it may
with sleeve nut (39) temporarily.
3 Sleeve nut:
leak the fuel. Accordingly, replace it with
a new one. 0.2 0.8 Nm {0.02 0.08 kgm}
q Taper seal section (j) at the connecting
3) Install the fuel injection pipe and tighten
end: Check that there is no visible streaky sleeve nut (39) to the specified torque
slits (k) or spotty dimples (l) in the 2 mm according to the following procedure.
3 Sleeve nut:
distance area from the end.
q (Check that portion (m) (the end of the ta-
35 3.5 Nm {3.57 0.36 kgm}
per seal section: 2 mm from the end) is 1] #1 cylinder head side
not stepped (deformed) that your nail can 2] #4 cylinder head side
feel. 3] #4 common rail side
4] #1 common rail side
5] #2 cylinder head side
6] #3 cylinder head side
7] #2 common rail side
8] #3 common rail side

1) Tighten common rail assembly (42) tempo-

rarily with mounting bolts (41).
3 Mounting bolt:
0.2 0.8 Nm {0.02 0.08 kgm}

HB205-1, HB205LC-1 50-49

(01)
Engine and cooling system
Removal and installation of cylinder head assembly
4) Install fuel high-pressure pipe (40) between
the fuel supply pump and common rail and
tighten it with sleeve nut (39) temporarily.
3 Sleeve nut:
0.2 0.8 Nm {0.02 0.08 kgm}
5) Tighten the sleeve nut on the fuel supply
pump side first, and then tighten that on the
common rail side to the specified torque.
3 Sleeve nut:
35 3.5 Nm {3.57 0.36 kgm}
6) Install fuel high-pressure pipe clamps (37)
and (38).
3 Mounting bolt:
24 4 Nm {2.4 0.4 kgm}
7) Tighten common rail assembly (42) mounting
bolts (41) to the specified torque.
a When common rail assembly was re-
moved
3 Mounting bolt:
24 4 Nm {2.4 0.4 kgm}
50-50
8) Install the boots to all the fuel high-pressure
pipes.
k Install the boots with the slits out and
down.
a The boots are installed so that fuel does
not spout over the hot parts of the engine
and catch fire when it leaks for some rea-
son.
9) Install quick couplers (33), (34), and (35) of
the fuel return tube.
a Handling of fuel pressure sensor and fuel re-
lief valve
1) Procedure for installing fuel pressure sensor
(a)
If fuel pressure sensor (a) was removed from
common rail assembly (42), be sure to
replace it with a new one.
1] Check the fuel pressure sensor connector
for cracking/breakage, damage of seal,
foreign matter at pin, corro-
sion/bend/breakage of pin, etc.
2] Install a new fuel high-pressure sensor.
a Apply clean gear oil (#90) to the
threaded portion.
3 Fuel pressure sensor:
70 5 Nm {7.1 0.5 kgm}
HB205-1, HB205LC-1
(01)
 Engine and cooling system
Removal and installation of cylinder head assembly

3] Connect wiring connectors (24)and (29).

At this time, take care not to connect the
connectors in reverse.
(After starting the engine, check for
leakage. For the checking procedure, see
Testing and adjusting, "Testing fuel
system for leakage".)

a If injector harness connector (IHC) is re-

moved, apply liquid gasket LG-7 to O-ring
(o) and flange (p) of the connector.
Apply a bead of LG-7 f3 mm in diameter
to the O-ring so that the ring groove is
completely sealed.
If the O-ring is damaged, replace it and
2) Procedure for installing fuel pressure relief the harness assembly as a unit.
valve (b) 3 Connector flange mounting
1] Before removing the fuel pressure relief bolt:
valve, remove all mud from around it and 10 2 Nm {1 0.2 kgm}
clean thoroughly.
2] Remove the fuel pressure relief valve.
3] If the leakage through the fuel pressure
relief valve exceeds the specified value,
do not reuse that relief valve.
4] Ensure that the fuel pressure relief valve
and rail high-pressure seal surface (A)
are free from damage.
5] Install the fuel pressure relief valve.
2 Threaded portion of fuel pres-
sure relief valve:
Gear oil (#90)
3 Fuel pressure relief valve:
100 4 Nm {10.2 0.4 kgm}
a Tightening too strongly can cause
20. Install the air conditioner compressor mounting
leakage.
bracket according to the following procedure.
(After starting the engine, check for
1) Install brackets (22) and (23) as a unit and
leakage. For the checking procedure,
install two bolts (21).
see Testing and adjusting, "Testing
fuel system for leakage".)

HB205-1, HB205LC-1 50-51

(01)
Engine and cooling system
Removal and installation of cylinder head assembly

2) Install three bolts (20). q When using a new hose

3) Install wiring clamps (18) and (19). 4) Tighten until dimension BDG becomes as
4) Install ribbon heater wiring E01 (17). follows.
(x), (y): 7 10 mm

21. Install air hose (13).

q If a hose is equipped with a MIKALOR clamp,
install it according to the following procedure.
a Use a new MIKALOR clamp.
1) Set the hose to the original position (marked
when the hose was removed).
(Hose insertion depth)
Hose (16) between aftercooler and air intake
manifold
(x): 80 mm
(y): 80 mm
2) Place bridge (BR) under the clamp bolt and
set overlap (b) between bridge (BR) and
band to the following dimension.
Dimension (b): Min. 5 mm
3 Threaded portion of clamp bolt
22. Install the air conditioner compressor assembly
according to the following procedure.
(BC):
1) Install air conditioner compressor assembly
Lubricating oil (THREEBOND PAN-
(15), and install air conditioner compressor
DO 18B)
fixing bolt (12) and belt tension adjustment
a Do not use an impact wrench.
bolt (13).
q When reusing the hose
2) Install air conditioner compressor drive belt
3) Install the clamp to the clamp mark made on
(14), and install air conditioner compressor
the hose.
3 Clamp bolt:
bolt (12) and belt tension adjustment bolt
(13).
Min. 6 Nm {0.6 kgm}
a Adjust the tension of the air conditioner
compressor drive belt. For details, see
Testing and adjusting, "Adjusting belt ten-
sion".
q If mounting bolts (MB) of the air condition-
er compressor were loosened, tighten
them to the following torque.
a Tightening to too high torque can
damage the internal bearings. Ob-
serve the specified torque strictly.
3 Mounting bolt:
2.45 29.4 Nm {2.5 3.0 kgm}

50-52 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of cylinder head assembly

7) Install fan guard (6).

3) Install bracket (11).

4) Install wiring clamp (10). 23. Install counterweight maintenance cover (5).

5) Install wiring clamps (8) and (9). 24. Close engine hood (4).
6) Install wiring connector AC02 (7).

HB205-1, HB205LC-1 50-53

(01)
Engine and cooling system
Removal and installation of cylinder head assembly

25. Open fuel stop valve (1).

q Refilling with coolant (engine cooling sys-

tem)
Supply coolant through the coolant filler port to
the specified level. Run the engine to circulate
the coolant through the system. Then, restart the
engine and check the coolant level again.
5 Engine cooling system (engine cool-
ant):
17.3 l

q Refilling of oil
Tighten the drain plug and supply diesel fuel
through the filler port.
5 Fuel tank:
400 l
q Bleeding air
a Bleed air from the fuel system. For details,
see Testing and adjusting, "Bleeding air from
fuel system".

50-54 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of radiator assembly

Removal and installation of radiator assembly 50-5

Removal 50-5 4. Open the engine hood.

k Park the machine on a level place and swing
the upper structure 90 deg., and then lower 5. Disconnect reservoir tank hose (5).
the work equipment to the ground safely and
stop the engine. 6. Disconnect turbocharger cooling hose (6).
k Disconnect the cable from the negative (-)
terminal of the battery. 7. Remove cover (7).

1. Remove cover (1). 8. Disconnect radiator hose fixing bracket (8).

9. Disconnect radiator upper hose (9). [*2]

a Make marks at the hose end and tube to indi-
cate their inserted positions.

2. Loosen radiator drain valve (2) to drain the

coolant.
6 Radiator:
17.3 l

3. Loosen hose clamp (3) and disconnect radiator

lower hose (4). [*1]

HB205-1, HB205LC-1 50-55

(01)
Engine and cooling system
Removal and installation of radiator assembly

10. Remove two bolts (10). Installation 50-56

q Perform installation in the reverse order to re-
moval.

[*1], [*2]
q Insert each hose to the position marked when re-
moved.
a Insertion depth: 45 mm (upper and lower)
3 Radiator hose mounting clamp:
10.8 11.8 Nm {1.1 1.2 kgm}
a Align the clamp to the original position.

[*3]
a Ensure that the heat insulation sealant (sponge)
around the radiator is not damaged.
11. Lift off radiator assembly (11). [*3] If the heat insulation sealant (sponge) is
4 Radiator assembly:
damaged, replace it.
15 kg a Check that convex part (A) at the radiator bottom
is matched with concave part (B) from the under-
cover side.

q Refilling of coolant
5 Radiator:
17.3 l
a Run the engine to circulate the coolant
through the system and then check the cool-
ant level again. If the coolant level is low, add
coolant.

50-56 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of hydraulic oil cooler assembly

Removal and installation of hydraulic oil cooler assembly 50-57

3. Remove two hose mounting bolts(3) and bracket

(4).

a Removal (and installation) procedures in this

section can be carried out by personnel other
than those who have finished a special training
course for handling low voltage electrical appli-
ances.
k Never disconnect the high-voltage wiring
(power cable) during the removal and instal-
lation work in this section.

Removal 50-57
k Park the machine on a level place and swing
the upper structure 90 deg., and then lower
the work equipment to the ground complete-
ly and stop the engine. 4. Open the engine hood.
k Loosen the hydraulic tank oil filler cap grad-
ually to release the pressure inside the tank 5. Remove the mounting bolts of cover (5).
and then set the lock lever to the LOCK posi-
tion.
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Remove cover (1).

6. Remove cover (6).

7. Remove two bolts (7) to disconnect hydraulic

tank return tube (8).

2. Loosen drain plug (2) to drain the oil from the

hydraulic oil cooler. [*1]
6 Hydraulic oil cooler:
9l

HB205-1, HB205LC-1 50-57

(01)
Engine and cooling system
Removal and installation of hydraulic oil cooler assembly

8. Remove two bolts (9). Installation 50-58

q Perform installation in the reverse order to re-
moval.

[*1]
a Ensure that the heat insulation sealant (sponge)
around the hydraulic oil cooler is not damaged.
If the heat insulation seal (sponge) is damaged,
replace it.
a Check that convex part (A) at the oil cooler bot-
tom is matched with concave part (B) from the
undercover side.

9. Sling and remove hydraulic oil cooler assembly

(10).
4 Hydraulic oil cooler assembly:
17 kg

q Refilling of oil (Hydraulic tank)

Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.
5 Hydraulic oil cooler:
9l

50-58 HB205-1, HB205LC-1

(01)

Removal and installation of aftercooler assembly
Removal 50-59
k Park the machine on a level place and swing
the upper structure 90 deg., and then lower
the work equipment to the ground complete-
ly and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.
1. Remove cover (1).
2. Remove bolts (2) and disconnect aftercooler
lower tube (3). [*1]
3. Remove three bolts (4) and move cover (5).
a Perform this work to prevent the flange at the
lower tube mounting portion from interfering
with other parts when the aftercooler is lifted
up.
HB205-1, HB205LC-1
(01)
Engine and cooling system
Removal and installation of aftercooler assembly
50-59
4. Open the engine hood.
5. Remove cover (6).
6. Remove four bolts (7) and disconnect after-
cooler hose fixing bracket (8) from shroud (9).
a The four bolts are fixed to the bracket on the
back side of shroud (9). When removing
them, insert your hand through the hole of re-
moved cover (6) and support the bracket.
(If you remove fan guard (10) and support the
bracket through that portion, you can work
easily.)
a Do not loosen U-clamp (11). [*2]
7. Disconnect aftercooler upper hose (12). [*3]
a Make marks at the hose end and tube to indi-
cate their inserted positions.
50-59
Engine and cooling system
Removal and installation of aftercooler assembly

8. Remove two bolts (13).

9. Sling and remove aftercooler assembly (14).[*4]

4 Aftercooler assembly:
10 kg

50-60 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of aftercooler assembly

Installation 50-61
q Perform installation in the reverse order to re-
moval.

[*1]
a Replace the O-ring with a new one.

[*2]
q If the U-clamp (11) was loosened or removed, in-
stall it and tighten to the following torque.
3 Mounting nut:
10.8 19.6 Nm {1.1 2.0 kgm}

[*4]
a Ensure that the heat insulation sealant (sponge)
around the aftercooler is not damaged.
If the heat insulation sealant (sponge) is
damaged, replace it.
a Check that convex part (A) at the aftercooler bot-
tom is matched with concave part (B) from the
undercover side.

[*3]
q Install hose (12) according to the following pro-
cedure.
a Use a new MIKALOR clamp.
1) Insert each hose to the position marked
when removed.
(Hose insertion length)
Aftercooler side: 60 mm
Removed tube side: 67 mm
2) MIKALOR clamp at 30 mm from the marked
position.
3) Place bridge (BR) under the clamp bolt and
set overlap (b) between bridge (BR) and
band to the following dimension.
Dimension (b): Min. 5 mm
2 Threaded portion of clamp bolt
(part BC):
Lubricating oil (THREEBOND, PAN-
DO 18B)
4) Tighten the clamp bolt to the following
torque.
(When reusing hose)
a Install the clamp to the clamp mark made
on the hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}

(When using new hose)

Tighten until dimension (BDG) becomes as
follows.
Dimension (BDG): 7 10 mm

HB205-1, HB205LC-1 50-61

(01)
Engine and cooling system
Removal and installation of engine front seal

Removal and installation of engine front seal 50-62

Special tools 50-62 Installation 50-62

1. Using tool A4, install front oil seal (3).

New/redesign
a Replace the engine front oil seal.

Necessity
Symbol Part number Part name a Before installing the engine front oil seal,

Sketch
check that crankshaft end corners and seal

Q'ty
lip sliding surfaces are free from a housing
4 795-799-6400 Seal puller t 1 flaw, burr, fin, rust, etc.
A
6 790-331-1120
Wrench
q 1 a When installing the engine front oil seal, do
(Angle) not apply oil or grease to the crankshaft and
seal lip. Thoroughly wipe off oil and grease
Removal 50-62 from the crankshaft.
1. Remove the engine, motor-generator, and main
pump assembly referring to the section of
"Removal (and installation) of engine,
motor-generator, and main pump assembly".

2. Remove crank pulley mounting bolts (1) and

crank pulley (2).

a The projection and runout of engine front oil

seal (3) from cover (4) must be as follows.
q Projection (x): Max. 0.38 mm
q Facial runout (y): Max. 0.25 mm

3. Remove engine front seal (3).

50-62 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of engine front seal

2. Crankshaft pulley (When not using angle tightening tool A6)

1) Check the dowel pin position on the reverse 5] After performing steps 1] 3] above,
side of crankshaft pulley (2) and install the make marks on the crankshaft pulley and
crankshaft pulley to the crankshaft. bolts.
a If the dowel pin was removed, install it be- 6] Tighten the bolts in the diagonal order to
fore installing the crankshaft pulley. the following angle.
2) Install crankshaft pulley mounting bolts (1) Tightening angle: 90 5deg.
according to the following procedure.
1] Tighten the bolts in the diagonal order to
the following torque.
3 Mounting bolt:
55 5 Nm {5.6 0.5 kgm}
2] Loosen all the bolts 180 deg.
3] Tighten the bolts in the diagonal order to
the following torque.
3 Mounting bolt:
55 5 Nm {5.6 0.5 kgm}
4] Using angle tightening tool A6, tighten the
bolts in the diagonal order to the following
torque. (See Special Tools List.)
Tightening angle: 90 5deg.
q Perform the subsequent installation in the re-
verse order to removal.

HB205-1, HB205LC-1 50-63

(01)
Engine and cooling system
Removal and installation of engine rear seal

Removal and installation of engine rear seal 50-64

5. Remove the flywheel according the following

procedure.
1) Remove two flywheel mounting bolts (3) on a
Special tools 50-64
diagonal line and install guide bolts [1]. [*1]

New/redesign
2) Sling flywheel (4) and remove the remaining
mounting bolts.

Necessity
Symbol Part number Part name 3) Pull out flywheel (4) toward you.

Sketch
4) Remove guide bolts [1] and lift off flywheel

Q'ty
(4).
4 Flywheel: 15 kg
A 5 795-799-6500 Seal puller t 1

Removal 50-64
1. Remove the engine, motor-generator, and main
pump assembly by referring to "Removal (and
installation) of engine, motor-generator, and
main pump assembly".

2. Remove the main pump assembly. For details,

see "Removal and installation of main pump
assembly".

3. Remove the motor-generator and housing

assembly by referring to "Removal (and installa-
tion) of motor-generator and housing assembly".

4. Remove ten bolts (1) and coupling (2).

50-64 HB205-1, HB205LC-1

(01)

6. Pulling out of rear oil seal
1) Install tool A5 to the crankshaft.
2) Drive tapping screw [2] of tool A5 into the
seal carrier of engine rear oil seal (5).
3) Rotate the handle clockwise to remove
engine rear oil seal (5).
HB205-1, HB205LC-1
(01)
Engine and cooling system
Removal and installation of engine rear seal
Installation 50-65
1. Install the oil seal according to the following
procedure.
a Replace the engine rear oil seal.
a Do not remove pilot [3] which is attached to
rear oil seal (5) until it is inserted to the crank-
shaft.
a Before installing the engine rear oil seal, de-
grease, clean and dry the crankshaft sealing
face and the seal lip face to prevent oil leak-
age.
2. Insert pilot [3] to crankshaft (6) and push engine
rear oil seal (5) into flywheel housing (7).
3. Push in engine rear oil seal (5) further and then
pull out pilot [3].
50-65
Engine and cooling system
Removal and installation of engine rear seal

4. Install engine rear oil seal (5) on flywheel [*1]

housing (7) to the proper depth by using tool A5.
a Push in engine rear oil seal (5) with care not
to bend it.
a Extrusion of engine rear oil seal (5) from fly-
wheel housing (7)
(X): Max. 0.38 mm
a Part (6) in the following figure is the crank-
shaft.
a Tighten the eight flywheel assembly mounting
bolts (3) in the order of [1] through [8] as shown
in the figure below.
3 Flywheel assembly mounting bolt:
137 7 Nm {13.97 0.71 kgm}

a Tighten the bolts using bar [4] for preventing ro-

tation of the flywheel assembly.

q Perform the subsequent installation in the re-

verse order to removal.

50-66 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of engine rear seal

q Measurement of radial runout

a Radial runout: Max. 0.13 mm
1) Install dial gauge [5] on the stand, and set the
stand on flywheel housing (7).
2) Make the probe of dial gauge contact with
spigot joint portion (a) or outer circumference
of the flywheel at a right angle.
3) Rotate the flywheel 360 deg. and measure
the maximum swing width of the dial gauge
[5] indicator.
a Check that the dial gauge [5] indicator is
back in the original position after the fly-
wheel is rotated 360 deg.
q Measuring facial runout
a Facial runout: Max. 0.20 mm
1) Similarly to the measurement of radial
runout, make the probe of dial gauge [5]
contact at a right angle with the end face (b)
near the outer circumference of the flywheel.
a Perform the measurement with the crank-
shaft pulled to either the front or rear side
of the engine to prevent errors caused by
backlash.
2) Rotate the flywheel 360 deg. and measure
the maximum swing width of the dial gauge
[5] indicator.

HB205-1, HB205LC-1 50-67

(01)
Engine and cooling system
Removal and installation of fuel cooler assembly

Removal and installation of fuel cooler assembly 50-68

Removal 50-68 3. Remove two mounting bolts (6) of the fuel cooler
k Park the machine on a level place, lower the mounting bracket.
work equipment to the ground completely,
and stop the engine. 4. Remove fuel cooler assembly (7) and bracket (8)
k Disconnect the cable from the negative (-) together.
terminal of the battery.

1. Close fuel stop valve (1).

(Position of fuel cooler assembly (7) after counter-

weight is removed)

2. Disconnect fuel hoses (2) and (3). [*1]

a Prepare an oil container to receive the fuel
flowing out of the fuel hoses.
a When loosening each fuel hose, hold elbows
(4) and (5) on the fuel cooler side.

50-68 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of fuel cooler assembly

Installation 50-69
q Perform installation in the reverse order to re-
moval.

[*1]
a When tightening each fuel hose, hold elbow on
the fuel cooler side using a wrench.

q Bleeding air
After adding fuel, bleed air from the fuel system.
For details, see Testing and adjusting, "Bleeding
air from fuel system".

HB205-1, HB205LC-1 50-69

(01)
Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

Removal (and installation) of engine, motor generator, and main pump

assembly 50-70

k When opening the coolant filler cap or drain-

ing the coolant, ensure that coolant tempera-
ture is low and it does not scald you.
k Removal (and installation) procedures in this
section must be carried out by a person who
has finished a special training course for
handling low voltage electrical appliances.
Understand the contents of 00 Introduction,
safety, and basic information, "Safety pre-
cautions 1. Precautions peculiar to hybrid
machine" and "Handling of hybrid devices
and high-voltage wirings" before starting
work.
a Do not disconnect the generator motor from the
engine for quality assurance.

Special tools 50-70

New/redesign
Necessity
Q'ty

Symbol Part number Part name

8 796T-401-1110 Plate q 1
9 795-790-9300 Lifting tool q 1
10 796-460-1210 Oil stopper q 1
A
11 796-770-1320 Adapter q 1
12 Commercially Megaohm tester t 1
available

Removal 50-70
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.

k Discharge the capacitor. For details, see 00

Introduction, safety, and basic information,
"Handling of hybrid devices and high-voltage
wirings", "Discharge procedure for capaci-
tor".
k Disconnect two one-touch connectors (cable
terminals of (+) and (-)) from the capacitor
(See step 3).

k Referring to Testing and adjusting, "Releas-

ing remaining pressure in hydraulic circuit",
release the pressure inside the hydraulic cir-
cuit and then set the lock lever to the LOCK
position.
k Disconnect the cable from the negative (-)
terminal of the battery.

50-70 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

k While draining the coolant, take care that the 3. Disconnect two one-touch wiring connectors
coolant does not stick to your skin or enter HB01 (CC) (cable terminals of (+) and (-)) from
your eye. the capacitor.
Super Coolant mixed in the coolant is toxic. a While pressing the lock portion of the con-
If the coolant splashes on your skin or enters nector with your thumb to unlock the connec-
your eye, wash it away immediately with tor, pull out the connectors.
plenty of water and then consult a doctor.
a Record the installed positions, connector Nos.,
or hose band colors of the disconnected wires
and pipes so that you do not make a mistake in
their connection positions.

1. Open left inspection cover (1).

4. Remove counterweight maintenance cover (4).

2. Remove three nuts (2) from the top of inverter

and remove cover (3).

5. Remove lower covers (5) to (9).

k Since each cover is heavy, remove them
carefully.

HB205-1, HB205LC-1 50-71

(01)
Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

6. Close fuel stop valve (10).

50-72 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

7. If the fuel level is above the prefilter adapter,

drain some fuel through fuel drain valve (11) so
that it does not flow out when the hose is discon-
nected.

9. Remove the engine hood according to the

following procedure.
1) Open engine hood (14) and sling it.
2) Remove pins (15) and (16) and disconnect
8. Loose drain plug (12) to drain the oil from the two gas springs (17) on the right and left
hydraulic oil tank. sides.
6 Hydraulic tank
: 232 l(Specified amount of oil)
: 135 l(Refill capacity)

3) Remove four bolts (19) from hinges (18) and

lift off engine hood (14).
a Make marks of (x) and (y) to hinges (18)
a If you do not drain the oil from the hydraulic to indicate their installed positions.
tank, install the stopper by using tool A10 ac- 4 Engine hood:
cording to the following procedure. 45 kg
1) Remove cover (13).
2) Remove the strainer.
3) Assemble tool A10 (oil stopper) and A11
(adapter).
4) Install tools A10 and A11 together to the
position of the removed strainer.
5) Install cover (13).
a Tighten with several bolts temporarily.

HB205-1, HB205LC-1 50-73

(01)
Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

10. Remove the covers and frames according to the 6) Remove frame (28).
following procedure. 7) Remove heat insulation plate (29).
1) Remove cover (20). a Remove rubber partition (29a) and heat
2) Remove partitions (21) and (22). insulation plate (29) together.
a To remove partition (21), remove cover
(20) and remove bolt (21a), and the re- 11. Disconnect prefilter (30) and bracket (31)
move two bolts (21b) from the control together from frame (32).
valve side.
a Remove bolt (23) to remove partition (22).
3) Remove two bolts (24) and partition (25).
a Remove bolt (24) from the control valve
side.
a Remove partition (25) by pulling it up.
4) Remove cover (26).
5) Remove frame (27).

12. Disconnect connector P47 (34) of water-in-fuel

sensor (33).

50-74 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

13. Disconnect fuel filter (35) and bracket (36)
together from frame (37).
a Place fuel filter (35) and bracket (36) together
on the engine.
14. Disconnect lubricating oil filter (38) of the gener-
ator motor from bracket (36).
a Bind lubricating oil filter (38) of the mo-
tor-generator to the engine/ motor-generator
/ main pump assembly.
16. Disconnect the following seven hoses
connected to the main pump.
(40) Rear load pressure input port hose
(Collar band color: None)
(41) EPC source pressure port hose
(Collar band color: Yellow)
(42) Front load pressure input port hose
(Collar band color: Red)
(43) Pump pressure input port hose
(Collar band color: Blue)
(44) Drain port hose
(45) Pump discharge port hose (2 pieces)
(45a) Branch hoses (2 pieces)

17. Remove four bolts (46) and disconnect suction

tube (47).

15. Remove pump side door (39) on the rear right

side of the machine.
4 Door:
26 kg

HB205-1, HB205LC-1 50-75

(01)
Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

18. Remove motor-generator connector CM01 (48)

and clamp (49).

19. Disconnect and move the air conditioner

compressor so that it is not an obstacle
according to the following procedure.
1) Remove fan guard (50).
2) Disconnect wiring connector AC02 (51).

20. Remove hose (58) returning from the after-

cooler.
[*2]
a Do not loosen U-bolts (59).
a Make marks at the hose end and tube to indi-
cate their inserted positions.

21. Remove radiator upper hose (60). [*3]

3) Disconnect wiring clamps (52) and (53).
4) Loosen air conditioner compressor fixing bolt
(54) and belt tension adjustment bolt (55)
and remove air conditioner compressor drive
belt (56).
a Do not loosen air conditioner compressor
mounting bolts (MB). [*1]
5) Remove air conditioner compressor fixing
bolt (54) and belt tension adjustment bolt (55)
and disconnect air conditioner compressor
assembly (57).
a Make marks at the hose end and tube to indi-
cate their inserted positions.
22. Disconnect turbocharger cooling hose (61).
a Disconnect clip (62).
23. Disconnect bypass hose (63) and heater hose
(64).
24. Disconnect hose (65) between the turbocharger
and air cleaner from the turbocharger. [*4]

50-76 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

26. Disconnect ribbon heater wiring (69).

27. Disconnect wiring clamps (70) and (71).

28. Disconnect hose (72) going to the aftercooler

from elbow (72a) on the engine side. [*5]

29. Disconnect radiator lower hose (73) from the

water pump. [*6]

30. Disconnect heater hose (74) from the water

pump.

25. Remove covers (66), (67), and (68).

HB205-1, HB205LC-1 50-77

(01)
Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

31. Disconnect starting motor wiring (75) and wiring 37. Remove connector cover (84) of the
connector E10 (76) high-voltage wiring (power cable).

38. Remove clamp (85) of the high-voltage wiring

(power cable).

39. Disconnect connectors (86) and (87) of the

high-voltage wiring (power cable). [*7]
(Connector No.) (Number of line)
(86): GM03 A2 (2 lines)
(87): GM02 A1 (1 line)

32. Disconnect wiring clamps (77) and (78).

a Work from underside of the engine.

33. Disconnect wiring connectors E08 (79) and P44

(80).
a Work from underside of the engine.

40. Disconnect hose clamps (88), (89), and (90).

34. Disconnect wiring connector GM01 (81).

35. Disconnect wiring clamp (82).

36. Disconnect ground cable (83).

50-78 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

41. Disconnect wiring connectors CE02 (91) and 47. Disconnect wiring connector K02 (101).
CE03 (92) from the engine controller.
48. Disconnect engine controller ground strap T12
(102).

49. Disconnect wiring clamps (103) and (104).

42. Disconnect fuel return hose (93). [*8]

43. Disconnect fuel hoses (94) and (95) between the

supply pump and fuel filter. [*9]
a After disconnecting the hose, plug its both 50. Disconnect ground cable (105).
ends.
51. Remove four engine mounting bolts (106).
44. Disconnect fuel hose (96) between the supply [*11]
pump and prefilter. a When removing three engine mounting bolts
a After disconnecting the hose, plug its both (103) other than the one at the right front of
ends. the engine (engine grounding portion), se-
cure nut (N) with nut lock tool A8 and bolt (B).
45. Disconnect fuel hose clamp (97). (Nuts (N) other than the one at the right front
of engine will be dragged if not held because
46. Disconnect hybrid swing motor lubrication hoses they are not welded to the frame.)
(98) to (100). [*10]

HB205-1, HB205LC-1 50-79

(01)
Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

52. Lift off engine/ generator motor/ main pump

assembly (107).
a As a sling for this work, tool A9 is a recom-
mended.
(See tool table)
a Ensure that all the wiring and hoses are dis-
connected before lifting off the assembly.
4 Engine, motor-generator, and main
pump assembly:
870 kg

50-80 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

Installation 50-81
q Perform installation in the reverse order to re-
moval.

[*1]
q If mounting bolts (MB) of the air conditioner com-
pressor were loosened, tighten them to the fol-
lowing torque.
a Tightening to too high torque can damage
the internal bearings. Observe the specified
torque strictly.
3 Mounting bolt:
24.5 29.4 Nm {2.5 3.0 kgm}
[*2], [*5]
q If a hose is equipped with a MIKALOR clamp, in-
stall it according to the following procedure.
a Use a new MIKALOR clamp.
1) Set the hose to the original position (marked
when the hose was removed).
(Hose insertion depth)
q Air intake manifold side (58)
Tube side: (x) 80 mm
Manifold side (y): 80 mm
q Aftercooler side (72)
Aftercooler side: 60 mm
Tube side: (z) 67 mm
q Hose (72) between aftercooler and turbo-
charger
Tube side: 85 mm a If air intake connector (108) was removed, re-
Aftercooler side: 80 mm place the O-ring with a new one.
2) Place bridge (BR) under the clamp bolt and 3 Air intake connector mounting bolt :

set overlap (b) between bridge (BR) and 8.8 10.8 Nm {1.1 1.2 kgm}
band to the following dimension.
Dimension (b): Min. 5 mm
2 Threaded portion of clamp bolt
(BC):
Lubricating oil (THREEBOND PAN-
DO 18B)
a Do not use an impact wrench.

q When reusing the hose

1) Install the clamp to the clamp mark made on
the hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}

q When using a new hose

1) Tighten until dimension BDG becomes as
follows.
(Dimension BDG)
q Air intake manifold side (58)
Tube side: (x) 7 10 mm
Manifold side (y): 9 to 12 mm
q Aftercooler side (72)
Aftercooler side: 7 10 mm
Tube side: (z) 7 10 mm

HB205-1, HB205LC-1 50-81

(01)
Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

a When using two MIKALOR clamps at a place, [*3]

set their clamp portions (A) and (B) at 180 deg. a Insert each hose to the position marked when re-
to each other. moved.
(Reference)
Hose insertion length (engine side): 49 mm
(Three places on radiator side): 45 mm
3 Hose clamp bolt:
10.8 11.8 Nm {1.1 1.2 kgm}

[*4]
3 Air hose clamp bolt:
10.0 11.0 Nm {1.02 1.12 kgm}

[*6]
a Insert each hose to the position marked when re-
moved.
(Reference) Hose insertion length: 45 mm
3 Hose clamp bolt:
10.8 11.8 Nm {1.1 1.2 kgm}

[*7]
q Install the connector of the high-voltage wiring
(power cable) according to the following proce-
dure.
a Before installing the connector of the
high-voltage wiring (power cable), measure
the insulation resistance of the generator mo-
tor according to the following procedure.

1. Precautions for measuring

k Since high voltage (DC 500 V) is applied
a Reference for measurement of the insulation resis-
Radiator hose insertion depth tance, observe the following.
1) Connection of test plugs
a Ensure the test plugs P (+) and P (-) are
connected to the objective portions to be
measured.
a Check the test plugs with extreme care so
that they do not come off and touch an-
other part or a human body during mea-
surement (while high voltage is applied).
2) Do not touch the generator motor assembly
during measurement.
Do not touch the object of measurement
(MOTORA) during measurement (while high
voltage is applied).
During measurement, the measurer must
alert around.

50-82 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

2. Measurement a Match the number of marking lines of each

1) Measurement of insulation high-voltage wiring (power cable) with that on
Connect the following items as shown in the the generator motor side.
figure at left. 1) Check plug (P) on the cable side for dirt and
Between lines A and B flaw.
Between lines A and C 2) Thinly apply grease to insertion sealing
Between lines B and C portion (R) of the flange.
2 Insertion sealing portion of flange:
(Criteria) Grease (G2-LI)
a Insulation resistance between lines A and 3) Apply a string of liquid gasket (LG-7) approx-
B: Min. 5 Mz imately 1 to 2 mm in diameter to the
a Insulation resistance between lines A and connecting surface of power supply
C: Min. 5 Mz connector (T).
a Insulation resistance between lines B and 4) Install connectors (86) and (87).
C: Min. 5 Mz a Install connector (86) (2 lines) up and (87)
(1 line) down, with their line marks on the
right side, facing them.
a Insert plug (P) on the cable side straight
into power feed terminal socket (S) on the
motor side.
3 High-voltage wiring connector
bolt:
8.8 10.8 Nm {0.9 1.1 kgm}

2) Measurement of insulation between phases

Connect the following items as shown in the
figure.
Between A and motor case phase
Between B and motor case phase
Between C and motor case phase

(Criteria)
a Insulation resistance between phase A
and case phase: Min. 5 Mz
a Insulation resistance between phase B
and case phase: Min. 5 Mz
a Insulation resistance between phase C
and case phase: Min. 5 Mz

HB205-1, HB205LC-1 50-83

(01)
Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

[*8], [*9] [*11]

q When installing a connector of quick coupler a When installing the bolts, take care since their
type, observe the following points. lengths are different.
a The internal parts of the adapter may be dam- (Engine front side is longer than engine rear
aged when the hose is removed. Accordingly, side)
do not reuse the adapter. When installing, re- a When installing the engine mount rubbers, take
place with a new one. care since their sizes are different.
a Ensure that mud or dirt is not sticking to the hose (Engine front side is smaller than engine rear
joint portions in advance. side)
a Push the connector straight (in the direction of
(b)). Do not pry it in or wobble it.
If it is difficult to insert the connector, do not push
it in forcibly but pull it out. Then, check the
convex and concave parts for abnormality and
sticking mud.

2 Threaded portion of engine mounting

bolt:
Adhesive (LT-2)
3 Engine mount mounting bolt:
245 308.9 Nm {25 31.5 kgm}
(Reference)
[*10] 2 Engine mount bracket mounting bolt
a Ensure that mud or dirt is not sticking to the hose threads:
adapters and inside of the hoses. Adhesive (LT-2)
3 Lubricating oil hose sleeve nuts: 3 Engine mounting bracket (four points)
(98) Hose to swing motor: bolts :
54 93 Nm {5.5 9.5 kgm} 122.5 147 Nm{ 12.5 25 kgm}
(99) Hose from swing motor:
84 132 Nm {8.5 13.5 kgm}
(100) Hose from motor-generator:
128 186 Nm {13.0 19.0 kgm}

a If the elbows of hybrid swing motor lubrication

hoses (98) to (100) on the pump side were re-
moved, install them and tighten to the following
torque.
3 Hose mounting elbows:
(98) Swing motor discharge port:
25 29 Nm {2.6 3.0 kgm}
(99) Swing motor suction port:
25 29 Nm {2.6 3.0 kgm}
(100) Generator suction port:
59 98 Nm {6.0 10 kgm}

50-84 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal (and installation) of engine, motor generator, and main pump assembly

q Refilling of coolant
Add engine coolant through the coolant filler to
the specified level. Run the engine to circulate
the coolant through the system. Then, check the
coolant level again and add coolant if it is low.
5 Coolant:
17.3 l
a For the precautions for mixing proportion of
water and Super Coolant, see "Removal (and
installation) of radiator assembly".

q Refilling of oil (Hydraulic tank)

Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.
5 Hydraulic tank:
232 l
3 Hydraulic oil drain plug:
58.8 78.5 Nm {6.0 8.0 kgm}

q Bleeding air
See Testing and adjusting, Bleeding air from
each part.

HB205-1, HB205LC-1 50-85

(01)
Engine and cooling system
Removal and installation of fuel tank assembly

Removal and installation of fuel tank assembly 50-86

Removal 50-86
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Open right inspection cover (1).

2. Open fuel drain valve (1) to drain the fuel.

5. Remove four bolts (6) and move battery box (4)

forward.

3. Remove six bolts (2) and handrail (3).

a Two bolts (2) are installed to the left front side
of battery box (4).

4. Remove mirror (5).

6. Disconnect wiring connector (7) of the fuel level

sensor.

7. Remove two lower mounting bolts (9) of cover

(8).

50-86 HB205-1, HB205LC-1

(01)
 Engine and cooling system
Removal and installation of fuel tank assembly

8. Remove two upper mounting bolts (10) of cover 10. Remove lower cover (13).
(8) and remove cover (8).

11. Disconnect fuel supply hose (14), return hose

9. Remove four mounting bolts (11) and cover (12). (15), and drain hose (16).

12. Remove six fuel tank mounting bolts (17).

[*1]

13. Lift off fuel tank (18).

4 Fuel tank assembly:
140 kg

HB205-1, HB205LC-1 50-87

(01)
Engine and cooling system
Removal and installation of fuel tank assembly

Installation 50-8
q Perform installation in the reverse order to re-
moval.

[*1]
3 Fuel tank mounting bolt:
245 309 Nm {25.0 31.5 kgm}

q Bleeding air
After adding fuel, bleed air from the fuel system.
For details, see Testing and adjusting, "Bleeding
air from fuel system".

50-88 HB205-1, HB205LC-1

(01)
 Hybrid
Draining adding coolant and bleeding air for hybrid system

Hybrid 50-89
Draining adding coolant and bleeding air for hybrid system 50-89

Drain 50-89
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k When opening the coolant filler cap or drain-
a Removal (and installation) procedures in this
section can be carried out by personnel other ing the coolant, ensure that coolant tempera-
than those who have finished a special training ture is low and it does not scald you.
k While draining the coolant, take care that the
course for handling low voltage electrical appli-
ances. coolant does not stick to your skin or enter
k
your eye.
Never disconnect the high-voltage wiring Super Coolant mixed in the coolant is toxic.
(power cable) during the removal and instal- If the coolant splashes on your skin or enters
lation work in this section. your eye, wash it away immediately with
plenty of water and then consult a doctor.

1. Open left inspection cover (1).

SM: Electric swing motor

HR: Hybrid radiator
WP: Water pump for hybrid system
HI: Inverter 2. Check that water filler cap (2) of hybrid radiator
HC: Capacitor (HR) is at a temperature that you can touch with
(2): Water filler cap the bare hand and then open water filler cap (2)
(4): Drain valve slowly.
(5): Air bleeding plug of swing motor
(6): Coolant filler
(7): Swing motor elbow plug (IN)
(8): Swing motor elbow plug (OUT)
(9): Overflow hose

HB205-1, HB205LC-1 50-89

(01)
Hybrid
Draining adding coolant and bleeding air for hybrid system

3. Remove cover (3). Refilling coolant and bleeding air 50-90

a As coolant, use Komatsu genuine Super Coolant
(AF-NAC).
a Use city water to dilute.
k Undiluted Super Coolant is flammable. So
keep it away from open flame.

1. Install capacitor drain bolts (4).

3 Capacitor drain bolt:
5.88 8.82 Nm {0.6 0.9 kgm}

4. Place a container to receive the coolant under

the drain hose and remove capacitor drain bolts
(4) to drain the coolant.
6 Hybrid radiator:
5.4 l

2. Install cover (3).

50-90 HB205-1, HB205LC-1

(03)
 Hybrid
Draining adding coolant and bleeding air for hybrid system

3. Add coolant to the full level through filler port (6)
of the hybrid radiator slowly (taking approxi-
mately 5 minutes). (approximately 3.8 l)
a Add coolant through the coolant filler of the
hybrid radiator, taking care not to spill it.
a The minimum necessary volumetric percent-
age of Super Coolant is 30%.
a Decide the mixing proportion of the coolant to
the water according to the past minimum
temperature and the following mixing propor-
tion table.
Actually, set the proportion for a temperature
about 10 C lower than the past minimum
temperature.
Mixing proportion of city water and Super Coolant
(Refill capacity of hybrid system radiator: 5.4 l)
Min. temperature ( C)
Abo
ve-1 -15 -20 -25 -30 (-35)
0
Quantity
Mixing proportion(l)
4. Tighten the radiator cap and turn the key switch
to the ON position to run the water pump. And
turn the key switch to the OFF position after 2
minutes to stop the water pump.
k Never start the engine.
a If too long time passes before the starting
switch is turned to the ON position after the
coolant is added, air may be trapped on the
suction side of the water pump and the water
pump may have a suction trouble. According-
ly, turn the starting switch to the ON position
immediately after adding the coolant.
a Judge if hybrid system water pump (WP) is
running by directly touching water pump
(WP) with the hand. (Since the drive sound of
the pump is low, it is difficult to judge by the
drive sound.)
(-40)

of Super 1.6 1.9 2.2 2.5 2.7 (2.9) (3.1)

Coolant
Quantity
3.6 3.3 3.1 2.8 2.6 2.4 2.2
of water
Volumet-
ric ratio 30 36 41 46 50 (54) (58)
(%)

5. If the water pump runs, the coolant level lowers.

Add coolant until the system becomes full.

6. Close the radiator cap and turn the key switch to

the OFF position to complete the air bleeding
work.

7. Since air may remain in coolant circuit after

performing steps 3 to 6, check the coolant level
of hybrid radiator again after approximately 8
hours and fill it with coolant if the coolant level
lowers. With the radiator cap open, turn the key
switch to the ON position to rotate the water
pump.

HB205-1, HB205LC-1 50-91

(03)
Hybrid
Draining adding coolant and bleeding air for hybrid system

Replacement of all hybrid coolant 50-92 a Decide the mixing proportion of the cool-
a When changing the mixing proportion of Super ant to the water according to the past min-
Coolant or replacing all the coolant because of imum temperature and the following
entry of swing motor lubricating oil into it, replace mixing proportion table.
the coolant according to the following procedure. Actually, set the proportion for a tempera-
ture about 10 C lower than the past
1. See the preceding procedure of "drain" and drain minimum temperature.
from the draining part of capacitor. Mixing proportion of city water and Super Coolant
2. Install capacitor drain bolt and cover according (Refill capacity of hybrid system radiator: 5.4 l)
to "Refilling coolant and bleeding air", steps 1 Min. temperature ( C)
and 2.
Abo
3. Loosen clamp (10) of the tube (11) and hose (12)
ve-1 -15 -20 -25 -30 (-35) (-40)
returning from the swing motor and disconnect 0
tube (11).
Quantity

Mixing proportion(l)
a Before disconnecting tube (11), prepare a of Super 1.6 1.9 2.2 2.5 2.7 (2.9) (3.1)
container to receive the drained coolant un- Coolant
der the disconnecting point of the hose. Quantity
3.6 3.3 3.1 2.8 2.6 2.4 2.2
4. Install a thick vinyl bag, etc. to the tube (11) to be of water
disconnected to prevent the coolant from Volumet-
splashing around. ric ratio 30 36 41 46 50 (54) (58)
(%)
5. Close coolant filler cap (2) and supply 2) Open the radiator cap (2) and turn the key
compressed air (for an impact wrench, etc.) into switch to the ON position to run the water
the disconnected hose (12) to discharge all the pump. Turn the key switch to the OFF posi-
coolant forcibly. (For prevention of splashing of tion after 2 minutes to stop the water pump.
coolant) 3) Since the coolant level lowers after running
a Be sure to close the radiator cap before sup- the water pump, fill the tank with coolant.
plying compressed air. 4) Close the radiator cap (2) and turn the key
5 Quantity of drained coolant: switch to the ON position to run the water
6.8 l pump. Turn the key switch to the OFF posi-
6. Connect the disconnected hose and tighten the tion after 20 minutes to stop the water pump.
clamp temporarily. 5) Open the radiator cap (2) and fill the tank with
7. Add the specified quantity of coolant according coolant if the coolant level lowers.
to the procedure of "Refilling coolant and 6) Close the radiator cap (2) and complete the
bleeding air", steps 3 to 6, and wash the circuit. air bleeding work.
8. Repeat above steps 1 to 5. Then wash inside 7) Since air may remain in coolant circuit, check
and discharge. Repeat steps 7 to 8 if necessary, the coolant level of hybrid radiator again after
depending on the stain of the inside. performing work (after approximately 8
9. Insert the disconnected hose to the original posi- hours) and fill it with coolant if the coolant
tion of tube and fasten the clamp to the specified level lowers.
torque.
3 Tightening torque:
3.9 4.9 Nm {0.4 0.5 kgm}
10. Perform the following steps 1) to 7) (refilling
coolant and bleeding air after draining
completely), then add the specified quantity of
coolant and bleed air.
1) Add coolant through filler port (6) of the
hybrid radiator slowly taking approximately 5
minutes. (5.4 l)
a Add coolant through the coolant filler of
the hybrid radiator, taking care not to spill
it.
a The minimum necessary volumetric per-
centage of Super Coolant is 30%.

50-92 HB205-1, HB205LC-1

(03)
 Hybrid
Removal and installation of hybrid radiator assembly

Removal and installation of hybrid radiator assembly 50-93

2) Open coolant filler cap (2) of the hybrid radi-

ator.

a Removal (and installation) procedures in this

section can be carried out by personnel other
than those who have finished a special training
course for handling low voltage electrical appli-
ances.

k Never disconnect the high-voltage wiring

(power cable) during the removal and instal-
lation work in this section.
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.

k When opening the coolant filler cap or drain- 3) Remove lower cover (3).
ing the coolant, ensure that coolant tempera-
ture is low and it does not scald you.
k While draining the coolant, take care that the
coolant does not stick to your skin or enter
your eye.
Super Coolant mixed in the coolant is toxic.
If the coolant splashes on your skin or enters
your eye, wash it away immediately with
plenty of water and then consult a doctor.

1. Drain the coolant from the hybrid radiator

according to the following procedure.
1) Open left inspection cover (1).

4) Remove capacitor drain bolts (4) to drain the

coolant.
6 Hybrid radiator:
5.2 l

HB205-1, HB205LC-1 50-93

(01)
Hybrid
Removal and installation of hybrid radiator assembly

2. Remove three nuts (5) from the top of inverter 5. Disconnect overflow hose (10).
and remove cover (6).
6. Loosen clamp (11) and disconnect coolant hose
(12) from the radiator.

7. Disconnect radiator upper hose (13) from the

radiator.

8. Remove hose clamps (14) and (15). [*1]

9. Disconnect radiator lower hose (16) from the

radiator.

3. Remove three bolts (7) and remove bracket (8).

4. Remove wiring clamp (9).

10. Remove two bolts (17) and hybrid radiator

assembly (18). [*2]

50-94 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of hybrid radiator assembly

Installation 50-95
q Perform installation in the reverse order to re-
moval.

[*1]
3 Hose mounting bolt:
34 74 Nm {3.5 7.5 kgm}

[*2]
3 Hybrid radiator mounting bolt:
14.7 34.0 Nm {1.5 3.5 kgm}

q Refilling coolant and bleeding air

a Add coolant and bleed air. For details, see
"Draining adding coolant and bleeding air for
hybrid system".

HB205-1, HB205LC-1 50-95

(01)
Hybrid
Removal and installation of water pump assembly for hybrid system

Removal and installation of water pump assembly for hybrid system 50-96

1. Drain the coolant from the hybrid radiator

according to the following procedure.
1) Open left inspection cover (1).
k Removal (and installation) procedures in this
section must be carried out by a person who
has finished a special training course for
handling low voltage electrical appliances.
Understand the contents of 00 Introduction,
safety, and basic information, "Safety pre-
cautions 1. Precautions peculiar to hybrid
machine" and "Handling of hybrid devices
and high-voltage wirings" before starting
work.

Removal 50-96

2) Open coolant filler cap (2) of the hybrid radi-

k Discharge the capacitor. For details, see 00 ator.
Introduction, safety, and basic information,
"Handling of hybrid devices and high-voltage
wirings", "Discharge procedure for capaci-
tor".
k Disconnect two one-touch connectors (cable
terminals of (+) and (-)) from the capacitor
(See step 4).

k Park the machine on a level place, lower the

work equipment to the ground completely,
and stop the engine.
k Referring to Testing and adjusting, "Releas-
ing remaining pressure in hydraulic circuit",
release the pressure inside the hydraulic cir-
cuit and then set the lock lever to the LOCK
3) Remove lower cover (3).
position.
k Disconnect the cable from the negative (-)
terminal of the battery.
k When opening the coolant filler cap or drain-
ing the coolant, ensure that coolant tempera-
ture is low and it does not scald you.
k While draining the coolant, take care that the
coolant does not stick to your skin or enter
your eye.
Super Coolant mixed in the coolant is toxic.
If the coolant splashes on your skin or enters
your eye, wash it away immediately with
plenty of water and then consult a doctor.

50-96 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of water pump assembly for hybrid system

4) Remove capacitor drain bolts (4) to drain the 8. Remove overflow tank (13).
coolant.
6 Hybrid radiator:
5.2 l

9. Disconnect wiring (14) and hose (15) from

washer pump.

2. Remove three nuts (5) from the top of inverter 10. Remove three mounting bolts (16) and washer
and remove cover (6). tank (17).

3. Remove three bolts (7) and bracket (8). 11. Disconnect hose (18) between the water pump
and radiator.
4. Disconnect one-touch wiring connectors HB01
(9a) and (9b) from the capacitor. 12. Disconnect hose (19) between the water pump
a While pressing the lock portion of the con- and inverter.
nector with your thumb to unlock the connec-
tor, pull out the connectors.

5. Loosen clamp (10). (Remove as necessary.)

6. Disconnect coolant level sensor wiring

connector P24 (11).

7. Disconnect overflow hose clamp (12).

HB205-1, HB205LC-1 50-97

(01)
Hybrid
Removal and installation of water pump assembly for hybrid system

13. Disconnect wiring clamp (20) and connector Installation 50-98

(21). q Perform installation in the reverse order to re-
moval.

q Refilling coolant and bleeding air

a Add coolant and bleed air. For details, see
"Draining adding coolant and bleeding air for
hybrid system".

14. Remove four mounting bolts (22) and water

pump assembly (23).

50-98 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of inverter assembly

Removal and installation of inverter assembly 50-9

1. Drain the coolant from the hybrid radiator

according to the following procedure.
1) Open left inspection cover (1).
k Removal (and installation) procedures in this
section must be carried out by a person who
has finished a special training course for
handling low voltage electrical appliances.
Understand the contents of 00 Introduction,
safety, and basic information, "Safety pre-
cautions 1. Precautions peculiar to hybrid
machine" and "Handling of hybrid devices
and high-voltage wirings" before starting
work.

Removal 50-9

2) Open coolant filler cap (2) of the hybrid radi-

k Discharge the capacitor. For details, see 00 ator.
Introduction, safety, and basic information,
"Handling of hybrid devices and high-voltage
wirings", "Discharge procedure for capaci-
tor".
k Disconnect two one-touch connectors (cable
terminals of (+) and (-)) from the capacitor
(See step 6).
a When replacing the inverter assembly, replace it
and electric swing motor assembly as a set.

k Park the machine on a level place, lower the

work equipment to the ground completely,
and stop the engine.
k Referring to Testing and adjusting, "Releas-
ing remaining pressure in hydraulic circuit",
3) Remove lower cover (3).
release the pressure inside the hydraulic cir-
cuit and then set the lock lever to the LOCK
position.
k Disconnect the cable from the negative (-)
terminal of the battery.
k When opening the coolant filler cap or drain-
ing the coolant, ensure that coolant tempera-
ture is low and it does not scald you.
k While draining the coolant, take care that the
coolant does not stick to your skin or enter
your eye.
Super Coolant mixed in the coolant is toxic.
If the coolant splashes on your skin or enters
your eye, wash it away immediately with
plenty of water and then consult a doctor.

HB205-1, HB205LC-1 50-99

(01)
Hybrid
Removal and installation of inverter assembly

4) Remove capacitor drain bolts (4) to drain the 6. Remove three nuts (10) from the top of inverter
coolant. and remove cover (11).
6 Coolant:
3.5 l

7. Remove three bolts (13) and bracket (14).

2. Open the engine hood.

3. Remove two mounting bolts 15a to remove net
(5).
4. Remove covers (6) and (7).

8. Disconnect one-touch wiring connectors HB01

(15a) and (15b) from the capacitor.
a While pressing the lock portion of the con-
nector with your thumb to unlock the connec-
tor, pull out the connectors.
5. Remove frames (8) and (9).
9. Remove clamps (16) and (17) of the
high-voltage wiring (power cable).

10. Disconnect connectors (18) to (21) of the

high-voltage wiring (power cable). [*1]
(Connector No.): (From left)
(18): HC06
(19): HC05
(20): HC04
(21): HC03

50-100 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of inverter assembly

14. Remove four mounting bolts (30). [*2]

15. Install eyebolts to the cover mounting portions

(P).

11. Disconnect wiring connectors (22) to (25).

(Connector No.)
(22): HC02
(23): HC01
(24): HP01 16. Lift off inverter assembly (31).
(25): HK02 4 Inverter assembly:
39 kg
12. Remove bracket (26).

13. Disconnect hoses (27) and (28) from inverter

(29).

HB205-1, HB205LC-1 50-101

(01)
Hybrid
Removal and installation of inverter assembly

Installation 50-102
q Perform installation in the reverse order to re-
moval.

[*1]
q Install the connector of the high-voltage wiring
(power cable) according to the following proce-
dure.
1) Check plug (P) on the cable side for dirt and
flaw.
2) Thinly apply grease (G2-LI) to insertion
sealing portion (R) of the flange.
(For protection of the seal from the inserted
flange)
3) Insert plug (P) on the cable side straight into
power feed terminal socket (S) on the motor
side.
a Direct the black mark up.
a When inserting the plug, set disconnec-
tion detection contact (Q) of the power ca-
ble under the cable.
3 Mounting bolt of high-voltage wir-
ing (power cable) plug:
8.8 10.8 Nm {0.9 1.1 kgm}

[*2]
3 Tightening torque of inverter mounting
bolt:
59 74 Nm {6.0 7.6 kgm}

q Refilling coolant and bleeding air

a Add coolant and bleed air. For details, see
"Draining adding coolant and bleeding air for
hybrid system".

50-102 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of inverter and capacitor assembly

Removal and installation of inverter and capacitor assembly 50-103

1. Drain the coolant from the hybrid radiator

according to the following procedure.
6 Coolant:
3.5 l
k Removal (and installation) procedures in this 1) Open left inspection cover (1).
section must be carried out by a person who
has finished a special training course for
handling low voltage electrical appliances.
Understand the contents of 00 Introduction,
safety, and basic information, "Safety pre-
cautions 1. Precautions peculiar to hybrid
machine" and "Handling of hybrid devices
and high-voltage wirings" before starting
work.

Special tools 50-103

New/redesign
Necessity

Sketch

Sym-
Q'ty

Part number Part name

bol
2) Open coolant filler cap (2) of the hybrid radi-
B 3 796T-426-1110 Assembling jig t 1 N Q ator.

Removal 50-103

k Discharge the capacitor. For details, see 00

Introduction, safety, and basic information,
"Handling of hybrid devices and high-voltage
wirings", "Discharge procedure for capaci-
tor".
k Disconnect two one-touch connectors (cable
terminals of (+) and (-)) from the capacitor
(See step 12).
k Park the machine on a level place, lower the
work equipment to the ground completely, 3) Remove lower cover (3).
and stop the engine.
k Referring to Testing and adjusting, "Releas-
ing remaining pressure in hydraulic circuit",
release the pressure inside the hydraulic cir-
cuit and then set the lock lever to the LOCK
position.
k Disconnect the cable from the negative (-)
terminal of the battery.
k When opening the coolant filler cap or drain-
ing the coolant, ensure that coolant tempera-
ture is low and it does not scald you.
k While draining the coolant, take care that the
coolant does not stick to your skin or enter
your eye.
Super Coolant mixed in the coolant is toxic.
If the coolant splashes on your skin or enters
your eye, wash it away immediately with
plenty of water and then consult a doctor.

HB205-1, HB205LC-1 50-103

(01)
Hybrid
Removal and installation of inverter and capacitor assembly

4) Remove capacitor drain bolts (4) to drain the 6. Remove three nuts (10) from the top of inverter
coolant. and remove cover (11).

2. Open the engine hood. 7. Remove three bolts (12) and bracket (13).
3. Remove two mounting bolts 5a to remove net
(5). 8. Disconnect coolant level sensor wiring
4. Remove covers (6) and (7). connector P24 (14).

9. Disconnect overflow hose clamp (15).

10. Remove overflow tank (16).

11. Remove door frame (17).

5. Remove frames (8) and (9).

12. Disconnect one-touch wiring connectors HB01

(18a) and (18b) from the capacitor.
a While pressing the lock portion of the con-
nector with your thumb to unlock the connec-
tor, pull out the connectors.

13. Remove clamps (19) and (20) of the

high-voltage wiring (power cable).

50-104 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of inverter and capacitor assembly

14. Disconnect connectors (21) to (24) of the 17. Remove bolt (30), loosen hose clamp (30), and
high-voltage wiring (power cable). [*1] disconnect radiator lower hose (32). [*2]
(Connector No.): (From left)
(21): HC06 18. Remove bolt (33) and disconnect hose (34) from
(22): HC05 inverter (35).
(23): HC04
(24): HC03 19. Disconnect hose (36) from inverter (35).

20. Remove three bolts (37) and disconnect hose

fixing bracket (38) from inverter and capacitor
assembly (39).

15. Disconnect wiring connectors (25) to (28).

(Connector No.)
(25): HC02
(26): HC01
(27): HP02 21. Disconnect ground cable (40).
(28): HK02
22. Remove two mounting nuts (41) at the rear. [*3]
16. Remove bracket (29).

HB205-1, HB205LC-1 50-105

(01)
Hybrid
Removal and installation of inverter and capacitor assembly

23. Disconnect ground cable (42). Installation 50-106

q Perform installation in the reverse order to re-
24. Remove two mounting nuts (43) at the front. [*3] moval.

[*1]
3 Connector mounting bolt:
8.8 10.8 Nm {0.9 1.1 kgm}

[*2]
3 Tightening torque of coolant hose clamp
screw:
3.9 4.9 Nm {0.4 0.5 kgm}

25. Using the hanging bolts at the four capacitor
lower corners, lift off inverter and capacitor
assembly (39).
a Put cloths, etc. between the "inverter and ca-
pacitor assembly" and sling to protect the "in-
verter and capacitor assembly".
4 Inverter and capacitor assembly:
123 kg
[*3]
a Replace four mounting nuts (01596-01211) of
the "capacitor and inverter assembly" with new
ones.
(Replace the nuts once they are used since they
are loosened and the torque decreases.)
3 Tightening torque:
35 44 Nm{3.5 4.5 kgm}
Tighten the mounting bolts diagonally in the order of
[1] to [4] as shown below.

[*4]
a If the mounting bolts of the rubber mounts were
a Do not loosen mounting bolts (45) of four rub- loosened, position the rubber mounts according
ber mounts (44). [*4] to the following procedure.
1) Install rubber mount (44) and tighten
mounting bolt (46) with the fingers.

50-106 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of inverter and capacitor assembly

2) Install tool B3.

3) Using tool B3, position bolt (46) and tighten
rubber mount mounting bolt (45).

q Refilling coolant and bleeding air

a Add coolant and bleed air. For details, see
"Draining adding coolant and bleeding air for
hybrid system".

HB205-1, HB205LC-1 50-107

(01)
Hybrid
Draining and adding generator lubricating oil

Draining and adding generator lubricating oil 50-108

Refill with oil 50-108

1. Tighten oil drain plug
3 Oil drain plug:
58.8 78.4 Nm {6.0 8.0 kgm}
a Removal (and installation) procedures in this Target value: 68.6 Nm {7.0 kgm}
section can be carried out by personnel other
than those who have finished a special training
course for handling low voltage electrical appli-
ances.

k Never disconnect the high-voltage wiring

(power cable) during the removal and instal-
lation work in this section.

Drain 50-108
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.
2. Install generator motor lower cover (1).
1. Remove generator motor lower cover (1).

3. Open right inspection cover (4).

2. Place a container to receive the oil under oil
drain plug (3) of generator housing (2).

3. Loosen oil drain plug (3) to drain the oil.

6 Generator housing:
6l

50-108 HB205-1, HB205LC-1

(01)
 Hybrid
Draining and adding generator lubricating oil

4. Remove plug (6) of oil supply port (5) and add oil
to the specified level.
5 Generator housing:
6 l(TO10)
a Check the oil level with oil level gauge (7).
a Run the engine to circulate the oil in the lubri-
cation circuit, and then check the oil level and
add oil as necessary.
Check oil level
1) Remove oil level gauge (7) and wipe off oil on
the gauge with a cloth.
2) Insert oil level gauge (7) fully into the guide.
3) Pull out oil level gauge (7). When the oil level
is in the range shown in the figure, it is
normal.
q Before starting the engine: between (H)
and (L) marks on COLD SIDE
q 15 minutes after atopping the engine: be-
tween (H) and (L) marks on HOT SIDE
4) If the level is below (L) of oil level gauge (7),
add oil.
5) If the level is above (H) of oil level gauge (7),
loosen drain plug (3) to discharge the excess
oil.

5. Install plug (6).

3 Plug:
58.8 78.4 Nm {6.0 8.0 kgm}
Target value: 68.6 Nm {7.0 kgm}

HB205-1, HB205LC-1 50-109

(03)
Hybrid
Removal and installation of tandem pump assembly

Removal and installation of tandem pump assembly 50-1 0

3. Remove lower cover (4).

a Removal (and installation) procedures in this

section can be carried out by personnel other
than those who have finished a special training
course for handling low voltage electrical appli-
ances.

k Never disconnect the high-voltage wiring

(power cable) during the removal and instal-
lation work in this section.

Removal 50-1 0
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Disconnect the cable from the negative (-)
4. Referring to "Draining and adding lubricating oil",
loosen oil drain plug (5) to drain the oil. [*1]
6 Generator oil tank:

terminal of the battery. 6l

1. Close fuel stop valve (1).

5. Open engine hood (6).

2. If the fuel level is higher than the return hose,

open right inspection cover (2) and open fuel
drain valve (3) to drain the fuel.

50-110 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of tandem pump assembly

6. Remove counterweight maintenance cover (7).

8. Disconnect four lubrication hoses (14) to (17).

7. Remove the counterweight assembly. For
details, see "Removal and installation of coun-
terweight assembly".
a Record the disconnected and clamped por-
tions of each hose.
a Cover the end of each disconnected hose
with cloth.
1) Remove fuel hose clamp (8). [*2]
2) Disconnect connector (22).
[*6]
(14): Hose to swing motor
(15): Hose from swing motor
(16): Hose to motor-generator
(17): Hose from motor-generator
a Record the disconnected position of each
hose.
a Cover the end of each disconnected hose
with cloth.
a Do not remove elbows (14a) to (17a). [*7]
When loosening or removing an elbow to
replace it, record its installed direction.

9. Remove two bolts (18) and tandem pump

assembly (19). [*8]

3) Disconnect connector PUMP (9).

4) Disconnect hose (10) coming from the fuel
filter.
[*3]
5) Disconnect hose (11) going to the fuel filter.
[*4]
6) Disconnect hose (12) coming from the
prefilter.
[*5]
7) Disconnect fuel return hose (13) for fuel
returned from engine.

HB205-1, HB205LC-1 50-111

(01)
Hybrid
Removal and installation of tandem pump assembly

Installation 50-1 2 [*6]

q Perform installation in the reverse order to re- a Ensure that mud or dirt is not sticking to the hose
moval. adapters and inside of the hoses.
3 Lubricating oil hose sleeve nuts:
[*1] (14) Hose to swing motor:
3 Oil drain plug: 54 93 Nm {5.5 9.5 kgm}
58.8 78.4 Nm {6.0 8.0 kgm} (15) Hose from swing motor:
Target value: 68.6 Nm {7.0 kgm} 84 132 Nm {8.5 13.5 kgm}
5 Generator oil tank: (16) Hose to motor-generator:
6l 84 132 Nm {8.5 13.5 kgm}
(17) Hose from motor-generator:
[*2] 128 186 Nm {13.0 19.0 kgm}
a Clamp the fuel hose to the portion from which it
was removed. [*7]
a If elbows (11a) (14a) were removed, install
[*3], [*4] them in the directions recorded when they were
q When installing a connector of quick coupler removed.
type, observe the following points. 3 Hose mounting elbows:
a The internal parts of the adapter may be (14a) Swing motor discharge port:
damaged when the hose is removed. Ac- 25 29 Nm {2.6 3.0 kgm}
cordingly, do not reuse the adapter. (15a) Swing motor suction port:
When assembling, replace with a new one. 25 29 Nm {2.6 3.0 kgm}
a Ensure that mud or dirt is not sticking to the (16a) Motor-generator discharge port:
hose joint portions in advance. 35 63 Nm {3.6 6.4 kgm}
a Press and insert the connector straight (in di- (17a) Motor-generator suction port:
rection (b)) without prying or bending it to the 59 98 Nm {6 10 kgm}
right or left.
If it is difficult to insert the connector, do not [*8]
push it in forcibly but pull it out. Then, check a When installing the pump assembly, install
the male and female couplings for damage O-ring (20) and shaft (21) to the pump first.
and sticking mud. a Take care not to mistake the installed direction of
the pump assembly.
3 Tandem pump assembly mounting bolt:
59 74 Nm {6 7.5 kgm}

[*5]
3 Hose clamp bolt:
19.6 29.4 Nm {2.0 3.0 kgm}

50-112 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of motor-generator housing assembly

Removal and installation of motor-generator housing assembly 50-1 3

3. Loosen the drain plug to drain the oil from the

motor-generator housing. [*1]

4. Remove the main pump according to the

Special tools 50-1 3 following procedure.

New/redesign
1) Remove the parts.

Necessity

Sketch
Part q Muffler assemblyAss'y (1)

Q'ty
Symbol Part number q Dipstick pipe (2)
name
q Oil filter assembly (3)
a Bind the oil filter assembly and hose
1 796T-401-1210 Stand q 1 N Q
together to the engine
2 796T-401-1220 Plate q 1 N Q
1 3 01010-81690 Bolt q 2
4 01580-11613 Nut q 2
5 01643-31645 Washer q 4
B 1 796-410-1000 Guide t 1 N
2 796-410-1040 Bar t 1 N
3 796-410-1050 Plate t 1 N
2
4 01010-81030 Bolt t 2
5 01643-31032 Washer t 6
6 01010-81035 Bolt t 4
a When removing the generator motor and hous-
ing assembly, set the engine horizontally.

Removal 50-1 3
1. Remove the engine, motor-generator and main
pump assembly referring to the section of
"Removal and installation of engine,
motor-generator and main pump assembly".

2. By using tool B1, set the "engine, motor-gener-

ator and main pump assembly" horizontally.
a When not using tool B1, set the "engine, mo-
tor-generator and main pump assembly" hor-
izontally according to the following
procedure.
1) Install blocks [1] at the right and left mounts
on the front side of the engine.
a Adjust height (L1) of blocks [1] to the fol-
lowing dimension.
L1 = 332.5
2) Put block [2] to the horizontal part at the rear
of the oil pan.
3) Using two jacks [3], support block [2] at the
corners on the rear side of the oil pan.
a Adjust height (L2) of block[2] and jack [3]
to the following dimension.
L2 = 325

HB205-1, HB205LC-1 50-113

(01)
Hybrid
Removal and installation of motor-generator housing assembly

2) Sling hydraulic pump assembly (4) and

remove mounting bolts (5).
3) Lift off hydraulic pump assembly (4).
a If the hydraulic pump assembly is not
separated easily because of the gasket
sealant applied to its mounting face, hit
the cover surface lightly with a plastic
hammer.
4 Hydraulic pump assembly:
165 kg

8. Disconnect clamp bracket (11) from generator

motor housing (12).

5. Disconnect blow-by hose clamp (7).

(Removal of rotor and flange assembly)

9. Disconnect speed sensor wiring connector (13)
according to the following procedure.
a Do not remove speed sensor (14).
1) Disconnect speed sensor wiring clamp (15).
2) Disconnect mounting plate (16) of the speed
sensor connector. [*2]
3) Disconnect speed sensor wiring connector
(13).
6. Disconnect oil supply hose (8). 4) Disconnect wiring (17) from plate (16).

7. Disconnect lubrication hose (9) from hybrid

system oil cooler (10).

50-114 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of motor-generator housing assembly

5) Install plate (16) to the flange temporarily.
10. Remove seven mounting bolts (19b) of the rotor
and flange assembly, leaving two mounting bolts
(19a).
2) Insert tool B2-2 (bar) in the guide hole of tool
B2-1 (guide).
3) Tighten tools B2-4 (bolts) to the specified
torque.
a Press tool B2-1 (guide) against crank bar
center (C) securely and align it, and then
fix it with tools B2-4 (bolts).

11. Set tool B2 according to the following procedure.

1) Install tool B2-1 (guide) to the motor-gener-
ator housing (12) by using two tools B2-4
(bolt) and two B2-5 (washer).
a Tighten the two bolts with the fingers.
a When installing tool B2-1 (guide), take
care not to damage the sensor wiring har-
ness.

4) Install tool B2-3 (bar fixing plate) and fix it

with tools B2-6 (plate mounting bolts).

12. Remove remaining two mounting bolts (19a) of

rotor and flange assembly (18).

HB205-1, HB205LC-1 50-115

(01)
Hybrid
Removal and installation of motor-generator housing assembly

13. Install forcing screws [4] (M8 x 1.25) to forcing

tap holes (p) of the flange to disconnect rotor and
flange assembly (18) from generator motor
housing (12).
a Tighten two forcing screw [4] on the right and
left evenly to pull out rotor and flange assem-
bly (18) about 20 mm.

15. Install sling [5] to rotor assembly (20) and lift up

14. Pull out rotor and flange assembly (18) toward
you.
a Pull out rotor assembly (20) and flange (21)
together so that rotor assembly (20) is not
separated and left from flange (21) and does
not come off.
a When pulling out rotor and flange assembly
(18), take care not to damage the following
portions.
q Coil insulation portion (D) on housing side
q Core end portion (E) on housing side
q Core portion (F) on rotor side
temporarily.
a Be sure to use nylon sling so that the rotor is
not damaged. (Never use a wire or chain
sling which damages the rotor.)
a Shift sling [5] toward the flange and install it
around the rotor assembly.
(Apply the sling in this way so that the flange
does not lower and come off down when the
rotor assembly is lifted up.)
16. Remove tool B2-3 (bar fixing plate) and pull out
tool B2-2 (bar).

50-116 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of motor-generator housing assembly

17. Lift off rotor and flange assembly (18).

a When lifting up, take care that the end of rotor
assembly (20) is not damaged by touching
generator motor housing (12).
a Keep the end (part R) of the rotor assembly
down during the work from lifting of rotor and
flange assembly (18) to removal of it.
(Observe this to prevent the flange from
coming off.)
a When lowering rotor and flange assembly
(18) to the ground, spread soft cloths thickly
under it.
a When lowering the rotor and flange assembly
to the ground, slant is carefully so that end
(part R) of the rotor assembly (20) lowers first (Removal of generator motor housing assembly)
and flange (21) is set up. a After removing the rotor and flange assem-
4 Rotor and flange assembly:
bly, check again that the engine assembly is
45 kg in a horizontal position.
18. Remove tool B2-1 from the motor-generator 19. Remove the generator motor housing assembly
housing. according to the following procedure.
1) Remove two starting motor mounting bolts
(22) and nut (23) to remove starting motor
assembly (24).
[*3]

HB205-1, HB205LC-1 50-117

(01)
Hybrid
Removal and installation of motor-generator housing assembly

2) Install hanging bolts [J] (M10 x 1.5) to two 6) Lift off generator motor housing assembly
hanging bolt holes (G) of the housing, and (12).
sling generator motor housing assembly 4 Motor-generator housing assem-
(12). bly:
3) Remove the following mounting bolts and 120 kg
mounting nuts from the portions shown in the
following figure.
q Mounting bolts [1] - [15]
q Mounting nuts [16] - [18]
4) Install two guide pins [H] to the places of
guide bolts [3] and [5].

5) Using two forcing screws [L], disconnect

generator motor housing (12) from rear
housing (25).
a Tighten two forcing screws [L] on the right
and left evenly to disconnect the genera-
tor motor housing.
a When disconnecting generator motor
housing (12), take care not to damage the
coil portion of the housing and gear por-
tion (Q) of the rear housing.
a Since the mating stud bolts of nuts [16],
[17] and [18] are left installed to generator
motor housing (12) and rear housing (25),
remove generator motor housing assem-
bly (12) straight until those stud bolts
come out perfectly.

50-118 HB205-1, HB205LC-1

(01)
 Hybrid
Removal and installation of motor-generator housing assembly

Installation 50-1 9
(Installation of generator motor housing assembly)

1. Set the "engine, generator motor and hydraulic

pump assembly" horizontally according to the
removal procedure
2. Install the generator motor housing assembly
according to the following procedure.
1) Clean mating face (R) of the rear housing
and motor-generator housing and apply a
string of liquid gasket (approximately 1 to 2
mm) in diameter on this face.
2 Rear housing end face:
Liquid gasket (LG-7)
5) Tighten bolts [1] - [15] and nuts [16] - [18] in
the order of [1] - [18] shown in the following
figure.
3 Housing mounting bolts and nuts:
98 123 Nm{10.0 12.5 kgm}

2) Install guide pins [H] (two places ) to rear

housing (25).
3) Install hanging bolts [J] (M10 x 1.5) to gener-
ator motor housing assembly (12) and sling
it.
4) Install generator motor housing assembly to
rear housing (25) along the guide pins.
a When installing the generator motor
housing, take care not to damage the coil
portion of the housing and gear portion
(Q) of the rear housing.

HB205-1, HB205LC-1 50-119

(01)
Hybrid
Removal and installation of motor-generator housing assembly

(Installation of rotor and flange assembly)
1. Install the rotor and flange assembly according
to the following procedure.
1) Install tool B2-1 (guide) to housing (12) and
tighten two tools B2-4 (bolts) and B2-5
(washers) with the fingers.
3) Pass tool B2-2 (bar) through the shaft hole
of rotor and flange assembly (18) and insert
it until it reaches center (C) of the crankshaft.
4) While tool B2-2 (bar) is aligned, tighten tool
B2-4 (bolts) to the specified torque to fix tool
B2-1 (guide) to housing (12).
5) Install tool B2-3 (bar fixing plate) and fix it
with tools B2-6 (bolt).
6) Remove sling [5].

2) Sling rotor and flange assembly (18) and

align it with the crankshaft before generator
motor housing assembly (12).
a Be sure to use nylon sling so that the rotor
is not damaged. (Never use a wire or
chain sling which damages the rotor.)
a Shift sling [5] toward the flange and install
it around the rotor assembly. (Apply the
sling in this way so that the flange does
not lower and come off down when the ro-
tor assembly is lifted up.)
a While slinging rotor and flange assembly
(18), take care that flange (21) does not
come off rotor (20) and fall.

50-120 HB205-1, HB205LC-1

(01)

Removal and installation of motor-generator housing assembly
7) Insert rotor and flange assembly (18) in the
motor-generator housing along tool B2-2
(bar).
a When inserting rotor and flange assembly
(18), take care not to damage the follow-
ing portions.
q Coil insulation portion (D) on housing
side
q Core end portion (E) on housing side
q Core portion (F) on rotor side
8) Install flange mounting bolts (19).
9) Remove tool B2.
HB205-1, HB205LC-1
(03)
Hybrid
q Perform the subsequent installation in the re-
verse order to removal.
[*1]
3 Drain plug :
58.8 78.4 Nm {6.0 8.0 kgm}
[*2]
3 Plate mounting bolt :
5.8 8 Nm {0.6 0.8 kgm}
[*3]
a Clean the mounting face of the starting motor as-
sembly and apply gasket sealant to it.
(R: Periphery L = 4mm apart from end face)
2 Starting motor assembly mounting face:
Liquid gasket (LG-7)
q Refilling of oil
Add oil to the generator motor housing.
5 Motor-generator housing:
6.5 l
(Power line oil TO10)
a Check the oil level with oil level gauge.
a Run the engine to circulate the oil in the lubri-
cation circuit, and then check the oil level and
add oil as necessary.
50-121
Hybrid
Removal and installation of swing electric motor assembly

Removal and installation of swing electric motor assembly 50-12

your eye, wash it away immediately with

plenty of water and then consult a doctor.
k Drain coolant from hybrid system.

Serial No.: 1001 2634 1. Open left inspection cover (1).

Special tools 50-12

New/redesign
Necessity

Sketch
Sym-

Q'ty
Part number Part name
bol

F 4 01124-51490 Guide bolt t 1

k Removal (and installation) procedures in this

section must be carried out by a person who
has finished a special training course for
handling low voltage electrical appliances.
Understand the contents of 00 Introduction,
safety, and basic information, "Safety pre- 2. Remove three nuts (2) from the top of inverter
cautions 1. Precautions peculiar to hybrid and remove cover (3).
machine" and "Handling of hybrid devices
and high-voltage wirings" before starting
work.

Removal 50-12

k Discharge the capacitor. For details, see 00

Introduction, safety, and basic information,
"Handling of hybrid devices and high-voltage
wirings", "Discharge procedure for capaci-
tor".
k Disconnect two one-touch connectors (cable
terminals of (+) and (-)) from the capacitor
(See step 3). 3. Disconnect two one-touch wiring connectors
k Park the machine on a level place, lower the (cable terminals of (+) and (-)) from the capac-
work equipment to the ground completely, itor.
and stop the engine. a While pressing the lock portion of the con-
k Referring to Testing and adjusting, "Releas- nector with your thumb to unlock the connec-
ing remaining pressure in hydraulic circuit", tor, pull out the connectors.
release the pressure inside the hydraulic cir-
cuit and then set the lock lever to the LOCK
position.
k Disconnect the cable from the negative (-)
terminal of the battery.
k When opening the coolant filler cap or drain-
ing the coolant, ensure that coolant tempera-
ture is low and it does not scald you.
k While draining the coolant, take care that the
coolant does not stick to your skin or enter
your eye.
Super Coolant mixed in the coolant is toxic.
If the coolant splashes on your skin or enters

50-122 HB205-1, HB205LC-1

(04)
 Hybrid
Removal and installation of swing electric motor assembly

4. Remove lower cover (4). [*1]

10. Disconnect clip (12) and disconnect wiring

5. Loosen oil drain plug (5) to drain the oil. connector CN-P01 (13).
[*2]
6 Swing electric motor (in case): 11. Remove mounting bolt (14) to disconnect power
1.6 1.8 l cable plug (15). [*6]
(Drained amount):
1.6 l 12. Disconnect power cable fixing clamp (16) from
bracket (17).

13. Disconnect delivery hose (lubricating oil inlet)

(18).
[*7]

14. Disconnect delivery hose clamp (19) from

bracket (17).

15. Remove two mounting bolts (20) and bracket

(17). [*8]

6. Remove cover (6).

7. Remove mounting bolt (7) to remove plate (8).

[*3]

8. Remove six mounting bolts (9) and cover (10).

[*4]

9. Disconnect hose mounting bracket (11) from the

swing electric motor. [*5]

HB205-1, HB205LC-1 50-123

(04)
Hybrid
Removal and installation of swing electric motor assembly
16. Remove clamp (21) and disconnect two coolant
hoses (22). [*9]
a Make marks on the hoses so that you do not
mistake them for each other.
17. Disconnect lubricating oil outlet hose (23). [*10]
18. Disconnect lubricating oil drain hose (24). [*11]
19. Remove cover (31).
20. Remove hose clamp (25) and disconnect drain
hose (26) from the swing machinery.
21. Remove bracket (27).
50-124
22. Sling the swing electric motor and remove six
mounting bolts (28). [*12]
a Before removing the bolts, make a match
mark (X) between the swing electric motor
and swing machinery
23. Install hanging bolts [1] to hanging bolt holes (P)
(two places on a diagonal line).
a Eyebolt thread diameter: 8 mm
24. Lift off swing electric motor assembly (29).
k When removing the swing electric motor
assembly, the springs may jump out.
Sling carefully and slowly.
4 Swing electric motor assembly:
71 kg
HB205-1, HB205LC-1
(04)
 Hybrid
Removal and installation of swing electric motor assembly

Installation
q Perform installation in the reverse order to re-
moval.
[*1]
3 Cover mounting bolt:
98 123 Nm {10.0 12.5 kgm}
[*2]
3 Oil drain plug:
58.8 78.4 Nm {6.0 8.0 kgm}
Target value: 68.6 Nm {7.0 kgm}
[*3]
3 Plate fixing bolt:
27 34 Nm {2.8 3.5 kgm}
[*4]
3 Cover mounting bolt:
27 34 Nm {2.8 3.5 kgm}
[*5]
3 Mounting bolt of travel hose bracket:
27 34 Nm {2.8 3.5 kgm}
50-126
[*7]
3 Delivery hose sleeve nut:
54 93 Nm {5.5 9.5 kgm}
[*8]
3 Bracket mounting bolt:
59.7 74 Nm {6.0 7.5 kgm}
[*9]
a When connecting the coolant hoses, check their
marks made when they were removed.
(Left side): Outlet hose from swing electric motor
(Right side): Inlet hose to swing electric motor
[*10]
3 Sleeve nut of lubricating oil outlet hose:
84 132 Nm {8.5 13.5 kgm}
[*11]
3 Sleeve nut of lubricating oil drain hose:
84 132 Nm {8.5 13.5 kgm}

[*6]
q Install the connector of the high-voltage wiring
(power cable) according to the following proce-
dure.
1) Check plug (P) on the cable side for dirt and
flaw.
2) Thinly apply grease (G2-LI) to insertion
sealing portion (R) of the flange.
(For protection of the seal from the inserted
flange)
3) Insert plug (P) on the cable side straight into
power feed terminal socket (S) on the motor
side.
a Direct the black mark up.
a When inserting the plug, set disconnec-
tion detection contact (Q) of the power ca-
ble under the cable.
3 Mounting bolt of high-voltage wir-
ing (power cable) plug:
8.8 10.8 Nm {0.9 1.1 kgm}

HB205-1, HB205LC-1 50-125

(04)
Hybrid
Removal and installation of swing electric motor assembly
[*12]
q Install the swing electric motor assembly to the
swing machinery according to the following pro-
cedure.
1) Degrease mating faces (Q) of the swing elec-
tric motor and No. 1 ring gear (30).
2) Install tools F4 (guide bolts) to three places of
swing electric motor mounting face (R) of No.
1 ring gear (30).
4) Install 3 mounting bolts (28) of the swing
5) Remove tool F4 and evenly tighten the six
3) Install swing electric motor assembly (29) to
the swing machinery assembly, aligning the
match marks made at removal.
50-126
a When installing a new swing electric mo-
tor assembly (29), match mounting face
(S) of the oil supply pipe with piping port
face (T) of the swing electric motor and
use tool F4 to install.
a While checking that the springs are set to
the spring mounting face of the swing
electric motor, sling the swing electric mo-
tor assembly slowly.
k When positioning the springs, never
put your finger between the swing
electric motor and No. 1 ring gear.
(If you are required to position the
springs, use a screwdriver, etc.)
4 Swing electric motor assembly:
71 kg
electric motor and tighten them temporarily.
bolts, including the remaining three mounting
bolts.
3 Swing electric motor mounting
bolt:
157 196 Nm {16 20 kgm}
HB205-1, HB205LC-1
(04)
 Hybrid
Removal and installation of swing electric motor assembly

q Refilling of oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
piping. Then, check the oil level again.
5 Swing machinery case:
6 l(TO30)
5 Swing electric motor case:
1.6 1.8 l(TO10)
(Refill capacity):
1.6 l(TO10)

q Refilling coolant and bleeding air

a Add coolant and bleed air. For details, see
"Draining adding coolant and bleeding air for
hybrid system".

HB205-1, HB205LC-1 50-127

(04)
Hybrid
Removal and installation of swing electric motor assembly

Serial No.: 2635 and up 1. Open left side inspection cover (1).

Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

4 01124-51490 Guide bolt t 1

F
11 7875-35-2910 Cap t 1

k The removal and installation in this section

must be performed by people who completed
the special training for low-voltage electric
work.
Before performing work, understand 00 Fore-
word, Safety, Basic information, "Safety no- 2. Remove nuts (2) (3 pieces) at the top of the
tice 1. Precautions Specific to Hybrid inverter, and remove cover (3).
Equipment" and "Handling Hybrid Equip-
ment and High-Voltage Wires".

Removal

k Discharge the capacitors. For details, refer to

"Capacitor discharge procedure" in 00 Fore-
word, Safety, Basic information, "Handling
Hybrid Equipment and High-Voltage Wires".
k Disconnect the one-touch connectors ((+)
and (-) cable terminals) (2 pieces) (see step
3).

k Place the machine on a level ground, lower 3. Disconnect one-touch wiring connectors HB01
the work equipment to the ground, and stop (CC) ((+) and (-) cable terminals) (2 pieces) of
the engine. the capacitor.
k Release the remaining pressure in the hy- a Pull out the connector by pressing the lock
draulic circuit and set the lock lever to LOCK part of the connector with your thumb to re-
position. For details, see "Releasing remain- lease the lock.
ing pressure in hydraulic circuit" in Testing
and adjusting.
k Disconnect the cable from the negative (-)
terminal of the battery.
k Before opening the water filler cap or drain-
ing coolant, check that the coolant tempera-
ture cools down to the temperature safe
enough for anyone not to get burn.
k When draining coolant, be careful not to let
coolant contact your skin or enter your eye.
The super coolant mixed in the coolant is
poisonous. If the coolant sticks to your skin
or enters your eye, immediately rinse with
water thoroughly and see a doctor.
k Drain the coolant for hybrid.

50-128 HB205-1, HB205LC-1

(04)
 Hybrid
Removal and installation of swing electric motor assembly

4. Remove lower cover (4). [*1]

8. Remove mounting bolts (5 pieces), and remove

5. Loosen oil drain plug (5) to drain the oil. cover (10). [*4]
[*2]
6 Swing electric motor (in the case): 9. Disconnect hose mounting bracket (11) from the
1.6 to 1.8 l swing electric motor. [*5]
(Drain amount):
1.6 l

10. Disconnect clip (12), and disconnect wiring

connector CN-P01 (13).
6. Remove cover (6).
11. Remove mounting bolts (14), and disconnect
7. Remove accumulator and bracket assembly power cable plug (15). [*6]
according to the following procedure. (if
equipped)
1) Disconnect hoses (7a) to (7d).
2) Remove bracket (8). [*3]
3) Sling accumulator and bracket assembly (9),
and remove them.
4 Accumulator and bracket assembly
(9):
35 kg

HB205-1, HB205LC-1 50-128-1

(04)
Hybrid
Removal and installation of swing electric motor assembly

12. Disconnect power cable fixing clamp (16) from

bracket (17).

13. Remove mounting bolts (17a) (2 pieces), and

remove bracket (17). [*7]
a After disconnecting the high voltage wiring,
make sure to install tool F11.
a Tool F11 prevents water and dust from enter-
ing into the connector part.

14. Disconnect hose (18). [*8]

19. Remove hose clamp (25), and disconnect drain

hose (26) from the swing machinery assembly.

20. Remove bracket (27a).

21. Remove oil filler tube (27).

22. Sling the swing electric motor, and remove

mounting bolts (28) (6 pieces). [*12]
a Before removing the bolts, make match-
marks (X) on the swing electric motor side
15. Remove clamps (19) and (20) and disconnect and swing machinery side.
coolant hoses (21) and (22) (2 pieces). [*9]
a Make matchmarks on the hoses to prevent
any mistake of right and left.

16. Disconnect lubricating oil outlet hose (23). [*10]

17. Disconnect lubricating oil drain hose (24). [*11]

18. Remove cover (31).

50-128-2 HB205-1, HB205LC-1

(04)
 Hybrid
Removal and installation of swing electric motor assembly

23. Install eyebolts [1] to the eyebolt mounting screw Installation

parts (P) (2 places diagonally). q Perform installation in the reverse order of re-
a Eyebolt thread diameter: 8 mm moval.

24. Sling swing electric motor assembly (29), and [*1]

remove it. 3 Cover mounting bolts:
4 Swing electric motor assembly: 98 to 123 Nm {10.0 to 12.5 kgm}
70 kg
[*2]
3 Oil drain plug:
19.6 to 29.5 Nm {2.0 to 2.5 kgm}
Target value: 22.54 Nm {2.3 kgm}

[*3]
3 Bracket fixing bolt:
27 to 34 Nm {2.8 to 3.5 kgm}

[*4]
3 Cover mounting bolts:
27 to 34 Nm {2.8 to 3.5 kgm}

[*5]
3 Travel hose bracket mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}

[*6]
q Install the connector of the high voltage wiring
(power cable) according to the following proce-
dure.
1) Check that there is no stain or scratch on the
cable side plug (P).
2) Apply grease (G2-LI) lightly on insertion seal
part (R) of the flange.
(To protect the seal from damage during
insertion)
3) Insert the cable side plug straight into the
motor side power supply terminal socket (S).
a Make sure that black marking faces up-
ward.
a Insert power cable removal and installa-
tion detection contact (Q) with having the
cable facing the bottom.
3 High voltage wiring (power cable)
plug mounting bolt:
8.8 to 10.8 Nm {0.9 to 1.1 kgm}

HB205-1, HB205LC-1 50-128-3

(04)
Hybrid
Removal and installation of swing electric motor assembly

[*7] 2) Install tools F4 (guide bolt) (3 pieces) to

3 Bracket mounting bolt: swing electric motor mount bolt mounting
59.7 to 74 Nm {6.0 to 7.5 kgm} surface (R) (3 places) of No.1 ring gear (30).

[*8]
3 Delivery hose sleeve nut:
54 to 93 Nm {5.5 to 9.5 kgm}

[*9]
a Install the coolant hoses by checking right and
left hoses recorded during removal.
(Left side): Outlet hose from the swing electric
motor
(Right side): Inlet hose from the swing electric
motor

[*10]
3 Lubricating oil outlet hose sleeve nut: 3) Install swing electric motor assembly (29) to
84 to 132 Nm {8.5 to 13.5 kgm} the swing machinery assembly along with the
matchmarks (x) put before removal.
[*11] a When installing a new swing electric mo-
3 Lubricating oil drain hose sleeve nut: tor, match the oil filler pipe mounting sur-
84 to 132 Nm {8.5 to 13.5 kgm} face (S) and swing electric motor piping
port surface (T), and use tool F4 to install
[*12] swing electric motor assembly (29).
q Install the swing electric motor assembly to the
swing machinery according to the following pro-
cedure.
1) Degrease the mating face (Q) of the swing
electric motor and No.1 ring gear (30).

50-128-4 HB205-1, HB205LC-1

(04)

k When positioning the spring, never in-
sert your finger into the gap between
the swing electric motor and No.1 ring
gear.
(If positioning of the spring is re-
quired, use a screwdriver.)
a While checking that the spring stays in
the spring mounting face of the swing
electric motor, sling the swing electric mo-
tor assembly slowly.
4 Swing electric motor assembly:
70 kg
4) Install swing electric motor mounting bolts
(28) (3 pieces), and tighten them lightly.
5) Remove tool F4, and evenly tighten the 6
bolts in total including the remaining 3
mounting bolts.
3 Swing electric motor mounting
bolt:
157 to 196 Nm {16 to 20 kgm}
HB205-1, HB205LC-1
(04)
Hybrid
Removal and installation of swing electric motor assembly
q Refilling with oil
Refill it with oil to the specified level through the
oil filler port. Run the engine to circulate the oil
through the piping. Then check the oil level
again.
5 Swing machinery case:
6 l (TO30)
5 Swing electric motor case:
1.6 to 1.8 l (TO10)
(Refill capacity):
1.6 l (TO10)
q Refilling with coolant and bleeding air
a Refill coolant water and bleed air in the hybrid
radiator. For details, see "Procedures for
draining coolant, refilling with coolant, and
bleeding air for hybrid system".
50-128-5
Hybrid
Removal and installation of swing electric motor assembly

50-128-6 HB205-1, HB205LC-1

(04)
 Power train
Removal and installation of final drive assembly

Power train 50-129

Removal and installation of final drive assembly 50-129

Removal 50-129 4. Temporarily sling final drive assembly (6).

1. Remove the sprocket, referring to the section
Removal and installation of sprocket. 5. Remove 18 mounting bolts (7) and lift final drive
k Lower the work equipment completely to assembly (6) to remove. [*1]
the ground and stop the engine. Then, a Be careful so that the nipple sealing surface
loosen the hydraulic tank cap gradually to on the hose mounting block is not damaged.
release the pressure inside the hydraulic 4 Final drive assembly:
tank. 300 kg

2. Remove cover (1).

3. Disconnect travel speed selector hose (2), motor

hoses (3) and (4), and drain hose (5).

HB205-1, HB205LC-1 50-129

(01)
Power train
Removal and installation of final drive assembly

Installation 50-130
q Perform installation in the reverse order to re-
moval.

[*1]
3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}

q Refilling of oil
Fill power train oil (TO30) through the oil filler
port to the specified level. Start the engine to
circulate the oil through the pipings and recheck
the oil level.

q Bleeding air
See Testing and adjusting, Bleeding air from
each part.

50-130 HB205-1, HB205LC-1

(01)
 Power train
Disassembly and assembly of final drive

Disassembly and assembly of final drive 50-131

Special tools 50-131 4. Remove thrust washer (2).

New/redesign
Necessity
5. No. 1 carrier assembly

Sketch
Q'ty
Symbol Part number Part name 1) Remove No. 1 carrier assembly (3).

Wrench assem-
796-427-1400 t 1 N
bly
1 796-427-1410 q Wrench 1 N
796-427-1140 q Pin 3
01314-20612 q Screw 3
796T-427-1510 Push tool t 1 N Q
790-101-2510 Block t 1
790-101-3310 Block t 1
790-101-2610 Rod t 2
J
790-101-2730 Adapter t 2
01580-11613 Nut t 2
2
790-101-2570 Plate t 2
01643-31645 Washer t 2
Puller
790-101-2102 (294 kN {30 t 1 2) Disassemble No. 1 carrier assembly as
ton}) follows.
790-101-1102 Pump t 1 1] Push in pin (4) and drive out shaft (5) from
3 796-427-1520 Installer t 1 N
carrier (6).
a After removing the shaft, remove pin
Disassembly 50-131 (4).
1. Draining oil 2] Remove thrust washer (7), planetary gear
Remove the drain plug to drain the oil from the (8), bearing (9), and thrust washer (10)
final drive case. from carrier (6).
6 Final drive case:
3.5 l

2. Set the final drive assembly on the block [1].

3. Remove mounting bolts to remove cover (1).

a When cover (1) is difficult to be separated,
tap the cover (1) with a plastic hammer.

HB205-1, HB205LC-1 50-131

(01)
Power train
Disassembly and assembly of final drive

6. Remove No. 1 sun gear shaft (11).
7. Remove thrust washer (12).
8. Remove No. 2 sun gear (13).
3) Disassemble No. 2 carrier assembly as
follows.
1] Push in pin (18) and drive out shaft (17)
from carrier (19).
a After removing the shaft, remove pin
(16).
2] Remove thrust washer (19), planetary
gear (20), bearing (21), and thrust washer
(22).

9. No. 2 carrier assembly

1) Remove No. 2 carrier assembly (14).
4 No. 2 carrier assembly:
35 kg
2) Remove thrust washer (15).

10. Nut
1) Remove lock plate (23).
2) Use tool J1 to remove nut (24).
a Use bar [2] to hold.

50-132 HB205-1, HB205LC-1

(01)
 Power train
Disassembly and assembly of final drive

11. Hub assembly 13. Use puller [3] and push tool [4] to remove
1) Sling hub assembly (25) and remove from bearing (32).
travel motor. a Bearing may come off without using the pull-
2) Remove bearing (26). er.

3) Remove bearing outer races (27) and (28).

12. Remove floating seals (30) and (31) from travel

motor (29).
a Floating seal (30) may be sticking on hub as-
sembly (25).

HB205-1, HB205LC-1 50-133

(01)
Power train
Disassembly and assembly of final drive
Assembly 50-134
a Clean the parts completely and inspect them for
any foreign material or damage. Apply power
train oil (TO30) to the sliding surfaces before as-
sembly.
1. Hub assembly
1) Use push tool to press fit bearing outer races
(27) and (28) into hub (32).
2) Use tool J3 to install floating seal (30).
a Install the floating seal after degreasing
and drying completely the O-ring and
O-ring contacting surface.
a After installing the floating seal, check the
inclination of the seal. It must be 1 mm or
less.
a After floating seal installation, apply a thin
coat of power train oil (TO30)on the slid-
ing surfaces.
50-134
2. Install bearing (32) to travel motor (29).
a Warm the inner race of the bearing (32) to
50-70 C by using a heater.
a Cool the bearing (32) down. Tap the bearing
(32) with a drift and listen to the sound to
check that it is fully seated.
3. Use tool J3 to install floating seal (31) to travel
motor (29).
a Install the floating seal after degreasing and
drying completely the O-ring and O-ring con-
tacting surface.
a After installing the floating seal, check the in-
clination of the seal. It must be 1 mm or less.
a After floating seal installation, apply a thin
coat of power train oil (TO30) on the sliding
surfaces.
4. Set hub assembly (25) to travel motor.
HB205-1, HB205LC-1
(01)
 Power train
Disassembly and assembly of final drive

5. Install bearing (26) by tapping it lightly with the 7] Measure the size (a) under the condition
push tool. described in 6] above.

6. Nut 8] Measure thickness (b) of independent nut

1) Install nut as follows. (24).
1] Rotate the hub 2 - 3 times. 9] (a) - (b) = (c)
2] Use tool J2 and the push tool [5] to press 10] Use tool J1 to tighten nut (24) until the
the inner race of bearing (26). following condition is met:
a Pressing force: Dimension (d): (c) + 0.06/-0.04
29.4 38.2 kN {3.0 3.9 ton}
3] Rotate the hub to the both directions at
least 5 times in total with the bearing inner
race pressed.
4] Release the pressing force.
5] Press the bearing again.
a Pressing force:
17.7 21.6 kN {1.8 2.2 ton}
6] Rotate the hub 2 - 3 times.

2) Measure the tangential force of the hub

against the motor case in the rotation direc-
tion using the push scale [6].
a Tangential force: Max. 490 N {50 kg}
a The tangential force denotes the maxi-
mum force at start of the rotation.

HB205-1, HB205LC-1 50-135

(01)
Power train
Disassembly and assembly of final drive

3) Install lock plate (23). 3] Insert pin (16).

a Install the lock plate so that the splines a When inserting the pin, take care that
(A) of the motor and the lock plate are in the 3 claws (parts f) on the periphery
full contact. of the pin will not be placed on the thin
2 Mounting bolt thread: parts of the carrier (parts g). The thin
Adhesive (LT-2) wall part may be on the opposite side
a Do not apply the adhesive (LT-2) to the depending on carriers, however.
thread portion of the nut. Check each carrier and avoid setting
any claw of the pin to the thin wall part.
If there is a groove, avoid the groove.
a After assembling the carrier assem-
bly, check that gear (20) rotates
smoothly.

a After the pin is inserted, punch the pin

(B) on the carrier.

7. No. 2 carrier assembly

1) Assemble No. 2 carrier assembly as follows.
a Replace thrust washers (19) and (22) as
well as pin (16) with new ones.
a There is trace of punching on the end face
of carrier side hole (e) which was caused
when the pin was inserted and caulked.
Before pin installation, remove the protru-
sion in the pin hole as a result of punch-
ing.
1] Assemble bearing (21) to gear (20), fit top
and bottom thrust washers (19) and (22)
and then set the gear assembly on carrier
(18).
2] Align the pin holes on shaft (17) and the
carrier, and install shaft (17) by tapping it
lightly with a plastic hammer.
a Install the shaft, rotating planetary
gear (20). Take care so the thrust
washer is not damaged.
2) Install No. 2 carrier assembly (14).
a Align the 4 gear shaft ends of the carrier
assembly (14) with the 4 dimples on the
motor case end surface to install.

50-136 HB205-1, HB205LC-1

(01)

8. Thrust washer
Install thrust washer (15).
9. No. 2 sun gear
Install No. 2 sun gear (13).
10. No. 1 sun gear
Install No. 1 sun gear (11).
11. Thrust washer
Install thrust washer (12).
HB205-1, HB205LC-1
(01)
Power train
Disassembly and assembly of final drive
12. No. 1 carrier assembly
1) Assemble No. 1 carrier assembly as follows.
a Replace thrust washers (7) and (10) as
well as pin (4) with new ones. (See Pin
(4): 3].)
a There is trace of staking on the end sur-
face of carrier side hole (h), which was
performed by using a punch for locking of
the inserted pin. Remove the protrusion
due to the staking in the pin hole before-
hand.
1] Assemble bearings (8) and (9), fit top and
bottom thrust washers (7) and (10) and
then set the gear assembly on carrier (6).
50-137
Power train
Disassembly and assembly of final drive

2] Align the pin holes on shaft (5) and the 2) Install No. 1 carrier assembly (3).
carrier, and install shaft (5) by tapping it
lightly with a plastic hammer. 13. Thrust washer
a Install the shaft, rotating the planetary Install thrust washer (2).
gear (8). Take care so the thrust a After installing washer (2), measure dimen-
washer is not damaged. sion (i) from the upper end face of planetary
3] Insert pin (4). gear (8) to that of ring gear assembly (25) to
a When inserting the pin, take care that check for the correct assembly condition.
the 3 claws (parts f) on the periphery a If dimension (i) is 0.6 mm or larger, it is not
of the pin will not be placed on the thin assembled correctly. Check the assembling
parts of the carrier (parts g). The thin condition.
wall part may be on the opposite side
depending on carriers, however.
Check each carrier and avoid setting
any claw of the pin to the thin wall part.
If there is a groove, avoid the groove.
a After assembling the carrier assem-
bly, check that gear (8) rotates
smoothly.

a After the pin is inserted, punch the pin

(C) on the carrier at 2 locations.

50-138 HB205-1, HB205LC-1

(01)
 Power train
Disassembly and assembly of final drive

14. Cover
Install cover (1).
2 Cover mounting face:
Liquid gasket (LG-6)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}

15. Refilling of oil

Tighten the drain plug and supply power train oil
(TO30) from the oil filler port.
5 Final drive case:
3.5 l
a Do a final check of the oil level at the deter-
mined position after installing the final drive
assembly to the chassis.

HB205-1, HB205LC-1 50-139

(01)
Power train
Removal and installation of sprocket

Removal and installation of sprocket 50-140

Removal 50-140 Installation 50-140

1. Separate track shoe assembly. For details, see q Perform installation in the reverse order to re-
"Separation and connection of track shoe moval.
assembly".
[*1]
2. Swing work equipment 90, push up chassis with 2 Threads of sprocket mounting bolt:
work equipment and place block (1) between Adhesive (LT-2)
track frame and track shoe. 3 Sprocket mounting bolt:
441 490 Nm {45 50 kgm}
3. Remove sprocket (2), hanging as follows.
1) Remove mounting bolts (1). [*1]
a Before removing the final fixing bolt, place
block [2] under sprocket (2).
2) Put sprocket (2) on block [2], make a clear-
ance from final drive (FD), and lead sling [3]
in between.
4 Sprocket:
40 kg

50-140 HB205-1, HB205LC-1

(01)
 Power train
Removal and installation of swing motor and swing machinery assembly

Removal and installation of swing motor and swing machinery

assembly 50-141

1. Open left inspection cover (1).

Serial No.: 1001 2634

k Removal (and installation) procedures in this

section must be carried out by a person who
has finished a special training course for
handling low voltage electrical appliances.
Understand the contents of 00 Introduction,
safety, and basic information, "Safety pre-
cautions 1. Precautions peculiar to hybrid
machine" and "Handling of hybrid devices
and high-voltage wirings" before starting
work.
2. Remove three nuts (2) from the top of inverter
and remove cover (3).
Removal 50-141

k Discharge the capacitor. For details, see 00

Introduction, safety, and basic information,
"Handling of hybrid devices and high-voltage
wirings", "Discharge procedure for capaci-
tor".
k Disconnect two one-touch connectors (cable
terminals of (+) and (-)) from the capacitor
(See step 3).
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Referring to Testing and adjusting, "Releas- 3. Disconnect two one-touch wiring connectors
ing remaining pressure in hydraulic circuit", HB01 (cc) (cable terminals of (+) and (-)) from
release the pressure inside the hydraulic cir- the capacitor.
cuit and then set the lock lever to the LOCK a While pressing the lock portion of the con-
position.
k
nector with your thumb to unlock the connec-
Disconnect the cable from the negative (-) tor, pull out the connectors.
terminal of the battery.

HB205-1, HB205LC-1 50-141

(04)
Power train
Removal and installation of swing motor and swing machinery assembly

4. Remove lower cover (4). [*1] 8. Remove mounting bolt (9) to remove plate (10).
[*3]

9. Remove six mounting bolts (11) and cover (12).

[*4]

10. Disconnect travel hose mounting bracket (13)

from the swing electric motor. [*5]

5. Loosen oil drain plug (6a) to drain the oil. [*2]

6 In swing electric motor case:
1.6 1.8 l
Drained amount:
1.6 l

6. Remove drain block mounting bolts (5) and

disconnect swing electric motor drain block (6) 11. Disconnect clip (14) and disconnect wiring
and swing machinery drain block (7). connector CN-P01 (15).

7. Pull out swing machinery drain block (7) and 12. Remove mounting bolt (16) to disconnect power
drain hose (8) from the hole of the revolving cable connector (17). [*6]
frame.
13. Disconnect power cable fixing clamp (18) from
bracket (19).

14. Disconnect delivery hose (lubricating oil inlet)

(20).
[*7]

15. Disconnect delivery hose clamp (21) from

bracket (19).

16. Remove two mounting bolts (22) and bracket

(19). [*8]

50-142 HB205-1, HB205LC-1

(04)
 Power train
Removal and installation of swing motor and swing machinery assembly

17. Loosen clamp (23) and disconnect two coolant 23. Remove twelve mounting bolts (29). [*12]
hoses (24). [*9]
a Make marks on the hoses so that you do not
mistake them for each other.

18. Disconnect lubricating oil outlet hose (25). [*10]

19. Disconnect lubricating oil drain hose (26). [*11]

20. Remove cover (31).

24. Install eyebolt [1] and sling [2] to three places (P)
on the periphery.

21. Disconnect swing holding brake hose (27) from

the swing machinery.

22. Disconnect hose clamp (28) from the swing

machinery.

25. Sling and remove the swing motor and swing

machinery assembly (30).
4 Swing motor and swing machinery as-
sembly:
310 kg

HB205-1, HB205LC-1 50-143

(04)
Power train
Removal and installation of swing motor and swing machinery assembly

Installation 50-14 [*7]

q Perform installation in the reverse order to re- 3 Delivery hose sleeve nut:
moval. 54 93 Nm {5.5 9.5 kgm}

[*1] [*8]
3 Cover mounting bolt: 3 Bracket mounting bolt:
98 123 Nm {10.0 12.5 kgm} 59.7 74 Nm {6.0 7.5 kgm}

[*2]
3 Oil drain plug:
19.6 24.5 Nm {2.0 2.5 kgm}
[*3]
3 Plate fixing bolt:
27 34 Nm {2.8 3.5 kgm}
[*4]
3 Cover mounting bolt:
27 34 Nm {2.8 3.5 kgm}
[*5]
3 Mounting bolt of travel hose bracket:
27 34 Nm {2.8 3.5 kgm}
[*6]
q Install the connector of the high-voltage wiring
(power cable) according to the following proce-
dure.
1) Check plug (P) on the cable side for dirt and
flaw.
2) Thinly apply grease (G2-LI) to insertion
sealing portion (R) of the flange.
(For protection of the seal from the inserted
flange)
3) Insert plug (P) on the cable side straight into
power feed terminal socket (S) on the motor
side.
a Direct the black mark up.
a When inserting the plug, set disconnec-
tion detection contact (Q) of the power ca-
ble under the cable.
3 Mounting bolt of high-voltage wir-
ing (power cable) plug:
8.8 10.8 Nm {0.9 1.1 kgm}
[*9]
a When connecting the coolant hoses, check their
marks made when they were removed.
(Left side): Outlet hose from swing electric motor
(Right side): Inlet hose to swing electric motor
[*10]
3 Sleeve nut of lubricating oil outlet hose:
84 132 Nm {8.5 13.5 kgm}
[*11]
3 Sleeve nut of lubricating oil drain hose:
84 132 Nm {8.5 13.5 kgm}
[*12]
3 Swing machinery assembly mounting
bolt:
490 608 Nm {50 62 kgm}
q Refilling of oil
Add oil through the oil filler of the swing electric
motor to the specified level. Run the engine to
circulate the oil through the piping. Then, check
the oil level again.
5 Swing electric motor case:
1.6 1.8 l (TO10)
q Refilling coolant and bleeding air
a Add coolant and bleed air. For details, see
"Draining adding coolant and bleeding air for
hybrid system".

50-144 HB205-1, HB205LC-1

(04)
 Power train
Removal and installation of swing motor and swing machinery assembly

Serial No.: 2635 and up 1. Open left side inspection cover (1).

Special tool

Necessity
Sym-

Q'ty
Part No. Part name
bol

F 11 7875-35-2910 Cap t 1

k The removal and installation in this section

must be performed by people who completed
the special training for low-voltage electric
work.
Before performing work, understand 00 Fore-
word, Safety, Basic information, "Safety no-
tice 1. Precautions Specific to Hybrid 2. Remove nuts (2) (3 pieces) at the top of the
Equipment" and "Handling Hybrid Equip- inverter, and remove cover (3).
ment and High-Voltage Wires".

Removal

k Discharge the capacitors. For details, refer to

"Capacitor discharge procedure" in 00 Fore-
word, Safety, Basic information, "Handling
Hybrid Equipment and High-Voltage Wires".
k Disconnect the one-touch connectors ((+)
and (-) cable terminals) (2 pieces) (see step
3).
k Place the machine on a level ground, lower
the work equipment to the ground, and stop
the engine. 3. Disconnect one-touch wiring connectors HB01
k Release the remaining pressure in the hy- (CC) ((+) and (-) cable terminals) (2 pieces) of
draulic circuit and set the lock lever to LOCK the capacitor.
position. For details, see "Releasing remain- a Pull out the connector while pressing the lock
ing pressure in hydraulic circuit" in Testing part of the connector with your thumb to re-
and adjusting. lease the lock.
k Disconnect the cable from the negative (-)
terminal of the battery.

HB205-1, HB205LC-1 50-144-1

(04)
Power train
Removal and installation of swing motor and swing machinery assembly

4. Remove lower cover (4). [*1] 8. Remove cover (9).

9. Remove accumulator and bracket assembly

according to the following procedure. (if
equipped)
1) Disconnect hoses (10a) to (10d).
2) Remove bracket (11).
3) Sling accumulator and bracket assembly (12)
to remove it.
4 Accumulator and bracket assembly
(9):
35 kg

5. Loosen oil drain plug (6a) to drain the oil. [*2]

6 Swing electric motor (inside case):
1.6 to 1.8 l
Drain amount:
1.6 l

6. Remove drain block mounting bolt (5) and

disconnect swing electric motor drain block (6)
and swing machinery drain block (7).

7. Pull out swing machinery drain block (7) and

drain hose (8) through the hole of the revolving 10. Remove cover (13). [*3]
frame.
11. Disconnect travel hose mounting bracket (14)
from the swing electric motor. [*4]

50-144-2 HB205-1, HB205LC-1

(04)
 Power train
Removal and installation of swing motor and swing machinery assembly

12. Disconnect clip (15) and disconnect connector
CN-P01 (16).
13. Remove mounting bolts (17) and disconnect
high voltage wiring connector (18). [*5]
a After disconnecting the high voltage wiring,
make sure to install tool F11.
a Tool F11 prevents water and dust from enter-
ing into the connector part.
17. Loosen clamps (22) and (23) and disconnect
coolant hoses (24) and (25) (2 pieces). [*8]
a Make matchmarks on the hoses to prevent
any mistake of right and left.
18. Disconnect lubricating oil outlet hose (26). [*9]
19. Remove cover (27).

14. Disconnect clamp (19) from bracket (20).

15. Remove mounting bolts (20a) (2 pieces), and

remove bracket (20). [*6]

16. Disconnect hose (21). [*7]

20. Disconnect swing parking brake hose (28) from

the swing machinery.

HB205-1, HB205LC-1 50-144-3

(04)
Power train
Removal and installation of swing motor and swing machinery assembly

21. Remove mounting bolts (29) (12 pieces). [*10] Installation

q Perform installation in the reverse order of re-
22. Install eyebolt [1] and lifting tool [2] to 3 places on moval.
the periphery of (P) part.
[*1]
23. Sling swing motor and swing machinery 3 Cover mounting bolts:
assembly (30), and remove them. 98 to 123 Nm {10.0 to 12.5 kgm}
4 Swing motor and swing machinery as-
sembly: [*2]
310 kg 3 Oil drain plug:
19.6 to 24.5 Nm {2.0 to 2.5 kgm}
Target value: 22.54 Nm {2.3 kgm}

[*3]
3 Cover mounting bolts:
27 to 34 Nm {2.8 to 3.5 kgm}

[*4]
3 Travel hose bracket mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}

[*5]
q Install the connector of the high voltage wiring
(power cable) according to the following proce-
dure.
1) Check that there is no stain or scratch on the
cable side plug (P).
2) Apply grease (G2-LI) lightly on insertion seal
part (R) of the flange.
(To protect the seal from damage during
insertion)
3) Insert the cable side plug straight into the
motor side power supply terminal socket (S).
a Make sure that black marking faces up-
ward.
a Insert power cable removal and installa-
tion detection contact (Q) with having the
cable facing the bottom.
3 High voltage wiring (power cable)
plug mounting bolt:
8.8 to 10.8 Nm {0.9 to 1.1 kgm}

[*6]
3 Bracket mounting bolt:
59.7 to 74 Nm {6.0 to 7.5 kgm}

50-144-4 HB205-1, HB205LC-1

(04)
 Power train
Removal and installation of swing motor and swing machinery assembly

[*7]
3 Delivery hose sleeve nut:
54 to 93 Nm {5.5 to 9.5 kgm}

[*8]
a Install the coolant hoses by checking right and
left hoses recorded during removal.
(Left side): Outlet hose from the swing electric
motor
(Right side): Inlet hose from the swing electric
motor

[*9]
3 Lubricating oil outlet hose sleeve nut:
84 to 132 Nm {8.5 to 13.5 kgm}

[*10]
3 Swing machinery assembly mounting
bolt:
490 to 608 Nm {50 to 62 kgm}

q Refilling with oil

Refill with oil to the specified level through the oil
filler port of the swing electric motor. Run the
engine to circulate the oil through the piping.
Then check the oil level again.
5 Swing electric motor case:
1.6 to 1.8 l (TO10)

q Refilling with coolant and bleeding air

a Refill coolant water and bleed air in the hybrid
radiator. For details, see "Procedures for
draining coolant, refilling with coolant, and
bleeding air for hybrid system".

HB205-1, HB205LC-1 50-144-5

(04)
Power train
Removal and installation of swing motor and swing machinery assembly

50-144-6 HB205-1, HB205LC-1

(04)
 Power train
Disassembly and assembly of swing machinery assembly

Disassembly and assembly of swing machinery assembly 50-145

Special tools 50-145 3. Accessories

1) Remove machinery drain hose (2) and elec-

New/redesign
Necessity
tric swing motor drain hose (3).

Sketch
Q'ty
Symbol Part number Part name 2) Remove the oil level gauge according to the
following procedure.
1] Remove clamp mounting bolt (4) and
796T-426-1130 Plate t 1 Q remove hose (5).
1 790-101-5421 Push tool t 1 2] Remove two mounting bolts (6a) and two
01010-81240 Bolt t 1 mounting bolts (6b) to remove bracket
2 796-426-1120 Push tool t 1
F 3 796T-426-1410 Plate t 1 Q
(7).
4 01124-51490 Guide bolt t 3 3] Remove four mounting bolts (8a) and oil
1 796-426-1710 Collet t 1 filler pipe (8).
5 2 796-426-1720 Tapered cone t 1
3 796-426-1730 Collar t 1 4. Electric swing motor
1) Remove six mounting bolts (9a).
Disassembly 50-145 a Make match mark (P) between the case
1. Set the swing electric motor and swing of the electric swing motor assembly (9)
machinery assembly to a block. and swing machinery assembly (10).

2. Draining oil of swing machinery

Loosen oil drain plug (1) of the swing machinery
to drain the oil from the swing machinery case.
6 Swing machinery case:
7.1 l

HB205-1, HB205LC-1 50-145

(01)
Power train
Disassembly and assembly of swing machinery assembly

2) Lift off electric swing motor assembly (9). 8. Remove six mounting bolts (15) of the No. 1 ring
4 Electric swing motor assembly: gear.
71 kg

9. Lift off No. 1 ring gear (16).

5. Remove No. 1 sun gear (11).

6. Remove seven mounting bolts (12) and cover

(13).
k When removing cover (13) the springs
may jump out. Sling carefully and slowly.

10. No. 1 carrier assembly

1) Remove No. 1 carrier assembly (17).

7. Remove springs (14).

50-146 HB205-1, HB205LC-1

(01)
 Power train
Disassembly and assembly of swing machinery assembly

2) Disassemble the No. 1 carrier assembly 11. Using air gun [1], apply air pressure through
according to the following procedure. swing holding brake port (Q) to remove piston
1] Reverse carrier assembly (17). (29).
2] Remove Spirolock (18). k Use air pressure of 5-6 kg/cm .
2
a While lifting up the abutment joint of k When applying air pressure, hold piston
Spirolock (18) with a thin flat-head (29) to prevent it from jumping out.
screwdriver, move the screwdriver
around clockwise to remove Spirolock
(18).
q While lifting up the abutment joint of
Spirolock (18) with the fingers, move
the screwdriver around clockwise to
remove Spirolock (18).
3] Remove ring (19).
4] Remove shaft (20) from the carrier
assembly by using the push tool.
q Shaft pressing force (reference):
12.2 30.0 N {1,240 3,050 kg}
5] Remove plate (21), planetary gear (22),
bearing (23), plate (24), and ring (25).
6] Reverse No. 1 carrier assembly (17).
7] Remove holder (26).
a Take care not to lose ball (27).

12. No. 2 sun gear assembly

1) Disassemble the No. 2 sun gear assembly
according to the following procedure.
1] Remove snap ring (31) and plate (32)
from No. 2 sun gear (30).
2] Remove swing holding brake gear (33)
from No. 2 sun gear (30).

HB205-1, HB205LC-1 50-147

(01)
Power train
Disassembly and assembly of swing machinery assembly

15. Remove No. 2 sun gear (30).

16. No. 2 carrier assembly

1) Remove No. 2 carrier assembly (38).

13. Remove three plates (34) and two discs (35) in

this order.

2) Disassemble No. 2 carrier assembly as

follows.
1] Remove snap ring (39), thrust washer
(40), planetary gear (41), bearing (42),
and thrust washer (43) in this order.
2] Remove plate (44).
3] Reverse carrier (46) and remove snap
ring (45).

14. Remove six mounting bolts (36) and lift off case
(37).

50-148 HB205-1, HB205LC-1

(01)

3) Using push tool [1], remove shaft (47) from
carrier (46).
q Shaft pressing force (reference):
11.2 - 25.8 kN {1,140 - 2,630 kg}
17. Remove No. 3 sun gear (48).
18. Remove the mounting bolts and No. 2 ring gear
(49).
19. Remove holder mounting bolt (50).
20. No. 3 carrier assembly
1) Remove No. 3 carrier assembly (51).
HB205-1, HB205LC-1
(01)
Power train
Disassembly and assembly of swing machinery assembly
2) Disassemble the No. 3 carrier assembly
according to the following procedure.
1] Push in pin (52) and drive out shaft (53)
from carrier (54).
a After removing the shaft, remove pin
(52).
2] Remove thrust washer (55), planetary
gear (56), and bearing (57).
3] Remove plate (58).
21. Shaft and case assembly
1) Reverse shaft and case assembly (59).
2) Remove cover mounting bolts (60).
50-149
Power train
Disassembly and assembly of swing machinery assembly

3) Reverse shaft and case assembly (59) again 22. Shaft assembly
and set it to the press. 1) Using push tools [3] and [4], remove shaft
4) Using push tool [2], remove shaft assembly (62).
(61) from shaft and case assembly (59). 2) Remove bearing (64) and oil seal (65) from
cover (63).

23. Remove bearing (67) from case (66).

a Apply a proper tool on the periphery of the
outer race (bold line at Q) and tap around the
periphery evenly with a hammer to remove
the bearing gradually.
a If the outer race is slanted, the bearing binds.
Keep the bearing level while removing it.

50-150 HB205-1, HB205LC-1

(01)
 Power train
Disassembly and assembly of swing machinery assembly

Assembly 50-151 2. Using push tool [5], press fit bearing (64) to case
a Clean all the parts thoroughly, check them for (66).
dirt and flaw, and apply power train oil to the slid- a Use a new bearing.
ing parts before assembling.
a Do not reuse the removed bearings and oil seals
but replace them with new ones.

1. Oil seal
Using tool F1, install oil seal (65) to cover (63).
a Take care of the direction (top and bottom) of
the oil seal.
2 Outer periphery of oil seal:
Liquid gasket (LG-6)
a Take care that the liquid gasket (LG-6) does
not stick to the oil seal lip at the time of
press-fitting.

3. Install cover assembly (69) to case assembly

(68).
2 Cover mounting face:
Liquid gasket (LG-6)
a Take care that liquid gasket (LG-6) does not
stick to drain port (DP).
a Match the drain portion of the cover with
drain port (DP).

a When not using tool F1, use a push tool that

can press periphery (A) of oil seal (65) even-
ly.
a Take care not to slant oil seal (65).

4. Shaft and case assembly

1) Set case assembly (68) on shaft (62).
2 Oil seal lip:
Grease (G2-LI)
a Set the case assembly without touching
the oil seal.
2) Using tool F2, push tool [6], and hammer [7],
press fit the inner race of bearing (64) into
position by tapping.
a Sag sling [8].
k Press fit to such an extent that shaft (9)
does not drop when it is lifted.

HB205-1, HB205LC-1 50-151

(01)
Power train
Disassembly and assembly of swing machinery assembly
3) Set the assembly to the press.
4) Using tool F2 and push tools [9] and [10],
press fit the inner race of bearing (64).
a Put in push tool [10] against large slant of
the case assembly.
a If case assembly (68) slants, correct it by
hitting the flange lightly.
a Just before oil seal (65) enters shaft (B),
set case assembly (68) horizontally and
align it with shaft (62) to prevent damage
to the oil seal lip.
50-152
5. Bearing
Using tool F3 and push tool [11], press fit bearing
(67).
a Press the inner race and outer race of the
bearing simultaneously. Do not press only
the inner race.
q Bearing press fit force (reference):
9.4 35.5 kN {960 3,620 kg}
a After press-fitting the bearing, ensure that the
case rotates smoothly.
6. No. 3 carrier assembly
1) Assemble the No. 3 carrier assembly
according to the following procedure.
a There is a caulking mark made when the
pin was inserted at side hole (h) of carrier
(54) and the inside wall of the hole is
swelled at that mark. Flatten the swelled
part in advance. (See 5])
1] Install plate (58) to carrier (54).
2] Install bearing (57) and two thrust
washers (55) (top and bottom) to plan-
etary gear (56).
3] Set the planetary gear assembly to
carrier (54).
HB205-1, HB205LC-1
(01)
 Power train
Disassembly and assembly of swing machinery assembly

4] Match the pin holes of shaft (53) and
carrier with each other by lightly hitting
with a plastic hammer, and then install
shaft (53).
a When installing the shaft, rotate the
planetary gear so that the thrust wash-
ers are not damaged.
5] Insert pin (52).
a When inserting the pin, take care that
the 3 claws (parts a) on the periphery
of the pin will not be placed on the thin
parts of the carrier (parts b).
The thin wall part may be on the oppo-
site side depending on carriers,
however. Check each carrier and
avoid setting any claw of the pin to the
thin wall part.
a After inserting the pin, caulk two plac-
es (c) around the pin hole of the carri-
er.
7. No. 3 sun gear
Install No. 3 sun gear (48).
8. No. 2 ring gear
Using eyebolts (M10 x 1.5), install No. 2 ring
gear (49).
a Degrease mating faces of No. 2 ring gear
(49) and case (66).
a Do not stick gasket sealant to the mating fac-
es of the No. 2 ring gear and case.
a When installing the No. 2 ring gear, set its
match mark (c) to convex part (d) of the
flange as shown in the figure.
3 Mounting bolt:
157 196 Nm {16 20 kgm}
9. Install O-ring (71).

2) Install No. 3 carrier assembly (51) by using

bolt (50).
2 Mounting bolt thread:
Adhesive (LT-2)
3 Mounting bolt:
157 196 Nm {16 20 kgm}
3) Install O-ring (70) to case (66).

HB205-1, HB205LC-1 50-153

(01)
Power train
Disassembly and assembly of swing machinery assembly

10. No. 2 carrier assembly 2) Install No. 2 carrier assembly (38).

1) Assemble No. 2 carrier assembly as follows. 3) Install No. 2 sun gear (30).
1] Press fit shaft (47) to carrier (46) until the
snap ring groove is seen in the direction
of arrow (1st).
2] After installing snap ring (45) , push it
back from the opposite side (2nd direc-
tion) until snap ring contacts tightly with
face P of the carrier. Be careful not to
push too much at this time.
q Shaft pressing force (reference):
11.2 - 25.8 kN {1,140 - 2,630 kg}

11. Case
3] Install plate (44) to carrier (46).
4] Install thrust washer (43), bearing (42),
planetary gear (41), thrust washer (40),
and snap ring (39) in this order.
Install case (37) according to the following
procedure.
1) When installing case (37), match its notch (a)
with bolt (c) next to convex part (b) of the
flange as shown in the figure.
a Degrease mating faces of No. 2 ring gear
(49) and case (37).
a Do not stick liquid gasket to the mating
faces of No. 2 ring gear (49) and case
(37).
2) Install six mounting bolts (36).
3 Mounting bolt:
59 74 Nm {6.0 7.5 kgm}

50-154 HB205-1, HB205LC-1

(01)

12. Install three plates (34) and two discs (35).
a Do not clean the discs with trichloroethylene
or denatured alcohol or blow air strongly
against it.
a When installing the discs, apply clean lubri-
cating oil (TO30) to their surfaces.
a Install the plates and discs in the order shown
in the figure.
HB205-1, HB205LC-1
(01)
Power train
Disassembly and assembly of swing machinery assembly
13. No. 2 sun gear
1) Assemble No. 2 sun gear (30) according to
the following procedure.
1] Install swing holding brake gear (33) to
No. 2 sun gear (30).
2] Install plate (32) to No. 2 sun gear (30)
and install snap ring (31).
a Take care not to install swing holding
brake gear (33) upside down.
a Take care not to install plate (32) up-
side down.
50-155
Power train
Disassembly and assembly of swing machinery assembly

14. Install piston (29). 15. No. 1 carrier assembly

a Install piston (29) while matching its notch
(e)) with notch (d) of case (37) as shown in
the figure.
a When installing, take care not to damage the
O-ring.
1) Assemble the No. 1 carrier assembly
according to the following procedure.
1] Install holder (26) and ball (27) as a set.
2] Install ring (25), plate (24), bearing (23),
planetary gear (22), and plate (21) to
shaft (20) in this order.
3] Reverse the shaft and planetary gear
assembly and press fit it to carrier (17).
a When installing the shafts, direct the
shaft grooves (g) and carrier center
(h) as shown in the figure.
a Press fit the assembly so that distance
(j) between the carrier end and shaft
end is 5.2 to 6.1 mm.
q Shaft pressing force (reference):
12.2 30.0 kN {1,240 3,050 kg}

50-156 HB205-1, HB205LC-1

(01)
 Power train
Disassembly and assembly of swing machinery assembly

4] Reverse carrier assembly (17). 2) Install No. 1 carrier assembly (17).

5] Install ring (19).
6] Install the spirolock according to the
following procedure.
a Do not reuse the removed Spirolox
but replace it with a new one.
1] Set Spirolock (18) to tool F5-2
(tapered cone)
2] Install tool F5-1 (collet) to tool F5-2
and set them so that the end of tool
F5-2 is fitted tightly to the end of shaft
(20).
3] Press tool F5-1 until its end touches
the Spirolock.
4] Set tool F5-3 to end face of tool F5-1.
5] While hitting tool F5-3 lightly with a 16. Sling and install No. 1 ring gear (16).
plastic hammer, insert Spirolock (18)
in the groove of the shaft. 17. Tighten the mounting bolts.
2 Mounting bolt thread:
a When inserting, take care not to press
ring (19) too much. Adhesive (LT-2)
3
a Ensure that the spirolock3 is fitted to Mounting bolt:
the ring tightly. 59 74 Nm {6.0 7.5 kgm}

a After installing, check that dimensions 18. Install springs (14).

(i) and (j) are as follows.
(i): 7.9 8.5 mm 19. Install six mounting bolts (15) of the No. 1 ring
(j): 5.2 6.1 mm gear.

HB205-1, HB205LC-1 50-157

(01)
Power train
Disassembly and assembly of swing machinery assembly

20. Install cover (13) with seven mounting bolts (12). 2) Sling electric swing motor assembly (9) while
matching the match marks that were made
21. Install No. 1 sun gear (11). on the electric swing motor and No. 1 ring
a Before installing No. 1 sun gear (11), check gear at disassembly.
to see if there is the plate.
a If there is not the plate, install it before install-
ing No. 1 sun gear (11).
a When installing No. 1 sun gear (11), apply oil
(TO30) to the plate.
a When installing the plate, do not bruise or
scratch its face to be in contact with the ball.

a When installing a new electric swing mo-

a While checking that the springs are set to
22. Install the swing electric motor assembly
according to the following procedure.
a Degrease the mating faces of electric swing
motor assembly (9) and swing machinery as-
sembly (10).
a Do not stick liquid gasket to the mating faces
of the electric swing motor assembly and
swing machinery assembly (10).
1) Install tools F4 (guide bolts) (M14 x 2 x 90
mm) to three places of electric swing motor
mounting bolt holes (Q) of No. 1 ring gear
(16).
tor assembly or a new No. 1 ring gear,
match mounting face (S) of the oil supply
pipe with piping port face (T) of the elec-
tric swing motor and use tool F4 to install.
the spring mounting face of the electric
swing motor, sling the electric swing mo-
tor assembly slowly.
When aligning the spring positions, never
insert your fingers.
4 Electric swing motor assembly:
73 kg

50-158 HB205-1, HB205LC-1

(01)
 Power train
Disassembly and assembly of swing machinery assembly

3) Install three mounting bolts (9a) of the elec-

tric swing motor and tighten them tempo-
rarily.
4) Remove tool F4 and evenly tighten the six
bolts, including the remaining three mounting
bolts.
3 Mounting bolt:
157 196 Nm {16 20 kgm}

23. Fix oil fuller pipe (8) with four mounting bolts
(8a).
3 Mounting bolt:
27 34 Nm {2.8 3.5 kgm}

24. Connect hose (5). Fix bracket (7) with two

mounting bolts (6a) and two mounting bolts (6b).
3 Bracket mounting bolt:
6a: 27 34 Nm {2.8 3.5 kgm}
6b: 59 74 Nm {6 7.5 kgm}

25. Refilling of oil

Add oil to the swing machinery case.
2 Swing machinery case:
7.1 l

HB205-1, HB205LC-1 50-159

(01)
Power train
Removal and installation of swing circle assembly

Removal and installation of swing circle assembly 50-160

Removal 50-160 Installation 50-160

1. Disassemble the revolving frame assembly
referring to the section Disassembly and
assembly of revolving frame assembly.
2. Sling swing circle assembly (1) at three points
and remove mounting bolts to remove the
assembly. [*1]
4 Swing circle assembly:
270 kg
q Perform installation in the reverse order to re-
moval.
[*1]
a Bring the inner race soft zone position (S) mark:
(a) and the outer race soft zone position (S)
mark: (b) to the right side of the body as shown
below and install to the track frame.
2 Amount of filled grease:
Grease (G2-LI)14.6 l

2 Swing circle mounting bolt threaded por-

tion:
Adhesive (LT-2)
q Perform angle tightening.
3 Swing circle mounting bolt:
1) Initial torque: 191.3 19.6 Nm {19.5 2 kgm}
2) After that, rotate the bolt 48 5 deg.

50-160 HB205-1, HB205LC-1

(01)
 Undercarriage and frame
Separation and connection of track shoe assembly

Undercarriage and frame 50-161

Separation and connection of track shoe assembly 50-161

Special tools 50-161 3. Set the location of master pin (2).

1) Pushing against ground with the work equip-

New/redesign
Necessity
ment, lift the track shoes.

Sketch
Sym

Q'ty
Part number Part name 2) Locate master pin (2) at around the center of
bol
lower track shoes and between 2 track
rollers.
791-630-3000 Remover and installer t 1 3) Put blocks [1] under the track below the idler
Cylinder and sprocket.
R 790-101-1300 t 1
(980 kN {100 ton})
790-101-1102 Pump t 1

Separation of track shoe 50-161

1. Turn the upper structure by 90 deg.

2. Loosening lubricator (1), slacken the tension of

track shoes. [*1]
k Since the inner pressure of adjusting cyl-
inder is extremely high, never loosen the
lubricator more than one turn. If the
grease does not come out smoothly,
move the machine forward and reverse.

4. Using tool R, remove master pin (2).

[*2]
a Press fit guide pin (GP), so that master pin
(2) will be pushed out.

HB205-1, HB205LC-1 50-161

(01)
Undercarriage and frame
Separation and connection of track shoe assembly

5. Set the location of guide pin (GP). Installation of track shoe 50-162
1) Pushing against ground with the work equip- q Perform connection in the reverse order to sep-
ment, lift the track shoes. aration.
2) Move away blocks [1] that were set under the
track below the idler and sprocket. [*1]
3) Move guide pin (GP) to the front of the idler. a Refer to the Checking and adjusting track shoe
4) Relieve the work equipment, and lower the tension section in the Testing and adjusting
machine. chapter of this manual.
5) Place block [1] under track (3) in front of the
idler. [*2]
1. Apply grease to master pin (2). (in the area
where bushing (4) and master pin (2) come
contact: shown hatched)
2 Between bushing and master pin
(hatched area):
Grease
NIGTIGHT LYK-2 from Nippon Grease
Co., Ltd.: part no. 44392708 or equiva-
lent

6. Pull out guide pin (GP), and move the machine

back slowly to separate track (3). [*3]
a Put some blocks between upper track shoes
and the track frame to prevent damages.

a When replacing dust seals, apply grease to

the end surfaces of bushing and the contact
surface (B) of dust seals.
2 Contact surface (B portion) between
bushing and dust seal: Grease
Grease
NIGTIGHT LYK-2 from Nippon Grease
Co., Ltd.: part no. 44392708 or equiva-
lent

50-162 HB205-1, HB205LC-1

(01)
 Undercarriage and frame
Separation and connection of track shoe assembly

a Press fit master pin (2) and push guide pin

(GP) out.
a Using tool R, press fit the master pin, so that
the protrusion amount (a) of master pin (2)
will be the dimension designated below.
Protruding amount of the master pin (a): 2.5
1 mm

[*3]
1. Using bar [2], roll up track shoes (3) while the
machine moves forward slowly.

2. As for latter half of the operation, use a forklift or

the work equipment, to pull wire [3] to fix the
track shoes.

HB205-1, HB205LC-1 50-163

(01)
Undercarriage and frame
Disassembly and assembly of idler

Disassembly and assembly of idler 50-164

Special tools 50-164 3. Remove idler (4) from the assembly of shaft (5)
and support (7).

New/redesign
a Since 250 cc of oil is filled in, drain it at this

Necessity

Sketch
Sym-

Q'ty
Part number Part name timing, or underlay some cloth to prevent any
bol
careless smearing.

L 3 791-530-1510 Installer t 1 4. Remove floating seals (6) on the opposite side

from idler (4) and the assembly of shaft (5) and
Disassembly 50-164 support (7).
q Structural illustration

5. Remove dowel pin (8) to remove support (7)

from shaft (5).

6. Remove bushings (9) and (10) from idler (4).

1. Remove dowel pin (1) to dismount support (2).

2. Remove floating seals (3) from support (2) and

idler (4).

50-164 HB205-1, HB205LC-1

(01)
 Undercarriage and frame
Disassembly and assembly of idler

Assembly 50-165
q Structural illustration

3. Using tool L3, install floating seal (6) to idler (4)

and assembly of shaft (5) and support (7).
a Completely clean, degrease and dry the con-
tact surfaces (hatched area shown in the
drawing) of the floating seal and the O-ring.
a Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.
a After inserting the floating seal, verify that the
inclination of the seal is less than 1 mm per
its diameter and that the protrusion height
shown as (a) in the illustration falls within the
range of 7 to 11 mm.

1. Press fit bushings (9) and (10) to idler (4).

2. Install support (7) with the O-ring to shaft (5) by

using dowel pin (8).

HB205-1, HB205LC-1 50-165

(01)
Undercarriage and frame
Disassembly and assembly of idler

4. Install the assembly of shaft (5) and support (7) 6. Install support (2) with the O-ring to the shaft by
to idler (4). using dowel pin (1).
a See structural illustration.

7. Supply oil and tighten the plug.

5 Idler:
245 255 cc(TO30)
3 Plug:
205.8 49 Nm {21 5 kgm}

5. Using tool L3 (above-mentioned), install floating

seals (3) to idler (4) and to support (2).
a Completely clean, degrease and dry the con-
tact surfaces (hatched area shown in the
drawing) of the floating seal and the O-ring.
a Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.
a After inserting the floating seal, verify that the
inclination of the seal is less than 1 mm per
its diameter and that the protrusion height
shown as (a) in the illustration falls within the
range of 7 to 11 mm.

50-166 HB205-1, HB205LC-1

(01)
 Undercarriage and frame
Disassembly and assembly of idler cushion assembly

Disassembly and assembly of idler cushion assembly 50-167

Special tools 50-167 1. Remove piston assembly (2) from idler cushion
assembly (1).

New/redesign
Necessity

Sketch
Sym-

Q'ty
Part number Part name 2. Disassembling idler cushion assembly
bol
1) Set tool M1 to idler cushion assembly (1).
k The tool must be installed correctly as
791-600-2001 Compressor (A) the load at installed length of the
or t 1 spring is large and dangerous.
791-685-8006 Compressor (B) a Load at installed length of spring:
790-201-2780 Spacer
109.2 kN {11,150 kg}
1 791-635-3160 Extension t 1
Cylinder
790-101-1600
(686 kN {70 ton})
790-101-1102 Pump t 1
M 790-640-2180 Guide bolt t 1
790-101-5201 Push tool kit (B) q 1
790-101-5241 q Plate 1
2
790-101-5221 q Grip 1
01010-51225 q Bolt 2
790-201-1500 Push tool kit q 1
790-201-1620 q Plate 1
3
790-101-5021 q Grip 1
01010-50816 q Bolt 1

Disassembly 50-167
q Structural illustration
2) Apply hydraulic pressure gradually to
compress the spring and remove lock plate
(3) and nut (4).
a Compress the spring up to the point
where the nut gets loose.
a Release the hydraulic pressure slowly to
release the tension of the spring.
a Free length of spring: 531 mm
3) Remove yoke (6) and cylinder (7) from spring
(5).
4) Remove snap ring (8), dust seal (9) and
bushing (10), in turn from cylinder (7).

3. Further disassembly of piston assembly (2)

1) Remove lock plate (12) from piston (11), and
then valve (13).
2) Remove snap ring (14), then remove
U-packing (15) and ring (16).

HB205-1, HB205LC-1 50-167

(01)
Undercarriage and frame
Disassembly and assembly of idler cushion assembly

Assembly 50-168
q Structural illustration
4) Install cylinder (7) and yoke (6) to spring (5).
Install the assembly to tool M1.
2 Sliding surface of cylinder:
Grease (G2-LI)

1. Assembly of piston assembly (2)

1) Install ring (16) and U-packing (15) to piston
(11), and secure them with snap ring (14).
2) Tighten valve (13) lightly, and secure it with
lock plate (12). 5) Apply hydraulic pressure slowly to compress
the spring, and then tighten nut (4) so that the
2. Building idler cushion assembly installed length of the spring is dimension (a)
1) Using tool M2, press fit bushing (10) into and secure it with lock plate (3)
cylinder (7). a Installing length(a) of spring: 417 mm
2) Using tool M3, install dust seal (9) to cylinder
(7).
3) Secure them by using snap ring (8).

6) Remove idler cushion assembly (1) from tool

M1.

3. Install piston assembly (2) to idler cushion

assembly (1).
2 Sliding surface of cylinder: :
Grease (G2-LI)
2 Wear ring:
Grease (G2-LI)
a Install the piston assembly with the valve in-
stalled position facing outward.
a Pump 300 cc of grease (G2-LI) into the cylin-
der and bleed air. Check that grease comes
out of the grease hole.

50-168 HB205-1, HB205LC-1

(01)
 Undercarriage and frame
Disassembly and assembly of track roller

Disassembly and assembly of track roller 50-169

Special tools 50-169 Assembly 50-169

1. Using push tool [1], press fit bushings (9) and

New/redesign
Necessity
(10) to roller (4).

Sketch
Sym-

Q'ty
Part number Part name
bol
2. Install collar (8) with the O-ring to shaft (5), and
install pin (7).
L 2 796-670-1020 Installer t 1

Disassembly 50-169
1. Remove pin (1), then remove collar (2).

2. Remove floating seals (3) from collar (2) and

roller (4).

3. Remove roller (4) from the assembly of shaft (5)

and collar (8).
a Since 195 cc of oil is filled in, drain it at this
timing, or underlay some cloth to prevent any
careless smearing.

4. Remove floating seals (6) on the opposite side

from roller (4), and the assmbly of shaft (5) and
collar (8).

5. Remove pin (7) and then collar (8) from shaft (5).

6. Remove bushings (9) and (10) from roller (4).

HB205-1, HB205LC-1 50-169

(01)
Undercarriage and frame
Disassembly and assembly of track roller

3. Using tool L2 install floating seal (6a) to collar 5. Install shaft (5) to roller (4).
(8).
a Completely clean, degrease and dry the con- 6. Turn over the assembly of roller (4) and shaft (5).
tact surfaces (hatched area in the drawing) of
the floating seal and the O-ring. And take
care not to have any dirt stuck on the contact
surfaces.
a After inserting the floating seal, verify that the
inclination of the seal is less than 1 mm per
its diameter and that the protrusion height
shown as (a) in the illustration falls within the
range of 7 to 11 mm.
4. Using tool L2, install floating seals (6b) and (3b)
to roller (4).
a As to precautions for installation of floating
seals (6b) and (3b), refer to a marked com-
ments in step 3.
7. Using tool L2, install floating seal (3a) to collar
(2).
a For precautions for installing floating seal
(3a), see a mark in step 3.
a Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.

8. Install collar (2) with the O-ring to the shaft with

pin (1).

9. Supply oil and tighten the plug.

5 Track roller:
190 200 cc(E030-CD)
3 Plug:
1.5 5 Nm {1.5 0.5 kgm}

50-170 HB205-1, HB205LC-1

(01)
 Undercarriage and frame
Disassembly and assembly of carrier roller

Disassembly and assembly of carrier roller 50-171

Special tools 50-171 2. Using push tool [1], push the end surface of the
shaft to remove shaft (2) from carrier roller (1) to

New/redesign
Necessity
separate followings.

Sketch
Sym-

Q'ty
Part number Part name q The assembly of roller (4) and ring (5), shaft
bol
(2) and cover (3).
q Press fit force (reference): 59 kN {6,000 kg}or
L 1 790-434-1660 Installer t 1 more.
a The press fit between shaft (2) and ring (5),
q Sectional view and also between roller (4) and cover (3) are
a A number in the drawing is the number shown in disengaged.
the text. a Shaft (2) and cover (3) under the shaft are re-
moved as a unit.

Disassembly 50-171
1. Remove plug (9) and drain the oil from carrier 3. Remove ring (5) from roller (4).
roller (1).
6 Carrier roller:
4. Remove floating seal (6) from ring (5).
75 85 cc a Take care not to damage the sealing surface.

HB205-1, HB205LC-1 50-171

(01)
Undercarriage and frame
Disassembly and assembly of carrier roller

5. Remove floating seal (7) from roller (4).

a Take care not to damage the sealing surface.

6. Using push tools [2] and [3], remove bushing (8)

from roller (4).

50-172 HB205-1, HB205LC-1

(01)
 Undercarriage and frame
Disassembly and assembly of carrier roller

Assembly 50-173
1. Using push tools [3] and [4], press fit bushing (8)
to roller (4).
a Press fit it from the side of cover (3)

2. Floating seal
1) Using tool L1, install floating seal (7) to roller
(4).
2) Using tool L1, install floating seal (6) to roller
(5)
a Completely clean, degrease and dry the
contact surfaces (hatched area in the
drawing) of the floating seal and the
O-ring. And take care not to have any dirt
stuck on the contact surfaces.
3. Install roller (4) and ring (5) to shaft (2).
a When installing floating seals, use tool L1
a Apply oil to the sliding surface of the floating
and make sure to press the O-ring.
seal, and take care not to have any dirt stuck
a After inserting the floating seal, verify that
on it.
the inclination of the seal is less than 1
mm per its diameter and that the protru-
sion height shown as (a) in the illustration
falls within the range of 7 to 11 mm.

HB205-1, HB205LC-1 50-173

(01)
Undercarriage and frame
Disassembly and assembly of carrier roller

4. Place washers [7] between push tool [6] and 6. Fill carrier roller assembly (1) with oil and tighten
roller (4). Press fit ring (5) to shaft (2) until the plug (9).
height difference between roller (4) and ring (5) 5 Carrier roller:
becomes 1.8 0.2 mm. 75 85 cc(E030-CD)
a Thickness of washer [7] = 1.8 0.2 mm 3 Plug:
a Use push tool [5] to support shaft (2) on it. 15 5 Nm {1.5 0.5 kgm}

5. Using push tool [8], press fit cover (3) to roller

(4).
a Degrease, wash and dry the surfaces where
roller (4) and cover (3) fit tight.
q Press fitting force (reference): 59 kN {6,000
kg} or more

50-174 HB205-1, HB205LC-1

(01)
 Undercarriage and frame
Removal and installation of revolving frame assembly

Removal and installation of revolving frame assembly 50-175

Removal 50-175
k Safely lower the work equipment to the
ground by extending the arm and the bucket
completely. Set the lock lever in the lock po-
sition.

1. Remove work equipment assembly. For details,

see "Removal and installation of work equipment
assembly".

2. Disassemble the counterweight assembly, refer-

ring to the "Removal and installation of counter-
weight assembly" section in this manual.

3. Disconnect 4 boom cylinder hoses (1).
a Put an oil stopper to the hose.
6. From center swivel joint assembly, disconnect 6
hoses (8) to (13).
q (8): Center swivel joint (port D) to
Swing motor (T port)
q (9): Center swivel joint (port E) to
Solenoid valve
q (10): Center swivel joint (port B) to
L.H. travel control valve (A2 port)
q (11): Center swivel joint (port D) to
R.H. travel control valve (B5 port)
q (12): Center swivel joint (port A) to
L.H. travel control valve (B2 port)
q (13): Center swivel joint (port C) to
R.H. travel control valve (A5 port)

7. Pull out pin (14) on the center swivel joint, and

4. Sling the boom cylinder assembly (2). detach jam plate (15) from the center swivel
joint.
5. Remove plate (3) and pin (4) and lift off boom
cylinder assembly (2).
a Remove the boom cylinder on the opposite
side in the same manner.
4 Boom cylinder assembly:
180 kg

HB205-1, HB205LC-1 50-175

(01)
Undercarriage and frame
Removal and installation of revolving frame assembly

8. Remove the 32 mounting bolts and sling Installation 50-176

revolving frame assembly (16) to remove it. [*1] q Perform installation in the reverse order to re-
a Using levers and blocks, hold the balance of moval.
revolving frame assembly front and rear, and
left and right. [*1]
k When removing the revolving frame as- 2 Swivel circle mating surface:
sembly, take care that it will not interfere Liquid gasket (LG-1)
with the center swivel joint assembly. 2 Threads of revolving frame mounting
4 Revolving frame assembly: bolt:
5,100 kg Adhesive (LT-2)
q Tighten the revolving frame mounting bolt with
torque plus angle method in the following proce-
dure.
1) Tighten the bolts in the following order so that
the pressure to bolt seat surface becomes
equal.
1] 6 each front and rear
2] 6 each right and left
3] All the remaining bolts
3 Tightening torque (Initial
torque):
294.2 29.4 Nm {30 3 kgm}
2) Then tighten the bolts turning by 60 6 deg.

q Refilling of oil (Hydraulic tank)

Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.

q Bleeding air
Bleed air from the travel motor referencing the
"Bleeding air from each part" section in the
Testing and adjusting chapter of this manual.

50-176 HB205-1, HB205LC-1

(01)
 Undercarriage and frame
Removal and installation of counterweight assembly

Removal and installation of counterweight assembly 50-17

Special tools 50-17

New/redesign
Necessity

Sketch
Sym-

Q'ty
Part number Part name
bol

Commer-
cially avail- Impact wrench q 1
able
Z
Commer- Socket wrench
cially avail- (Width across flats : q 1
able 46 mm)

a Use the impact wrench and socket wrench with

the torque capacities enough for tightening the
counterweight mounting bolts.
3 Counterweight mounting bolt:
1.52 1.91 kNm {155 195 kgm}

Removal 50-17
k Park the machine on a level place and swing
the upper structure 90 deg., and then lower
the work equipment to the ground complete-
ly and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Open the engine hood.

2. Remove rear view mirror.

3. Remove rear camera (2) according to the

following procedure.
1) Remove cover (3).
a Insert thin flat-head screwdriver [1] in hole
(a) of cover (3) and pull it toward you to 4. Disconnect wiring connector (8) for the rear
remove cover (3). camera.
2) Remove cover mounting bolts (4) and cover
(5).
3) Loosen wiring connector (6) and disconnect
it from the camera.
a To disconnect wiring connector (6), rotate
it counterclockwise to loosen.
a Bind the wirings to the machine with
strings.
4) Remove rear camera mounting bolts (7) and
remove rear camera assembly (2).

HB205-1, HB205LC-1 50-177

(01)
Undercarriage and frame
Removal and installation of counterweight assembly

5. Using impact wrench Z and socket wrench Z, Installation 50-178

remove counterweight mounting bolts (9). [*1] q Perform installation in the reverse order to re-
moval.

[*1]
2 Mounting bolt:
Adhesive (LT-2)
3 Counterweight mounting bolt:
1.52 1.91 kNm {155 195 kgm}

[*2]
a Installation and adjustment of counterweight
1) Adjust the level difference from the exterior
parts (horizontal clearance) with shims.
a Shims: 1 mm(205-46-25150)
2) Fix the counterweight so that the clearances
6. Sling and remove counterweight assembly (10). in the direction of front and rear are even and
[*2] within the limit of 10 5 mm for both from the
q Counterweight assembly: 3,450 kg
doors and from the revolving frame.
3) The difference in level in left to right direction
between the exterior of door (D) and counter-
weight (C)
(a): 10 4 mm
The difference in level in left to right direction
between revolving frame (R) and counter-
weight (C)
(b): 5 mm or less
The difference in level in up and down direc-
tion between exterior upper cover (UC) and
counterweight (C)
c: 0 5 mm
are the respective limits for the mounting
adjustment.
a Rear view (Enlarged drawing for right
hand side)

50-178 HB205-1, HB205LC-1

(01)
 Hydraulic system
Removal and installation of center swivel joint assembly

Hydraulic system 50-179

Removal and installation of center swivel joint assembly 50-179

Removal 50-179 4. Disconnect 8 hoses (7) through (14).

k Lower the work equipment to the ground q (7): Center swivel joint (port E) to
completely, after the engine is stopped, loos- Left travel motor (port P)
en the hydraulic tank cap gradually to reduce q (8): Center swivel joint (port E) to
the pressure inside, and set the lock lever in Right travel motor (port P)
the lock position. q (9): Center swivel joint (port D) to
a Put tags to the disconnected hoses and tubes to Swing motor (T port)
prevent a mistake in re-connecting them. q (10): Center swivel joint (port E) to
Solenoid valve
1. Swing to right 45 deg. (for hydraulic tank oil q (11): Center swivel joint (port B) to
drain) L.H. travel control valve (B2 port)
a For the method of not draining the oil of the q (12): Center swivel joint (D port)
hydraulic tank by using the oil stopper, see R.H. travel control valve (B5 port)
"Removal of main pump assembly". q (13): Center swivel joint (port A) to
2. Drain the oil from the hydraulic tank. L.H. travel control valve (A2 port)
6 Hydraulic tank: q (14): Center swivel joint (port C) to
232 l(Specified amount of oil) R.H. travel control valve (A5 port)
135 l (Refill capacity)
5. Pull out pin (15) on the center swivel joint side,
3. Disconnect 6 hoses (1) through (6) between and remove the jam plate from center swivel
travel motor and center swivel joint. joint.
q (1): Center swivel joint (port T) to
Left travel motor (port T)
q (2): Center swivel joint (port T) to
Right travel motor (port T)
q (3): Center swivel joint (port B) to
Left travel motor (port PA)
q (4): Center swivel joint (port D) to
Right travel motor (port PB)
q (5): Center swivel joint (port A) to
Left travel motor (port PB)
q (6): Center swivel joint (port C) to
Right travel motor (port PA)

HB205-1, HB205LC-1 50-179

(01)
Hydraulic system
Removal and installation of center swivel joint assembly

6. Remove 4 pieces of mounting bolt (16). Installation 50-180

q Perform installation in the reverse order to re-
moval.

[*1]
Install the center swivel joint (CSJ) facing in the di-
rection shown in the figure. (The figure shows the
machine body as seen from above.)
a S: Sprocket
A to D: Port name

7. Lift off center swivel joint assembly (17). [*1]

4 Center swivel joint assembly:
40 kg

q Refilling with oil (Hydraulic tank)

Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.
5 Hydraulic tank:
232 l(Specified amount of oil)
135 l (Refill capacity)
3 Hydraulic tank drain plug:
58.8 78.5 Nm {6.0 8.0 kgm}

q Bleeding air
See Testing and adjusting, Bleeding air from
each part.

50-180 HB205-1, HB205LC-1

(01)
 Hydraulic system
Disassembly and assembly of center swivel joint assembly

Disassembly and assembly of center swivel joint assembly 50-181

Special tools 50-181 1. Remove elbows (1), (2) and tee (3).

New/redesign
2. Remove cover (4).

Necessity
Sym-
Part number Part name

Sketch
bol
3. Remove snap ring (5) and ring (6).

Q'ty
790-101-2501 Push-puller q 1 4. Using tool T1, pull out swivel shaft (8) from swivel
790-101-2510 q Block 1 rotor (7).
790-101-2520 q Screw 1
791-112-1180 q Nut 1
A 790-101-2540 q Washer 1
790-101-2630 q Leg 2
790-101-2570 q Plate 4
790-101-2560 q Nut 2
790-101-2650 q Adapter 2

Disassembly 50-181

5. Remove seal (9) and O-ring (10) from swivel

rotor (7).

6. Remove dust seal (11) from cover (12).

HB205-1, HB205LC-1 50-181

(01)
Hydraulic system
Disassembly and assembly of center swivel joint assembly

Assembly 50-182
a See figure at left.
1. Install seal (9) and O-ring (10) to swivel rotor (7).

2. Install dust seal (11) to cover (12).

3. Install cover (12) to swivel shaft (8).

4. Set swivel shaft (8) to block, then using push

tool, tap swivel rotor (7) with a plastic hammer to
install.
2 Contact surface of rotor, shaft:
Grease (G2-LI)
a When installing rotor, be extremely careful
not to damage the dust seal and O-ring.

5. Install ring (6) and fix with snap ring (5).

6. Fit O-ring and install cover (4).

3 Mounting bolt:
31.4 2.9 Nm {3.2 0.3 kgm}

7. Install elbows (1), (2) and tee (3).

3 Elbow (1):
128 186 Nm {13 19 kgm}
3 Elbow (2), tee (3):
35 63 Nm {3.5 6.5 kgm}

8. Install plug (13) according to the following proce-

dure.
1) Clean, degrease, and dry the threaded
portion of the plug, and install the plug.
2) After installing the plug, ensure that it is lower
than the shaft end.
3 Plug:
33.3 3.9 Nm {3.4 0.2 kgm}

50-182 HB205-1, HB205LC-1

(01)
 Hydraulic system
Removal and installation of hydraulic tank assembly

Removal and installation of hydraulic tank assembly 50-183

Removal 50-183 4. Remove side cover (4) according to the following

k Park the machine on a level place, lower the procedure.
work equipment to the ground completely, 1) Remove four mounting bolts (6) of battery
and stop the engine. box (5) and move battery box (5) forward.
k Loosen the hydraulic tank cap gradually to
release the pressure in the hydraulic tank
and set the lock lever in the LOCK position.
k Disconnect the cable from the negative (-)
terminal of the battery.
a Put tags to the disconnected hoses and tubes to
prevent a mistake in re-connecting them.

1. Swing to right 45 deg. (for hydraulic tank oil

drain)

2. Remove covers (1) and (2).

3. Loose drain plug (3) to drain oil from the

hydraulic oil tank. [*1]
6 Hydraulic tank:
2) Remove two lower mounting bolts (8) of
cover (7).
232 l(Specified amount of oil)
135 l (Refill capacity)

HB205-1, HB205LC-1 50-183

(01)
Hydraulic system
Removal and installation of hydraulic tank assembly

3) Remove two upper mounting bolts (9) of 2) Remove four bolts (15) from hinge (14) and
cover (7) and remove cover (7). lift off engine hood (12).
a Make marks of (x) and (y) to hinges (14)
to indicate their installed positions.

4) Remove two each of mounting bolts (10) and

(11) and remove side cover (4).
6. Remove cover (16).

5. Remove engine hood (12) according to the

following procedure. 7. Remove the covers on the engine side
1) Disconnect right and left dampers (13). according to the following procedure.
1) Remove cover (17).

50-184 HB205-1, HB205LC-1

(01)
 Hydraulic system
Removal and installation of hydraulic tank assembly

2) Remove frames (18) and (19). 8. Disconnect pre-filter (23) and bracket (24)
3) Remove partition (20). together from frame (25).
4) Remove partition (21).
9. Disconnect drain hoses (26) - (28).

10. Disconnect clamp (29).

5) Remove frame (22).

11. Disconnect drain hoses (30) - (34).

q (30): Solenoid valve drain
q (31): Main valve drain
q (32): PPC drain
q (33): Travel motor drain
q (34): Pump drain

HB205-1, HB205LC-1 50-185

(01)
Hydraulic system
Removal and installation of hydraulic tank assembly

12. Disconnect suction hose (35). [*2] 14. Remove six mounting bolts (37). [*3]
a Put marks on the hose and tube to indicate
their fitting positions.

13. Disconnect hose clamp (36).

15. Sling and remove tank assembly (38).

50-186 HB205-1, HB205LC-1

(01)
 Hydraulic system
Removal and installation of hydraulic tank assembly

Installation 50-187 [*3]

q Perform installation in the reverse order to re- 3 Mounting bolt:
moval. 245 309 Nm {25 31.5 kgm}

[*1] q Refilling with oil (Hydraulic tank)

3 Hydraulic tank drain plug: Supply hydraulic oil through the oil filler port to
58.8 78.5 Nm {6.0 8.0 kgm} the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
[*2] level again.
a Use a new MIKALOR clamp. 5 Hydraulic tank:
2 Whole circumference of tube part of hose: 232 l(Specified amount of oil)
Adhesive (ThreeBond No.4314) 135 l (Refill capacity)
a Set the hose to the original position.
1) Set the hose to the original position (marked q Bleeding air
position). See Testing and adjusting, Bleeding air from
a Reference each part.
Hose installation length: 85 mm (left and
right)
2) Set the bridge (BR) under the clamp bolt and
lap it over the band at least (b) becomes
Min.5 mm.
Dimension (b): Min.5 mm
2 Threaded portion of clamp bolt
(BC):
Lubricating oil (THREEBOND PAN-
DO 18B)
a Do not use an impact wrench.

q When reusing the hose

3) Set the clamp on its trace on the hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}

q When using a new hose

4) Tighten the clamp so that BDG dimension is
as follows.
BDG:7 to 10 mm

HB205-1, HB205LC-1 50-187

(01)
Hydraulic system
Removal and installation of main pump assembly

Removal and installation of main pump assembly 50-18

Special tools 50-18

New/redesign
Necessity
Sym-
Part number Part name

Sketch
bol

Q'ty
10 796-460-1210 Oil stopper q 1
A
11 796-770-1320 Adapter q 1

Removal 50-18
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Referring to Testing and adjusting, "Releas-
ing remaining pressure in hydraulic circuit",
release the pressure inside the hydraulic cir-
cuit and then set the lock lever to the LOCK
position.
k Disconnect the cable from the negative (-)
terminal of the battery.
a Record the installed positions, connector
Nos., or hose band colors of the disconnect-
ed wires and pipes so that you do not make a
mistake in their connection positions.

1. Swing to right 45 deg. (for hydraulic tank oil

drain)

2. Remove lower cover (1).

3. Remove lower covers (2) and (3).

50-188 HB205-1, HB205LC-1

(01)
 Hydraulic system
Removal and installation of main pump assembly

4. Loose drain plug (4) to drain oil from the 5. Remove the engine hood according to the
hydraulic oil tank. [*1] following procedure.
6 Hydraulic tank: 1) Open engine hood (6) and sling it.
232 l(Specified amount of oil) 2) Remove pins (7) and (8) and disconnect two
135 l (Refill capacity) gas springs (9) on the right and left sides.

a If you do not drain the oil from the tank, skip 3) Remove four bolts (11) from hinge (10) and
steps 1, 2, and 4, and install the stopper by lift off engine hood (6).
using tool A10 according to the following pro- a Make marks of (x) and (y) to hinges (10)
cedure. to indicate their installed positions.
1) Remove cover (HC). 4 Engine hood:
2) Remove the strainer. 45 kg
3) Assemble tool A10 (oil stopper) and A11
(adapter).
4) Install tools A10 and A11 together to the
position of the removed strainer.
5) Install cover (5).
a Tighten with several bolts temporarily.

6. Remove cover (12).

HB205-1, HB205LC-1 50-189

(01)
Hydraulic system
Removal and installation of main pump assembly
7. Remove frames (13) and (14).
8. Remove partition plate(15).
9. Disconnect prefilter (16) and bracket (17)
together from frame (18).
10. Disconnect hybrid system lubrication oil filter
(19) from bracket(20).
11. Disconnect fuel filter (21) and bracket (20)
together from frame (22).
50-190
12. Disconnect the following five hoses connected to
the main pump.
(23): Rear load pressure input port hose
(Collar band color: None)
(24): EPC source pressure port hose
(Collar band color: Yellow)
(25): Front load pressure input port hose
(Collar band color: Red)
(26): Pump pressure input port hose
(Collar band color: Blue)
(27): Drain port hose
a When using tool A10 without draining oil from
the hydraulic tank, prepare a large container
if the oil level in the tank is higher than the
drain port for the main pump.
(Oil will flow out when the drain hose is
disconnected.)
13. Remove lubricating oil supply hose (28) of the
motor-generator.
14. Disconnect lubricating oil check hose (29) of the
motor-generator from bracket (30).
15. Disconnect engine oil filter assembly(31) from
bracket (32).
16. Remove bracket (32).
HB205-1, HB205LC-1
(01)
 Hydraulic system
Removal and installation of main pump assembly

17. Disconnect the four hoses connected to the
main pump.
(33): Pump discharge port hose (2 pieces)
(33a): Branch hose (2 pieces)
18. Remove four bolts (34) and disconnect suction
tube (35) from the main pump assembly.
21. Sling main pump assembly (40).
22. Remove twelve mounting bolts (41).
23. Lift and remove main pump assembly (40).
4 Main pump assembly:
165 kg

19. Disconnect wiring clamp (36).

20. Disconnect wiring connectors (37), (38), and

(39).

HB205-1, HB205LC-1 50-191

(01)
Hydraulic system
Removal and installation of main pump assembly

Installation 50-192
q Perform installation in the reverse order to re-
moval.
k If the main pump is replaced or adjusted, per-
form pump calibration according to "Special
function of machine monitor".

[*1]
3 Hydraulic tank drain plug:
58.8 78.5 Nm {6.0 8.0 kgm}

q Refilling of oil (Hydraulic tank)

Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.
6 Hydraulic tank:
232 l(Specified amount of oil)
135 l (Refill capacity)

50-192 HB205-1, HB205LC-1

(03)
 Hydraulic system
Removal and installation of main pump input shaft oil seal

Removal and installation of main pump input shaft oil seal 50-193

Special tools 50-193 Installation 50-193

q Perform installation in the reverse order to re-

New/redesign
moval.

Necessity
Sym-
Part number Part name

Sketch
bol
[*1]
2

Q'ty
Oil seal lip:
S 796T-467-2410 Push tool t 1 N Grease (G2-LI)
2 Oil seal outer periphery:
Removal 50-193 Grease (G2-LI)
1. Remove the main pump assembly. For details, a Apply a thin film of the grease on the oil seal out-
see "Removal (and installation) of main pump er circumference.
assembly". a By using tool S and tools [1] and [2], press fit oil
2. Remove snap ring (1) and then remove spacer seal (3).
(2).
3. By using a screwdriver, pry off oil seal (3).
[*1]
a Take care not to damage the shaft when re-
moving the oil seal.

HB205-1, HB205LC-1 50-193

(01)
Hydraulic system
Removal and installation of control valve assembly

Removal and installation of control valve assembly 50-194

Removal 50-194 4. Remove the following cover and partitions.

k Park the machine on a level place, lower the q Control valve top cover (4)
work equipment to the ground completely, q Partition (5) between control valve and en-
and stop the engine. gine
k Referring to Testing and adjusting, "Releas-
ing remaining pressure in hydraulic circuit",
release the pressure inside the hydraulic cir-
cuit and then set the lock lever to the LOCK
position.
k Disconnect the cable from the negative (-)
terminal of the battery.
a Record the installed positions, connector
Nos., or hose band colors of the disconnect-
ed wires and pipes so that you do not make a
mistake in their connection positions.

1. Turn the upper structure by 45 deg. (To drain oil

from hydraulic tank.)
q Partition (6) between control valve and en-
2. Remove covers (1) and (2). gine

3. Loosen drain plug (3) to drain oil from the

hydraulic tank. [*1]
6 Hydraulic tank:
232 l(Specified amount of oil)
135 l (Refill capacity)

50-194 HB205-1, HB205LC-1

(01)
 Hydraulic system
Removal and installation of control valve assembly

5. Disconnect hose (7) going to the left travel

motor.

6. Disconnect port PLS1 hose (8).

a Hose band color: No color

7. Disconnect port PLS2 hose (9).

a Hose band color: No color

8. Disconnect hoses and tubes on the front side of

the control valve.
q Line A: In order from top
Port A1 (bucket head side) (hose)
Port A2 (left travel motor reverse) (tube -
hose)
Port A3 (boom bottom) (tube)
Port A5 (right travel motor reverse) (hose)
Port A6 (arm head) (hose)
q Line B: In order from top
B1 port (bucket bottom side) (tube - hose)
Port B2 (left travel motor forward) (tube -
hose)
Port B3 (boom head) (tube)
Port B5 (right travel motor forward) (tube -
hose)
Port B6 (arm bottom) (hose)
a Remove tube and hose from port A2 (left
travel motor reverse), port B1 (bucket bot-
tom side), and port B5 (right travel motor
forward). Then remove tube from the con-
trol valve.
a At port B2, remove tube (10) according to
the following procedure.
1) Disconnect hose (11) from tube (10).
2) Remove two clamps (12) and bracket (13).
3) Remove tube (10).

a Remove tube (14) at port A3 (boom bottom)

and tube (15) at port B3 (boom head) accord-
ing to the following procedure.
1) Remove boom tube mounting clamp (16).
2) Disconnect two horns (17) from the bracket.
3) Disconnect four boom hoses (18).
4) Remove two boom tube mounting clamps
(19).
5) Remove tubes (14) and (15).

HB205-1, HB205LC-1 50-195

(01)
Hydraulic system
Removal and installation of control valve assembly
q (20): Port B6 (arm bottom) (above-men-
tioned)
q (21): Port T1 (drain hose)
9. Disconnect the wiring connector and hose at the
control valve (engine side) according to the
following procedure.
1) Disconnect the sensor side connectors (22)
and (23) from the clip.
2) Disconnect wiring connectors CV23 (22) and
V24 (23).
3) Disconnect clamp (24).
4) Disconnect brackets (25) and (26) from the
control valve.
50-196
5) Disconnect wiring connectors P25 (27) and
P26 (28).
6) Disconnect hoses (29) to (33).
q (29): Port PP1 hose (from rear pump)
q (30): Port PP2 hose (from front pump)
q (31): Port T hose (to hydraulic tank)
q (32): Port PPS2 hose (to front pump con-
trol)
q (33): Port PR hose (to solenoid valve)
10. Disconnect the hoses on the right side of the
control valve according to the following proce-
dure.
1) Disconnect PPC hoses (34) to (39).
q (34): (Attachment)
q (35): Port P2 hose (bucket CURL PPC)
q (36): Port P4 hose (left travel PPC)
q (37): Port P6 hose (boom LOWER PPC)
q (38): Port P10 hose (right travel PPC)
q (39): Port P12 hose (arm IN PPC)
2) Disconnect port PST hose (solenoid valve)
(40).
HB205-1, HB205LC-1
(01)
 Hydraulic system
Removal and installation of control valve assembly

11. Disconnect the hoses on the left side of the 14. Disconnect following six connectors (58).
control valve according to the following proce- (From top)
dure. q V06
1) Disconnect PPC hoses (41) to (48). q V05
q (41): (Attachment) q V04
q (42): Port P2 hose (bucket CURL PPC) q V03
q (43): Port P4 hose (left travel PPC) q V02
q (44): Port P6 hose (boom LOWER PPC) q V01
q (45): Port P10 hose (right travel PPC)
q (46): Port P12 hose (arm IN PPC) 15. Disconnect clamp (59).
q (47): (Attachment)
q (48): Port P2 hose (bucket CURL PPC) 16. Keep away solenoid valve assembly (60) from
2) Disconnect port PST hose (solenoid valve) control valve bracket (B).
(49).
17. Remove four mounting bolts (62) of the control
valve.

12. Remove cover (50).

18. Lift off control valve assembly (63).

13. Remove hoses (51) to (57).

(Hose band color:)
q (51): No color
q (52): Red
q (53): No color
q (54): No color
q (55): Red/Yellow
q (56): Brown
q (57): No color

HB205-1, HB205LC-1 50-197

(01)
Hydraulic system
Removal and installation of control valve assembly

Installation 50-198
q Perform installation in the reverse order to re-
moval.

[*1]
3 Hydraulic tank drain plug:
58.8 78.5 Nm {6.0 8.0 kgm}

q Refilling of oil (Hydraulic tank)

Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.
6 Hydraulic tank:
232 l(Specified amount of oil)
135 l (Refill capacity)

q Bleeding air
See Testing and adjusting, Bleeding air from
each part.

50-198 HB205-1, HB205LC-1

(01)
 Hydraulic system
Disassembly and assembly of control valve

Disassembly and assembly of control valve 50-19

a This section explains only the precautions for as- Replacement of pressure compensation valve
sembling the contol valve assembly. seal 50-19
a Since there are many types of pressure compen-
Special tools 50-19 sation valve, put a mark and note the installed
position when removing it.

New/redesign
1. Remove piston (2), plug (3) and spring (4) from

Necessity
Sym-
Part number Part name pressure compensation valve (1).

Sketch
bol

Q'ty
2. Remove seals (5) and (6) from piston (2).
796-946-1310 Guide f21.8
t 1
(For 723-46-40100)
796-946-1610 Guide f21.4
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2
(For 723-46-43100 and t 1
2 723-46-43400)
796-946-1910 Guide f21.0
(For 723-46-46101 and t 1
723-46-46300)
796-946-2210 Guide f20.6
(For 723-46-45100 and t 1
723-46-45700)
796-946-1320 Guide f21.8
t 1
(For 723-46-40100)
796-946-1620 Guide f21.4
t 1
(For 723-46-41100) a There are many types of pistons.
796-946-1820 Guide f21.2
(For 723-46-43100 and t 1
723-46-43400) 3. Install tool T2 on piston (2), put the seal on the
3 tool and slowly push seal (5) down by hand so
T 796-946-1920 Guide f21.0
(For 723-46-46101 and t 1 that it evenly expands.
723-46-46300)
796-946-2220 Guide f20.6 a You may put the seal on the tool and push it
t 1
(For 723-46-45100) down to the flat part of the tool, and them in-
796-946-1420 Guide f21.6
t 1 stall the tool to the pistion to install the seal in
(For 723-46-42700)
796-946-1330 Sleeve position.
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
(For 723-46-43100 and t 1
723-46-43400)
4
796-946-1930 Sleeve
(For 723-46-46101 and t 1
723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)

HB205-1, HB205LC-1 50-199

(01)
Hydraulic system
Disassembly and assembly of control valve

4. Likewise, set tool T3 to piston (2) in the same
direction and push it slowly by hand so that
another seal (6) may be spread out evenly.
a You may put the seal on the tool and push it
down to the flat part of the tool, and them in-
stall the tool to the pistion to install the seal in
position.
6. Fit plug (3) and spring (4) to piston (2), then
install pressure compensation valve (1).
a After the installation, push the piston by hand
and check that the piston returns only with
spring force.

5. Install settling tool T4 on piston (2) for approx.

one minute to make seals (5) and (6) settle.
a Check that there is no protrusion or cut on the
seal.

50-200 HB205-1, HB205LC-1

(01)
 Hydraulic system
Disassembly and assembly of control valve

Assembly of control valve 50-201

q Apply engine oil to the sliding surfaces before

assembling.
q When installing spools (7) and (8) in the valve
chamber, set drilled holes (H1) and (H2) to the
direction shown in the diagram.
a The same applies to cross sections H-H, K-K,
L-L, and M-M.

q Install filters (13) in PLS1 and PLS2 PORTs as

shown in the drawing. (Check the positions of
the crimped parts*.)
TRUE: Correct
ERROR: Incorrect

HB205-1, HB205LC-1 50-201

(01)
Hydraulic system
Disassembly and assembly of control valve

q Upper and lower control valve cover blocks

2 Mating face of upper and lower control
valve cover blocks (SE):
Loctite 242 or equivalent
q Tighten the mounting bolts for the upper and
lower control valve covers in order of figure.
(AoDoCoB)
3 Mounting bolt for upper and lower control
covers:
156.9 176.5 Nm {16 18 kgm}

q Pump merge-divider valve

2 Merge valve mating face (SE2):
Loctite 242 or equivalent
q Tighten the mounting bolts for the merge-divider
valve in the same sequence as that for the con-
trol valve cover mounting bolts.
3 Merge-divider valve mounting bolt:
156.9 176.5 Nm {16 18 kgm}
q Tighten the mounting bolts of the back pressure
valve, boom lock valve, arm quick return valve,
and arm check valve in the same order as that
for the control valve cover.
3 Mounting bolts of back pressure valve,
boom lock valve, and arm quick return
valve, and arm check valve:
58.8 73.6 Nm {6 7 kgm}
q After assembling, put stoppers (CAP) to prevent
oil and detergent liquid from entering through
f12 holes.

q Pressure compensation valve

a Install each pressure compensation valve,
checking the mark that was put when remov-
ing it. Especially, do not install BKC1 and
BKC2 adversely.

q Main relief valve assembly

After assembling the main relief valve assembly
in the control valve, refer to the section of
"Measuring and adjusting oil pressure in work
equipment, swing and travel circuits", Testing
and adjusting, in this manual.

50-202 HB205-1, HB205LC-1

(01)
 Hydraulic system
Disassembly and assembly of work equipment PPC valve assembly

Disassembly and assembly of work equipment PPC valve assembly 50-203

a Only precautions for assembling the work equipment PPC valve assembly are described below.

Disassembly 50-203 Assembly 50-203

a Spring (6) and (7) consist of two springs each of
two types with different loads at assembled
length, so check the mounting position (hydrau-
lic port) and mark with tags to prevent mistakes
when installing.
a Before assembly, thoroughly clean the parts and
check them for any dirt, rust or damage to pre-
vent failures.
a The head of plug (2) must not be projected from
the surface of valve body (1).
3 Plug (2):
6 11 Nm {0.6 1.1 kgm}
a When installing plug (3) to body (1), check the in-
sertion depth so that the tip of plug does not en-
ter the inside f20 hole of the body.
3 Plug (3):
4 9 Nm {0.4 0.9 kgm}

a Install spring (5) with its small diameter side on

the shim (4) side.
q Diameter of spring (Inside diameter)
Small diameter end: f4.9 mm
Large diameter end: f5.55 mm

HB205-1, HB205LC-1 50-203

(01)
Hydraulic system
Disassembly and assembly of work equipment PPC valve assembly
a When installing springs (6) and (7), note that
they are different by hydraulic port to install.
q Installed height: 31.9 mm (all)
q Load at installed length of spring
Spring (6) (P1, P2): 35.3 N {3.6 kg}
Spring (7) (P3, P4): 21.6 N {2.2 kg}
a When installing piston (8), apply grease (G2-LI)
to its outside and the inside of the body (1) hole.
3 Bolt (11):
11.8 14.7 Nm {1.2 1.5 kgm}
a When installing joint (12) to valve body (1), apply
Loctite according to the following procedure.
1) When installing the joint, apply a drop
(approximately 0.02 g) of Loctite (No. 262) to
each female thread portion (A) (2 places) of
the valve body. Before installing the joint,
degrease its male threads and the female
threads of the valve body with Drysol and dry
them.
2) Drop LOCTITE to the following positions.
2 Female thread (A) of valve body:
Loctite No. 262
3 Joint (12):
39 49 Nm {4 5 kgm}
50-204
a Apply grease (G2-LI) to the sliding parts of joint
(12) and contact surfaces of disc (13) and piston
(8).
2 Quantity of grease (G2-LI)
1) Rocking parts of joint: 2 to 4 cc/entire
periphery
2) Contact parts of disc and piston:
0.3 to 0.8 cc/part
a Install disc (13) according to the following proce-
dure. Adjust the disc so that the play at the lever
end is within the following range.
Lever play:
0.5 to 3 mm (at 200 mm from lever pivot point)
a See Testing and adjusting, "Adjusting play of
work equipment and swing PPC valve".
a Tighten nut (14) to the following tightening
torque.
3 Nut (14):
69 88 Nm {7 9 kgm}
HB205-1, HB205LC-1
(01)
 Hydraulic system
Disassembly and assembly of travel PPC valve

Disassembly and assembly of travel PPC valve 50-205

Special tools 50-205 5. Remove mounting bolt (19) to remove plate (22).
a Note the thickness and installed position of
New/redesign
Necessity

each washer (18).

Sketch

Sym
a Remove pin (23) from body (1).
Q'ty

Part number Part name

bol

6. Remove seal (9) and collar (8).

4 796T-416-1010 Push tool t 1 Q
M 5 796T-416-1030 Push tool t 1 Q 7. Remove piston (7) to remove retainer (6),
6 796T-416-1020 Push tool t 1 Q springs (5) and (4) and shim (3).
a Note the installed position, quantity and
Disassembly 50-205 thickness of each pack of shims (3) and keep
1. Remove screw (20) and damper assembly (16). them.

2. Remove mounting bolt (21) to remove case (12), 8. Remove valves (2) from valve body (1).
shaft (14) and lever (15) assembly.

3. Remove pin (13).

4. Remove lever (15), bushing (10), (11) and shaft

(14) from the case.

HB205-1, HB205LC-1 50-205

(01)
Hydraulic system
Disassembly and assembly of travel PPC valve

Assembly 50-206 2) Using tool P2, insert busing (11) in case.

Only the precautions for assembling the travel PPC a Insert the bushing (11) from the 10 deg.
valve assembly are described. chamfered side.
a Insert bushing (11) so that dimension (b)
a Before assembly, thoroughly clean the parts and will be as follows.
check them for dirt, rust, or damage to prevent q Dimension (b): 0 mm
failure. Assemble the parts with utmost care. a Do not hit it with a hammer directly.
a Before installing piston (7), apply grease (G2-LI)
to the periphery of the piston and the bore in the
valve body.

a Install spring (4) with its small diameter end fac-

ing shim (3).
q Diameter of spring (Inside diameter)
Small diameter end: 4.9 mm
Large diameter end: 5.55 mm

a Assemble shaft (14) in the following procedure.

1) Using tool M4, install bushing (10) to the
case.
a Insert the bushing (10) from the 10 deg.
chamfered side. 3) Insert lever (15).
a Insert bushing so that dimension (a) will 4) Insert shaft (14).
be as follows. 5) Using tool P3, insert pin (13).
q Dimension (a): 20.4 0.3 mm
a Insert pin (13) so that dimension (c) will
a Do not hit it with a hammer directly. be as follows.
q Dimension (c): 0 0.5 mm
a Do not hit it with a hammer directly.

50-206 HB205-1, HB205LC-1

(01)
 Hydraulic system
Disassembly and assembly of travel PPC valve

a Apply grease (G2-LI) to the rocking parts

of shaft (14), contact surfaces on lever
(15) and piston (7), and contact surfaces
on damper (16) and pin (17).
2 Quantity of grease (G2-LI)
Rocking parts of shaft (16): 4 to 8
cc/entire periphery
Contact surfaces of lever (15) and
piston (7):
0.3 - 0.8 cc/part
Contact surfaces of damper (16)
and pin (17):
0.3 - 0.8 cc/part
a Install washer (18) 1.6 mm thick first. If
the difference between both sides at the
stroke end of the lever exceeds 0.7 deg.,
change the washer thickness to reduce
the difference to below 0.7 deg.. (If the
thickness of the washer is reduced by 0.3
mm, the full stroke angle of the lever in-
creases by 0.39 deg..)
q Thickness and varieties of washer
(18):
1.0, 1.3, 1.6, 1.9, 2.2 mm

a Tighten each part to the following torque.

q Bolt (19): 27 34 Nm {2.8 3.5 kgm}
q Screw (20):
0.4410.588 Nm {0.0450.06 kgm}
q Bolt (21): 25 31 Nm {2.5 3.2 kgm}
q Bolt (24): 19.6 27.4 Nm {2.0 2.8 kgm}
q Plug (25): 24.5 34.3 Nm {2.5 3.5 kgm}
q Plug (26): 24.5 34.3 Nm {2.5 3.5 kgm}
q Plug (27): 9.8 14.7 Nm {1.0 1.5 kgm}
q Plug (28): 4 9 Nm {0.4 0.9 kgm}
q Plug (29): 6 11 Nm {0.6 1.1 kgm}
q Plug (30):
1.47 0.2 Nm {0.15 0.02 kgm}

HB205-1, HB205LC-1 50-207

(01)
Work equipment
Removal and installation of work equipment assembly

Work equipment 50-208

Removal and installation of work equipment assembly 50-208

Special tools 50-208 5. Start the engine and then retract the piston rod.
a Bind the piston rod with wire etc. and put it

New/redesign
Necessity
down on the blocking tools so that the piston

Sketch
Sym-

Q'ty
Part number Part name rod does not slip out, or allot a support so that
bol
the cylinder doesn't fall down to the bottom
side. If a support is allotted, remove the
796-900-1200 Remover t 1 grease fitting at the bottom side.
796-900-1210 q Sleeve 1 a Remove the boom cylinder on the opposite
792-900-1520 q Plate 1
side in the same way.
799-900-1230 q Screw 1
796-900-1240 q Adapter 1
a If bumping of the lifting hook against the work
V equipment lamp is anticipated in lifting the
01643-33080 q Washer 1
01803-13034 q Nut 1 work equipment, the lamp must be removed.
Puller
790-101-4000 t 1
(490 kN {50 ton}, long) 6. Disconnect 2 pieces of bucket cylinder hose (6)
790-101-1102 Pump (294 kN 30 ton}) t 1
and 2 pieces of arm cylinder hose (7).
a Apply the oil restraining plug and then fix the
Removal 50-208 hoses to the valve side by use of ropes.
k Safely lower the work equipment to the
ground by extending the arm and the bucket 7. Disconnect intermediate connector for working
completely. Set the lock lever in the lock po- lamp A13 (8).
sition.
k Release the residual pressure in the hydrau-
lic circuit. Refer to the "Releasing residual
pressure from hydraulic circuit" section in
the Testing and adjusting chapter of this
manual.

1. Disconnect grease hose (1).

2. Sling the boom cylinder assembly (2).

3. Remove lock bolt (3).

4. Remove plate (4) and remove the head pin.

[*1] 8. Lift the work equipment assembly, remove plate
a Shims are installed, so note their quantity (9) and pin (10) at the foot. [*2]
and thickness.

50-208 HB205-1, HB205LC-1

(01)
 Work equipment
Removal and installation of work equipment assembly

q Removal by using tool V Installation 50-209

Remove plate (9) and remove pin (10) at the
foot using tool V.
a Shims are installed, so note their quantity
and thickness.
q Perform installation in the reverse order to re-
moval.
[*1]
2 Inside surface of bushing when installing
pin:
Antifriction compound (LM-P)
2 Greasing after installing pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers into the pin hole.
a st1: Resin shim (1.0 mm in thickness)
a Set the clearance (b) between cylinder rod (12)
and plate (4) to 1.5 mm or less by shimming.
Standard shim thickness: 1.0, 2.0 mm

9. Remove work equipment assembly (11).

4 Work equipment assembly:
3,300 kg

[*2]
2 Inside surface of bushing when installing
pin:
Antifriction compound (LM-P)
2 Greasing after installing pin:
Grease (LM-G)
a Set the clearance (c) between the foot end face
of boom (13) and bracket (14) to 1 mm or less by
shimming.
Standard shim thickness: 2.0, 2.5, 3.0, 3.5 mm

HB205-1, HB205LC-1 50-209

(01)
Work equipment
Removal and installation of work equipment assembly

q Bleeding air
See Testing and adjusting, Bleeding air from
each part.

q Refilling of oil (Hydraulic tank)

Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.

50-210 HB205-1, HB205LC-1

(01)
 Work equipment
Disassembly and assembly of work equipment cylinder assembly

Disassembly and assembly of work equipment cylinder assembly 50-21

Special tools 50-21

New/redesign
Necessity
Sym-
Part number Part name

Sketch
bol

Q'ty
790-502-1003 Cylinder repair stand q 1
1
790-101-1102 Pump q 1
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Rubber band
796-720-1670 q 1
(for boom and arm)
07281-01279 Clamp q 1
4
Rubber band
796-720-1660 q 1
(for bucket)
07281-01159 Clamp q 1 4) Disassemble the piston rod assembly as
790-201-1702 Push tool kit t 1 follows.
q Push tool 1] Place piston rod assembly (2) on tool U1.
790-201-1831 1
(for bucket)
q Push tool
790-201-1930 1
U 5 (For arm)
q Push tool
790-201-1940 1
(for boom)
790-101-5021 q Grip 1
01010-50816 q Bolt 1
Push tool kit (for
790-201-1500 q 1
bucket)
790-201-1640 q Push tool 1
790-101-5021 q Grip 1
01010-50816 q Bolt 1
6 Plate
790-201-1980 q 1
(for boom)
Plate
790-201-1990 q 1
(For arm)
790-101-5021 Grip q 1 2] Remove stopper screw (3) of piston
01010-50816 Bolt q 1
assembly.
a Common to the boom, arm and bucket
Disassembly 50-21 cylinder.
1. Piston rod assembly Screw size: M12 x pitch 1.75
1) Remove the piping from the cylinder
assembly.
2) Remove the mounting bolts and disconnect
cylinder head assembly (1).
3) Pull out piston rod assembly (2).
a Place an container under the cylinder to
receive the oil.

HB205-1, HB205LC-1 50-211

(01)
Work equipment
Disassembly and assembly of work equipment cylinder assembly

a If the caulking of screw (3) is too 7] Remove cap (8), and pull 12 balls (9),
strong and it cannot be removed, then remove plunger (10).
tighten the screw fully, then use tap q Arm cylinder only
(T) to the threads and remove the
screw.

2. Disassembly of piston assembly

3] Using tool U2, remove piston assembly
(4).
q When not using tool U2, use the drill
holes (H) (f10: 2 places) and loosen
piston assembly.
1) Remove ring (11).
2) Remove wear rings (12).
3) Remove piston ring (13).
4) Remove O-ring and backup rings (14).

4] Remove plunger (5).

q Boom, arm cylinder only
5] Remove collar (6).
q Boom, arm cylinder only
6] Remove head assembly (7).

50-212 HB205-1, HB205LC-1

(01)

Disassembly and assembly of work equipment cylinder assembly
3. Disassembly of cylinder head assembly
1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
HB205-1, HB205LC-1
(01)
Work equipment
Assembly 50-213
a Be careful not to damage the packings, dust
seals, O-rings, etc.
a Clean each part, then cover the piping ports and
pin-inserting hole to prevent dust from entering
them.
a Do not insert each backup ring forcibly, but warm
it in water at 5060 C and then insert it.
1. Assembly of cylinder head assembly
1) Using tool U5, press fit bushing (20).
2) Assemble buffer ring U5.
3) Install rod packing (18).
4) Using tool U6, install dust seal (17).
5) Install snap ring (16).
50-213
Work equipment
Disassembly and assembly of work equipment cylinder assembly

2. Assembly of piston assembly 3. Piston rod assembly

1) Using tool U3, expand piston ring (13) and 1) Set piston rod assembly (2) to tool U1.
install it to the piston.
a Set the piston ring on tool U3, and turn the
handle 8 10 times to expand the ring.
2) Set tool U4, and compress piston ring (13).

2) Assemble head assembly (7).

3) Fit the O-ring and backup ring to collar (6),
and then install them.
q Boom, arm cylinder only
3) Install backup ring and O-ring (14). 4) Install plunger (5).
4) Install wear ring (12). q Boom, arm cylinder only
5) Install ring (11).
a Be careful not to open the end gap of the
ring too wide.
2 Ring groove:
Grease (G2-LI)

50-214 HB205-1, HB205LC-1

(01)
 Work equipment
Disassembly and assembly of work equipment cylinder assembly

5) Set plunger (10) on the piston rod, assemble 2] Tighten screw (3).
12 balls (9) to it and secure with cap (8). 2 Screw part female screw side:
a Check that there is a small amount of play Loctite No. 262
at the tip of the plunger. 3 Screw:
a Put a mark on the end face of the rod so 58.9 73.6 Nm {6 7.5 kgm}
that the processing hole position of cap 3] Caulk thread at 4 places (a) of screw (3)
(8) is visual from outside. with punch.
q Arm cylinder only

q When using a new part for either or

6) Assemble piston assembly (4) according to both of piston rod assembly (2) and
the following procedure. piston assembly (4).

q When using piston rod assembly (2)
and piston assembly (4) again
a Wash the parts thoroughly and remove all
the metal particles and dirt.
1] Screw in piston assembly (4) by using tool
U2, and tighten piston assembly (4) until
the position of the screw thread hole (H1)
which is in piston rod assembly (2)
halfway matches.
a Remove any burr on the threaded por-
tion with a file.
a For the rod with bottom cushion, put a
mark to indicate the position of the cap
on the end surface of the rod. (See
step 3.5.)
q Arm cylinder only
1] Screw in until piston assembly (4)
contacts end surface (B) of rod, then
use tool to tighten.
3 Piston assembly:
294 29.4 Nm {30 3.0 kgm}
a After tightening the piston, check that
there is play in plunger (5).
q Boom, arm cylinder only

HB205-1, HB205LC-1 50-215

(01)
Work equipment
Disassembly and assembly of work equipment cylinder assembly

2] Make a threaded hole to install screw
(3).
a With a drill aligned with the V groove
where the threads of piston assembly
(4) and piston rod assembly (2) are
mated, drill a hole straight.
a For the arm cylinder, avoid the cap
machining holes position when ma-
chining. (See step 3.5.)
q Screw machining dimension (mm)
8) Assemble the cylinder tube to piston rod
assembly (2).
a Align axial center of the cylinder tube,
then insert.
a Check that the ring is not broken and has
not come out, then push in fully.

Bottom hole Tap drill hole Tapped hole

Tap
drill diameter depth depth
10.3 24 12 x 1.75 20
3] After machining, wash thoroughly to
remove all metal particles and dust.
4] Tighten screw (3).
2 Screw part female screw side:
Loctite No. 262
3 Screw:
58.9 73.6 Nm {6 7.5 kgm}
5] Caulk thread at 4 places (a) of screw 9) Tighten head assembly (1) with mounting
(3) with punch. bolts.
3 Mounting bolt:
Cylinder Tightening torque
Bucket 270 39 Nm {27.5 4.0 kgm}
Arm 373 54 Nm {38.0 5.5 kgm}
Boom 270 39 Nm {27.5 4.0 kgm}
q Adjusting
892 137 Nm {91.0 14.0 kgm}
cylinder

7) Set piston rod assembly (2) to tool U1.

10)Install piping.

50-216 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of operator's cab assembly

Cab and its attachments 50-217

Removal and installation of operator's cab assembly 50-217

Removal 50-217 9. Remove rear covers (10) to (13).

k Disconnect the cable from the negative (-)
terminal of the battery.

1. Remove front window (1).

2. Remove step plate (2).

3. Remove floor mat (3).

4. Remove monitor assembly (4). For details, see

"Removal and installation of monitor assembly".

5. Remove covers (5) and (6).

6. Remove cover and duct assembly (7). 10. Remove duct (14).

11. Remove cover (15).

a Disconnect connector H15 fixed on the back
from the clip.

7. Insert key (8), turn it to the right, and open the

fresh air filter cover.

8. Remove fresh air filter (9).

12. Remove plate (16).

13. Remove lock pin (17) and remove duct (18).

HB205-1, HB205LC-1 50-217

(01)
Cab and its attachments
Removal and installation of operator's cab assembly

14. Remove ducts (19) to (22).

17. Disconnect clamp (29) of wiring (28).

15. Remove two bracket mounting bolts (24) to
disconnect bracket (23) from the operator's cab. 18. Remove plate (30).

19. Disconnect connector L03 (31).

16. Disconnect connector R05 (25) and pump

controller connectors C01(26) and C02(27). [*1]
a Disconnect pump controller connectors (26)
and (27) according to the following proce-
dure.
1) While pressing lock (L1), move lever (L2) in
the direction of the arrow.
(Bar (B) pushes the lock to release.)
2) Pull down and disconnect the connector.

50-218 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of operator's cab assembly

20. Disconnect antenna cable (32) from KOMTRAX
communication module (K).
21. Disconnect connectors CK01(33) and CK02(34)
from KOMTRAX communication module (K).
26. Disconnect window washer hose (43).
27. Disconnect harness clamp (44).
28. Haul in antenna line (42).

22. Disconnect cab wiring intermediate connectors

H09 (36), H08 (37), and H16 (38).
a Cut cable tie (T).

23. Disconnect radio antenna (39).

a (23) is a removed plate.

29. Disconnect harness clamp (43) from the right

back side of cab.

24. Disconnect wiper motor connector M05 (40).

25. Disconnect harness (41) and antenna line (26)

from the cab wall.
a Cut the cable ties at two places.

30. Remove bolt (44) from under the cab and

remove lock plate (45). [*1]

31. Remove bolt (46). [*2]

HB205-1, HB205LC-1 50-219

(01)
Cab and its attachments
Removal and installation of operator's cab assembly

32. Remove six mounting bolts (47) and four Installation 50-2 0
mounting nuts (48). q Perform installation in the reverse order to re-
a Check the bolt length beforehand. moval.

[*1]
3 Mounting bolt (44) of lock plate (45):
98 123 Nm {10 12.5 kgm}

[*2]
3 Bolt (44):
245 309 Nm {25 31.5 kgm}

33. Lift off operator's cab assembly (49).

4 Operator's cab assembly:
470 kg

50-220 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

Removal and installation of operator's cab glass (adhered window glass)50-2 1

a Among the panes of window glass on the four (1): Right side window glass
sides of the operator's cab, five panes (1) to (4) (2): Left side rear window glass
and (18) are adhered. (3): Door lower window glass
a In this section, the procedure for replacing the (4): Front window glass
adhered glasses is explained. (5): Front window assembly
a When replacing front window glass (4), remove (Front window glass and front frame)
front window assembly (5). (6): Dam rubber
(It is impossible to replace only the front window (17): Center trim seal
glass while the front window assembly is (18): Rear glass
installed to the operators cab.)
a For the procedure for replacing the front window
assembly, see Removal and installation of front
window assembly.

HB205-1, HB205LC-1 50-221

(01)
Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

Special tools 50-2 2 Installation 50-2 2

1. Using a knife and scraper [5], remove the

New/redesign
Necessity
remaining adhesive and dam rubber from the

Sketch
Sym-

Q'ty
Part number Part name sheet metal (adhesion surfaces) of the oper-
bol
ators cab.
a Remove the adhesive and dam rubber to a
2 793-498-1210 Lifter (Suction cup) t 2 degree that they will not affect adhesion of
X
3 20Y-54-13180 Stopper rubber t 2 the new adhesive. Take care not to scratch
the painted surfaces.
Removal 50-2 2 (If the painted surfaces are damaged, adhe-
a Remove the window glass to be replaced ac- sion will be lowered.)
cording to the following procedure.
1. Use seal cutter [1] to cut the adhesive between
broken window glass (7) and operator cab
(metal sheet) (8).

2. Remove oil, dust, dirt, etc. from the adhesion

a If the window glass is broken finely, it may be
removed with knife [4] and a flat-head screw-
driver.
a Widening the cut with a flat-head screw-
driver, cut the adhesive and dam rubber with
knife [4].
surfaces on cab (8) and window glass (9) with
white gasoline.
a If the adhesion surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean all the black part on the back of the
window glass.
a After cleaning the adhesion surfaces, leave
them for at lease 5 minutes to dry.

2. Remove the window glass.

50-222 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

3. Apply primer (10).

a The using limit of primer is four months after
the date of manufacture. Do not use the prim-
er after this limit.
a Use the primer within two hours after opening
the container.
a Even if the container of the primer is capped
again just after it is opened, use it out within
24 hours after it is opened for the first time.
(Discard the primer in twenty-four hours after
it is opened.)
1) Stir the primers for painted surface and glass
sufficiently before using them.
a If the primer is stored in a refrigerator,
leave it at the room temperature for at a Places to apply: Apply over the entire cir-
least half a day before stirring it. cumference with dimension (a).
(If the primer is opened just after taken q Primer applying dimension (a): 25 mm
out of the refrigerator, water will be
condensed. Accordingly, leave the primer
at the room temperature for a sufficient
time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again for
dirt and contaminant.
a Prepare respective brushes for the paint-
ed surface primer and glass primer.

a In addition to the above places, addition-

ally apply primer to right side window
glass (1) and lower door window glass
(3).
q Range to apply primer additionally to right
side window glass (1): (b)
q Range to apply primer additionally to low-
er door window glass (3): (c)
a After applying the primer, leave it in air for
at least five minutes (maximum eight
3) Evenly apply painted surface primer to the
hours) to dry.
surfaces to stick dam rubber and its outside
surfaces to apply adhesive on operator cab
(8).
2 Primer for painted surface:
SUNSTAR PAINT PRIMER580 SU-
PER
a Do not apply the primer more than two
times.
(If it is applied more than two times, its
performance will be lowered.)

HB205-1, HB205LC-1 50-223

(01)
Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

a Never apply the wrong primer.
If the glass primer, etc. is applied by
mistake, wipe it off with white gasoline.
4) Evenly apply the glass primer to the adhe-
sion surfaces of window glass (9).
2 Primer for glass:
SUNSTAR GLASS PRIMER 580 SU-
PER
a Do not apply the primer more than two
times.
(If it is applied more than two times, its
performance will be lowered.)
4. Install dam rubber (double-faced tape)(6) along
the inside edge of the glass sticking section.
a Do not remove the release tape of dam rub-
ber on the glass sticking side before sticking
the glass.
a When installing the dam rubber, do not touch
the cleaned surface.
a Care should be taken not to slacken the dam
rubber of each sticking corner.

a Places to apply: Apply the primer to entire

circumferential area of sticking surface
(d) of window glass (9) for dam rubber (6)
installation position and operator's cab
(8).
a Do not apply the primer to the boarder
area of about 5 mm wide between the
black portion and transparent portion of
the glass.
a After applying the primer, leave it in air for
at least five minutes (maximum eight
hours) to dry.
a Never apply the wrong primer.
If you apply the primer for painted
surface, etc. by mistake, wipe it off with
white gasoline.

50-224 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

a When adhering dam rubber (6) goes around, 2) Stick dam rubber (6) for left side rear window
mind not to overlap dam rubber at the both glass (2) to the position as shown in the
ends. Or, provide a clearance of approxi- figure.
mately 5 mm at the mating portion (e).
1) Install dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.

3) Stick dam rubber (6) for door lower window

glass (3) to the position as shown in the
figure.

a Install additional dam rubber (6a) to right

side window glass (1).
q Positions to stick additional dam rubber
on the right side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm

a Stick dam rubber (6b) additionally to door

lower window glass (3).
q Positions to stick additional dam rub-
ber on the lower door window class:
(j): 110 mm
(k): 90 mm
(m): 200 mm

HB205-1, HB205LC-1 50-225

(01)
Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

4) Stick dam rubber (6) for front window glass a Do not remove the tapes left on the win-
(4) to the position as shown in the figure. dow glass and the operator's cab before
installing the window glass.

a Stick dam rubber (6c) of the lower side of

the front window glass along the outside
edge of the lower line, differently from
other dam rubbers (6). (If it is stuck along
the inside, it will be seen through the
transparent portion of the glass.)

a When positioning front window glass (4),

set its horizontal position to the frame
width.
And set its vertical position to make the
height difference (p) between the frame
top and the front window glass (4) 3 mm.
5. Position the new window glass.
1) Check the clearances between the window
glass and the operators cab on the right, left,
upper, and lower sides, and then position the
window glass with the clearance evenly.
2) Stick tapes [6] between window glass (9) and
operators cab (8) and draw a positioning line
(n) on the tape.
a Stick tapes [6] to three points, that is,
right, left and lower portions of the right
side window glass, left side rear window
glass, and door lower window glass for
accurate positioning.
3) Cut the tape between window glass (9) and
operators cab (8) with a knife, etc. and then
remove the window glass.

50-226 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

6. Apply adhesive. 3) Set adhesive cartridge (12) to caulking gun

a Use either of two types of adhesives accord- [7].
ing to the season. a An electric caulking gun is more efficient.
2 Adhesive (summer):
SUNSTAR penguine seal 580 super
"S"
2 Adhesive (winter season):
SUNSTAR penguine seal 580 super
"W"
a The effective period of the adhesive is four
months after the date of manufacture. Do not
use the adhesive after this limit.
a Keep the adhesive in a dark place where the
temperature is below 25 C.
a Never heat the adhesive higher than 30 C.
a When reusing the adhesive, remove all the
hardened part from the nozzle tip.
1) Remove aluminum seal (13) of the outlet of 4) Remove the release tape of the dam rubber
adhesive cartridge (12) and install the on the glass adhesive side.
nozzle. 5) Apply adhesive (15) to the outside of dam
rubber (6) of the operator cab.

2) Cut the tip of the adhesive nozzle (14) so that

dimensions (q) and (r) are as follows.
q Dimension (q): 10 mm
q Dimension (r): 15 mm

HB205-1, HB205LC-1 50-227

(01)
Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)
a Apply adhesive (15) to dam rubber (6) of
operator's cab (8) in the (s) and (t) dimen-
sions shown in the figure.
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Apply adhesive (15) thicker than dam rub-
ber (6).
a Apply the adhesive evenly with same
height level.
a Apply adhesive (15) additionally to addi-
tional dam rubber (6a) of right side win-
dow glass and additional dam rubber (6b)
of lower door window glass.
50-228
7. Install the window glass.
1) Install window glass (9), with the alignment of
the lines of the positioning tapes drawn in
step 5.
a Since the window glass cannot be re-
moved and adhered again, adhere it with
utmost care.
a Adhere the glass within 5 minutes after
applying the adhesive.
2) After adhering window glass (9), press all
around the glass until it adheres to the dam
rubber.
a Press the corners of the window glass
firmly.
a You can perform this work efficiently by
pulling window glass (9) from inside of the
operator's cab with suction cup X2.
HB205-1, HB205LC-1
(01)
 Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

a After installing front window glass (4) fill 8. Fix the window glass.
the clearances between it and center trim 1) After installing right window glass (1) to the
seal (16) with caulking material in range operator's cab, insert stopper rubbers X3 to 2
(s) with dimensions (t) and (u). places (v) at the bottom of the glass to fix the
After applying the primer to the part of glass.
window glass (4) shown in section A-A,
apply the adhesive as caulking material.
q Caulking dimension (t): 2 mm
q Caulking dimension (u): 5 mm
a When caulking, apply masking to the
glass side and form the adhesive with a
rubber spatula as shown in the figure.
a Wipe off the squeezed adhesive.
2 Primer for glass:
SUNSTAR GLASS PRIMER 580 SU-
PER
2 Adhesive:
SUNSTAR penguine seal 580 super
"S" or "W", or equivalent

2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and dam
rubber to adhere them completely.

HB205-1, HB205LC-1 50-229

(01)
Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

9. After installing the window glass, remove any

excess of the primer and adhesive from the
operator's cab and window glass.
a By using white gasoline, wipe off the adhe-
sive before it dries off.
a When cleaning the glass, do not give an im-
pact on it.

10. Cure the adhered window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for ten
hours as a curing period.
(ambient temperature 20 C / humidity 60%)
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
14 hours, at least 24 hours in total, before
operating the machine actually.

50-230 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of front window assembly

Removal and installation of front window assembly 50-231

k Lower the work equipment to the ground and

stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the opera-
tor's cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.

Removal 50-231
1. Pull up the front window assembly over the
ceiling and fix it with the rear locks (on the right
and left sides).

2. Remove left corner block (1) and right corner

block (2). [*1]

a Mounting bolt (4) and washer (3) for the left

corner block are used to hang the pull-up as-
sist cable in the following step 6.

6. Remove left lower pin (7). [*2]

a By removing left lower pin (7), plate (8) at the
end of pull-up assist cable (9) comes off.
a Hang plate (8) on the mounting bolt for the
left corner block (use washer) and set in
3. Release the rear locks of the cab. place.
k Pull-up assist cable (9) has a return load
4. Lower the front window assembly carefully a of 58.8 N {6 kg} on the rear side of the op-
little. Put out rollers (5) and (6) under the both erator's cab. Accordingly, care must be
sides of the front window through the portion taken when removing left lower pin (7) to
from which the corner blocks were removed in disconnect pull-up assist cable (9).
the above step 2. (the portion where the rail is
open) and hold them.

5. Remove rollers (5) and (6) at the bottom of both

sides of the front window.

HB205-1, HB205LC-1 50-231

(01)
Cab and its attachments
Removal and installation of front window assembly

9. Remove front window assembly (10) by twisting

it to the right and left to release right and left
upper rollers (11) and (12) from the rail.

7. Pull out the bottom of front window assembly

(10) though the rail opening portion and lower it
gradually.

8. Lower front window assembly (10) completely.

a Take care not to touch the front window as-
sembly to the monitor.

50-232 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of front window assembly

Installation 50-23
q Perform installation in the reverse order to re-
moval.
[*1]
q Adjust opening and closing of the front window
assembly according to the following procedure.
1. Open and close the front window to check that it
does not interfere with the rails and that the
rollers are not caught.
2. If there is any problem in opening and closing of
the front window, loosen the mounting bolt of
roller adjustment bracket (13) and adjust the
condition of the front window, and then tighten
the mounting bolt again.
a Make sure that bracket (13) is not slanted
when mounted.
3 Mounting bolt:
34.3 Nm {3.5 kgm}
3. Pull up the front window assembly and fix it with
the rear locks (on the right and left).
a Check that the locks in the rear of the opera-
tor's cab securely fasten.
4. Install right corner block (2).
a Fully tighten the block after adjusting the
"Close" position in the following step 6.
a Install right corner block (2) so that clearance
(a) between the rail and right corner block (2)
becomes 0 to 2.0 mm.
a Install right corner block (2) so that there is no
level difference on rail surface (R) of the roll-
er.

HB205-1, HB205LC-1 50-233

(01)
Cab and its attachments
Removal and installation of front window assembly
5. Install left corner block (1).
a Fully tighten the block after adjusting the
"Close" position in the following step 6.
a Install left corner block (1) so that clearance
(b) between the rail and left corner block (1)
becomes 0 to 2.0 mm.
a Install left corner block (1) so that there is no
level difference on rail surface (R) for the roll-
er. (See the figure above.)
6. Adjust the "Close" position of the front window
assembly lock according to the following proce-
dure.
1) Tighten left and right corner blocks (1) and
(2) at roughly right positions so that front
window glass (14) is attached firmly to
cab-side trim seal (15).
50-234
2) Check the working condition of right and left
locks (17) and (16) when opening and
closing the front window assembly.
q If right and left locks (17) and (16) do not
work normally;
1] Loosen lock fixing bolt (18), move lock
(16) forward, and then tighten the bolt
again.
a The same applies to the right side.
2] After moving the lock, check the fitness of
the front window glass (14) and cab-side
trim seal (15) which is checked in step 1).
3] Repeat the work in 1] and 2] until the
fitness of the front window glass and the
working condition of locks (16) and (17)
are both acceptable, and then tighten the
mounting bolts of the right and left corner
blocks.
HB205-1, HB205LC-1
(01)
 Cab and its attachments
Removal and installation of front window assembly

7. After the adjustment, splash water heavily over q When adjustment is necessary after the
the front window glass and check that the water above check
does not leak into the cab. 3) Close front window assembly (10).
4) Loosen locknut (20) of right and left side of
8. Adjust the "Open" position of the front window rubber stoppers (18), and then pull back both
assembly lock. rubber stoppers (18) so that they won't
1) After adjusting the "Close" position of the contact with the front window assembly when
front window assembly lock in steps 6 and 7, it is in "Open" position.
pull up the front window assembly to the
ceiling.
2) Set the front window assembly locks on the
both sides of rear of the operator's cab to the
Open" position, and then check the following
items.
q Check the working condition of right and
left locks (16) and (17) (as explained
above).
q Front window assembly must be in con-
tact with the right and left rubber stoppers
(18), and furthermore, must be pushing
them backward by 1.5 to 3.0 mm.
q The front window assembly must be
pushing the limit switch (19) backward by 5) Loosen both sides of locknuts (22), and
4 to 7 mm. adjust the position of striker bolts (21).
a The position of limit switch (19) cannot be a Striker bolt (21): M10, inner diameter of
adjusted. Therefore, the "Open" position plate (23): f14.5 mm
of the front window assembly is set within
the range where this switch works.
a The limit switch (19) prevents wiper oper-
ation if the wiper switch is accidentally
turned on when the front window assem-
bly is in "Open" position. If the wiper is op-
erated when the front glass is missing,
the wiper will fall inside the cab and may
fail.
To check whether limit switch (19) is
working, turn the key switch on and see
that, even if the wiper switch is turned on,
the wiper does not operate when the front
window assembly is in "Open" position.

HB205-1, HB205LC-1 50-235

(01)
Cab and its attachments
Removal and installation of front window assembly
1] The front window assembly (10) (in
"Open" position) must be pushing the limit
switch (19) backward by 4 to 7 mm.
2] Working condition of lock (17).
6) Adjustment of right and left rubber stoppers
(18).
1] Bring front window assembly (10) (the
lock should be in "Open" position) into
contact with right and left rubber stoppers
(18).
50-236
2] Close front window assembly (10).
3] Turn right and left rubber stoppers (18) to
the left one and a half rotation.
a One turn of rubber stopper (18) to the
left is equivalent to squashing the rub-
ber for approximately 1.5 mm.
a When the front window assembly is in
"Open" position, the front window as-
sembly must be pushing right and left
rubber stoppers (18) by 1.5 to 3.0 mm.
4] Tighten locknuts (20) of the right and left
rubber stoppers (18).
HB205-1, HB205LC-1
(01)
 Cab and its attachments
Removal and installation of front window assembly

9. Adjust stopper (24) of the front window [*2]

assembly. 3 Left lower pin:
1) Adjust and lock both sides of stopper (24) so 27 34 Nm {2.75 3.47 kgm}
that when pulling up the front window 2 Mounting bolt:
assembly (10), surface d of stopper (D)) of Adhesive (LT-2)
front window assembly (10) is in contact with
surface c of stopper (24).

10. Check the operating effort of the lock of the front

window assembly.
1) After finishing the adjustment of steps 6 to 9,
check that latching efforts of both right and
left locks (16) and (17) are even.
a Check the latching efforts on both "Close"
side (in the front of the operator's cab)
and "Open" side (in the rear of the opera-
tor's cab).

HB205-1, HB205LC-1 50-237

(01)
Cab and its attachments
Removal and installation of floor frame assembly

Removal and installation of floor frame assembly 50-238

Removal 50-238 6. Disconnect ground cable (2).

k Disconnect the cable from the negative (-)
terminal of the battery.
k If you drain the coolant or disconnect the
heater hose when the coolant temperature in
the radiator is high, you may be scalded. In
this case, wait until the coolant temperature
lowers and then disconnect the heater hose.

1. Collect the refrigerant (gas for air conditioner:

R134a) from the air conditioner circuit. [*1]
a Ask a qualified person for collecting, add-
ing, and filling operations of the refriger-
ant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If refrigerant gets in your eyes, you may
7. Disconnect the following PPC hoses from the
travel PPC valve. The color of the band is;
lose your sight. And if it touches your q (3): Red
skins, you may suffer from frostbite. Ac- q (4): No color
cordingly, put on protective eyeglasses, q (5): Green
gloves and working suits with long q (6): Blue
sleeves while you are collecting the re- a Prepare an oil sump.
frigerant or filling the air conditioner cir-
cuit with the refrigerant. Collecting and 8. Disconnect top and bottom of connector (7)
filling work must be conducted by a qual- Top: P09
ified person. Bottom: P10
q The amount of refrigerant to be collected:
870 50 g 9. Disconnect the following PPC hoses from the
PPC valve. The color of the band is;
2. Turn the upper structure by 90 deg. q (8): Yellow
q (9): No color
3. Drain the coolant. a Put an oil stopper to the hose.
6 Coolant:
17.3 l

4. Remove the operator's cab assembly by refer-

ring to Removal and installation of operator's
cab assembly.

5. Remove cover (1).

50-238 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of floor frame assembly

10. Disconnect ground cable (11). 16. Disconnect hose (17).

From the left, T04, T05, T06, T07, T09, and T10 a Check the connecting point.
a Put an oil stopper to the hose.
11. Disconnect clamp (12).
17. Disconnect heater hoses (18).
12. Disconnect connector A08 (13) from the clip. a Check the connecting point.

13. Disconnect connector P17 (14) from the air 18. Remove mounting bolt (19) and disconnect air
conditioner tube. conditioner tubes (20). [*1]

14. Remove the clamp and spacer (15). 19. Remove clamps (21) and (22). [*2]

15. Disconnect hose (16). 20. Disconnect clamp (23). (OPT)

a Check the connecting point.
a Put an oil stopper to the hose.
a Disconnect the work equipment PPC hose
(P) on the joint box side. (See step 33.)

21. Disconnect clamp (25) of wiring (24).

22. Disconnect air conditioner controller (ACCNT)

together with plate (26).

HB205-1, HB205LC-1 50-239

(01)
Cab and its attachments
Removal and installation of floor frame assembly

23. Disconnect connectors N10 (27) and AC01 (28). 30. Disconnect the clamp of wiring harness (35).

24. Disconnect connectors ECU10 and ECU11 (29) 31. Move plates (36) and (37) together with wiring
from the air conditioner controller (ACCONT). harness (35) to the boom side.

25. Cut cable tie (30) and draw in wiring harness

(31).

26. Disconnect the clamp of wiring harness (32).

32. Open the engine hood and remove cover (38).

27. Disconnect connector H15 (33).

28. Remove grommet(34).

29. Move wiring harness (35) to the outside of the

floor frame.
a (SP) is made of sponge.

50-240 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of floor frame assembly

33. Disconnect clamp (39). 36. Sling and remove floor frame assembly (42).
a Check that the hoses, connectors, clamps,
34. Disconnect PPC hose (40) of the work equip- and so on are disconnected without fail.
ment. 4 Floor frame assembly:
From the top, the color of the band is: 250 kg
White
Brown
None
Blue
Black
Green
Red
Yellow
a Prepare an oil sump.

35. Pull out the work equipment PPC hose assembly

(41).

HB205-1, HB205LC-1 50-241

(01)
Cab and its attachments
Removal and installation of floor frame assembly

Installation 50-242
q Perform installation in the reverse order to re-
moval.

[*1]
a When installing the air conditioner hose, take
care so that dust, dirt or water does not enter the
hose.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat the
O-ring with compressor oil for new refrigerant
(R134a) (Denso: ND-OIL8, VALEO THERMAL
SYSTEMS: ZXL100PGZXL100PG (PAG 46 or
equivalent)).
3 Mounting bolt:
8 12 Nm {0.8 1.2 kgm}

[*2]
a Make sure that the hoses do not lap over.

q Refilling with refrigerant

Refill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 870 50 g

q Refilling of coolant
Supply coolant through the coolant filler port to
the specified level. Run the engine to circulate
the coolant through the system. Then, check the
coolant level again.
5 Coolant:
17.3 l

50-242 HB205-1, HB205LC-1

(01)
 Cab and its attachments
Removal and installation of air conditioner unit assembly

Removal and installation of air conditioner unit assembly 50-243

Removal 50-243 8. Pull down opening and closing lever (8) of the
k Disconnect the cable from the negative (-) fresh air filter cover.
terminal of the battery.
k If you drain the coolant or disconnect the 9. Remove fresh air filter (9).
heater hose when the coolant temperature in
the radiator is high, you may be scalded. In
this case, wait until the coolant temperature
lowers and then disconnect the heater hose.

1. Collect the refrigerant (gas for air conditioner:

R134a) from the air conditioner circuit. [*1]
a Ask a qualified person for collecting, add-
ing, and filling operations of the refriger-
ant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If refrigerant gets in your eyes, you may
lose your sight. And if it touches your
skins, you may suffer from frostbite. Ac- 10. Remove rear covers (10) to (13).
cordingly, put on protective eyeglasses,
gloves and working suits with long
sleeves while you are collecting the re-
frigerant or filling the air conditioner cir-
cuit with the refrigerant. Collecting and
filling work must be conducted by a qual-
ified person.
q Refrigerant to be collected: 870 50 g

2. Turn the upper structure by 90 deg.

3. Drain the coolant.

6 Coolant:
17.3 l

4. Remove front window (1). 11. Remove duct (14).

5. Remove step plate (2). 12. Remove cover (15).

a Disconnect connector H15 fixed on the back
6. Remove floor mat (3). from the clip.

7. Remove covers (5) and (6).

HB205-1, HB205LC-1 50-243

(01)
Cab and its attachments
Removal and installation of air conditioner unit assembly

13. Remove plate (16). 18. Disconnect connectors N10 (27) and AC01 (28).

14. Remove lock pin (17) and remove duct (18). 19. Disconnect connectors ECU10 and ECU11 (29)
from the air conditioner controller (ACCONT).

20. Loosen cable tie (30) and draw in wiring harness

(31).

15. Remove ducts (19) to (23).

a Cut a cable tie.

21. Remove cover (32).

16. Disconnect clamp (25) of wiring (24).

17. Disconnect air conditioner controller (ACCNT)

together with plate (26).

50-244 HB205-1, HB205LC-1

(01)

22. Remove mounting bolt (33) and air conditioner
tubes (34). [*1]
23. Disconnect heater hoses (35).
a Check the connecting point.
24. Remove the seven mounting bolts and remove
air conditioner unit assembly (36).
HB205-1, HB205LC-1
(01)
Cab and its attachments
Removal and installation of air conditioner unit assembly
Installation 50-245
q Perform installation in the reverse order to re-
moval.
[*1]
a When installing the air conditioner hose, take
care so that dust, dirt or water does not enter the
hose.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat the
O-ring with compressor oil for new refrigerant
(R134a) (Denso: ND-OIL8, VALEO THERMAL
SYSTEMS: ZXL100PGZXL100PG (PAG 46 or
equivalent)).
3 Mounting bolt:
8 12 Nm {0.8 1.2 kgm}
q Refilling with refrigerant
Refill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 870 50 g
q Refilling of coolant
Supply coolant through the coolant filler port to
the specified level. Run the engine to circulate
the coolant through the system. Then, check the
coolant level again.
5 Coolant:
17.3 l
50-245
Electrical system
Removal and installation of engine controller assembly

Electrical system 50-246

Removal and installation of engine controller assembly 50-246

Removal 50-246
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Turn the upper structure by 90 deg.

2. Remove cover (1).

3. Open the engine hood.

4. Disconnect connectors CE02 (2) and (3) from

the engine controller. [*1]
a The connector is locked with the inside hex
head bolt L6 (4 mm).

5. Disconnect connector (4) from the engine

controller by pushing the lock. [*1]

6. Remove the mounting bolts and engine

controller (5).
a Ground (E) and harness clamp are tightened
together.

50-246 HB205-1, HB205LC-1

(01)
 Electrical system
Removal and installation of engine controller assembly

Installation 50-247
q Perform installation in the reverse order to re-
moval.

[*1]
q Check that there is no sand, dust or water inside
the controller connecter (especially on the bot-
tom). If any of them is found, completely remove
them using a blower, etc. (Sand, dust or water
may cause defective contact in connectors or
defects by entering water.)

a Reference
q Method of replacing the O-ring seal of power
supply connector (4).
O-ring seal: 1010-074-0406 (NIHON-DEUTSCH
Ltd.) or equivalent

1. Remove cover (6) by holding down the tabs with

tweezers [1].

2. Remove O-ring (7) using tweezers [1].

HB205-1, HB205LC-1 50-247

(01)
Electrical system
Removal and installation of pump controller assembly

Removal and installation of pump controller assembly 50-248

Removal 50-248 3. Disconnect wiring connectors C014 (5) and C02

k Disconnect the cable from the negative (-) (6) according to the following procedure.
terminal of the battery. q While pressing lock (L1), turn lock (L2) in-
ward.
1. Remove cover (1). a Bar (B) comes out and the lock is released.

4. Remove four mounting bolts (7) and pump

controller assembly (8).

2. Remove two bracket mounting bolts (2). Discon-

nect bracket (3) and move it to the right.

50-248 HB205-1, HB205LC-1

(01)
 Electrical system
Removal and installation of pump controller assembly

Installation 50-249 a Connector without connector cover (1).

q Perform installation in the reverse order to re-
moval.

a Reference
1. Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2) Move lever (3) up.

2. Procedure for installing connector cover

1) Push in right and left sliders (4) as far as they
go.

3) Lightly push part (A) of connector cover (1)

from both sides to unfasten claw (B).
4) To escape tab (C), remove connector cover
(1) while swinging it just like drawing an arc.

a Right and left sliders (4) pushed in as far

as they go (Left figure)
2) Move lever (3) of connector cover (1) from
the upper position to the left position (lock
position) in the figure.
a (B), (C): tabs
a If the sliders and lever are not set as
shown in the following figure, the connec-
tor is not disconnected or locked securely
with the lever. Accordingly, check their
positions again

HB205-1, HB205LC-1 50-249

(03)
Electrical system
Removal and installation of pump controller assembly

3) Set tab (C) on the connector and place

connector cover (1) in position.
a Take care that wiring harness (5) is not
caught.

4) Set tab (B) and install connector cover (1).

5) Bind connector cover (1) and wiring harness

with a new cable tie. (See 1. 1).)

a If the pump controller is replaced, perform the

preceding and following adjustment according to
"Special function of machine monitor".
Only when it is changed before replacement:
Pump absorption torque (F)
Pump absorption torque (R)
Travel low speed setting
Attachment flow adjustment in combined op-
eration
Must be performed:
Pump calibration

50-250 HB205-1, HB205LC-1

(03)
 Electrical system
Removal and installation of machine monitor assembly

Removal and installation of machine monitor assembly 50-251

k Park the machine on a level place, lower the a Disconnect the body and control part of
work equipment to the ground completely, swing emergency stop switch (8) as follows.
and stop the engine. 1] While pressing right and left tabs (A) up,
k Disconnect the cable from the negative (-) pull lock part (B) toward the harness.
terminal of the battery. 2] Turn lock part (B) 45 deg. in the direction
of arrow (a).
1. Remove cover (1) according to the following
procedure.
1) Remove cap (2) and bolt.
2) Remove mounting bolts (3) and (4).
3) Remove cover (1).
4) While removing, disconnect connector P31
(5) of the sunlight sensor.

2. Remove cover (6) according to the following

procedure.
1) Insert a flat-head screwdriver into the slit (SL)
and lift it up to release the lock.
2) Pull up cover (6) to remove.
a The cover is fixed by using clip (7).
3) While removing, disconnect the body and 3. Remove one mounting bolt and duct (9).
control part of swing emergency stop switch
(8).

HB205-1, HB205LC-1 50-251

(01)
Electrical system
Removal and installation of machine monitor assembly

4. Disconnect connectors CM01 (10), CM02 (11) Installation 50-252

and CM03 (12). q Perform the subsequent installation in the re-
verse order to removal.
5. Disconnect rear camera wiring connector CM05
(13).

6. Disconnect wiring connector GT5 (14) for GPS.

7. Remove mounting bolt (15)and then remove

machine monitor assembly (16).

50-252 HB205-1, HB205LC-1

(01)
 Electrical system
Removal and installation of KOMTRAX terminal assembly

Removal and installation of KOMTRAX terminal assembly 50-253

Removal 50-253 Installation 50-253

k Disconnect the negative terminal (-) of the q Perform installation in the reverse order to re-
battery before starting the work. moval.

1. Remove covers (1) to (4).

2. Twist antenna wire (5) and disconnect it.

3. Disconnect connectors CK01 (6) and CK02 (7).

4. Remove four mounting bolts and remove

KOMTRAX terminal (8).

HB205-1, HB205LC-1 50-253

(01)
Electrical system
Removal and installation of KOMTRAX terminal assembly

50-254 HB205-1, HB205LC-1

(01)
 0-1
HB205-1, HB215LC-1

HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1

Machine model Serial number

HB205-1 1001 and up
HB215LC-1 1001 and up

60 Maintenance standard 30-1

HB205-1, HB215LC-1 60-1

 2
Contents

Contents 60-2

60 Maintenance standard
Engine and cooling system ..................................................................................................... 60- 4 4
Engine mount....................................................................................................................... 60- 4 4
Cooling system .................................................................................................................... 60- 5 5
Power train .............................................................................................................................. 60- 7 7
Swing circle.......................................................................................................................... 60- 7 7
Swing machinery.................................................................................................................. 60- 8 8
Swing brake ......................................................................................................................... 60- 10 10
Final drive ............................................................................................................................ 60- 12 12
Sprocket............................................................................................................................... 60- 14 14
Undercarriage and frame ........................................................................................................ 60- 16 16
Track frame and idler cushion.............................................................................................. 60- 16 16
Idler ...................................................................................................................................... 60- 18 18
Track roller ........................................................................................................................... 60- 20 20
Carrier roller ......................................................................................................................... 60- 21 21
Track shoe ........................................................................................................................... 60- 22 22
Hydraulic system..................................................................................................................... 60- 28 28
Main pump ........................................................................................................................... 60- 28 28
Control valve ........................................................................................................................ 60- 32 32
Travel motor......................................................................................................................... 60- 41 41
PPC valve ............................................................................................................................ 60- 44 44
Solenoid valve...................................................................................................................... 60- 54 54
Attachment circuit selector valve ......................................................................................... 60- 55 55
Center swivel joint................................................................................................................ 60- 56 56
Work equipment...................................................................................................................... 60- 58 58
Work equipment................................................................................................................... 60- 58 58
Dimension of work equipment.............................................................................................. 60- 60 60
Work equipment cylinder ..................................................................................................... 60- 64 64

60-2 HB205-1, HB215LC-1

 3
Contents

HB205-1, HB215LC-1 60-3

 4
Engine and cooling system
Engine mount

Engine and cooling system 4

Engine mount 4

60-4 HB205-1, HB215LC-1

 5
Engine and cooling system
Cooling system

Cooling system 5

HB205-1, HB215LC-1 60-5

 6
Engine and cooling system
Cooling system

60-6 HB205-1, HB215LC-1

 7
Power train
Swing circle

Power train 7

Swing circle 7

Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance
Axial clearance of bearing
1 (when installed on machine) Replace
0.5 1.6 3.2

HB205-1, HB215LC-1 60-7

 8
Power train
Swing machinery

Swing machinery 8

60-8 HB205-1, HB215LC-1

 9
Power train
Swing machinery

Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance
Backlash between No. 2 planetary
1 gear and No. 2 ring gear 0.18 0.59 1.10
Backlash between No. 2 planetary
2 carrier and No. 3 sun gear
0.39 0.71 1.20
Backlash between No. 3 planetary
3 gear and No. 2 ring gear
0.18 0.59 1.00
Replace
Backlash between No. 3 sun gear
4 and No. 3 planetary gear
0.16 0.50 0.90
Backlash between swing pinion
5 and No. 3 planetary carrier
0.07 0.23
Backlash between swing pinion
6 and swing circle
0.22 1.32 2.00
Standard dimension Repair limit Apply hard
Wear of swing pinion surface
7 chrome plating or
contacting with oil seal f125 (0/0.100) replace
Standard clearance Allowable clearance
Clearance between No. 3 sun
8 gear and plate 1.66 2.94
Replace
Clearance between plate and
9 No. 3 planetary carrier
0.66 1.14

HB205-1, HB215LC-1 60-9

 10
Power train
Swing brake

Swing brake 10

Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance Replace
Backlash between swing motor
1 shaft and No. 1 sun gear 0.07 0.18
Backlash between No. 1 sun gear
2 and No.1 planetary gear
0.12 0.31 0.80
Backlash between No. 1 planetary
3 gear and ring gear
0.14 0.43 0.90
Backlash between No. 1 planetary
4 carrier and No. 2 sun gear
0.07 0.21
Backlash between No. 2 sun gear
5 and No. 2 planetary gear
0.16 0.50 1.00

60-10 HB205-1, HB215LC-1

 11
Power train
Swing brake

HB205-1, HB215LC-1 60-11

 12
Power train
Final drive

Final drive 12

60-12 HB205-1, HB215LC-1

 13
Power train
Final drive

Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance
Backlash between No. 2 sun gear
1 and No. 2 planetary gear 0.13 0.47 1.00
Backlash between No. 1 planetary
2 gear and gear hub
0.17 0.57 1.10
Backlash between No. 2 planetary
3 carrier and motor
0.06 0.25
Replace
Backlash between No. 1 sun gear
4 and No. 1 planetary gear
0.14 0.46 1.00
Backlash between No. 2 planetary
5 gear and gear hub
0.16 0.56 1.10
Backlash between No. 1 planetary
6 carrier and No. 2 sun gear
0.38 0.66 1.00

7 Amount of wear on sprocket tooth Repair limit: 6

Build-up welding
Standard dimension Repair limit
or replace
8 Width of sprocket tooth
71 68

HB205-1, HB215LC-1 60-13

 14
Power train
Sprocket

Sprocket 14

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Wear of tooth tip
294.5 282.5
Build-up welding
2 Thickness of tooth root 17 11 for rebuilding or
replace
3 Width of tooth 71 68
Repair limit: 6
4 Wear of tooth shape
(use a full-size drawing of sprocket tooth shape to judge)

60-14 HB205-1, HB215LC-1

 15
Power train
Sprocket

Full-size drawing of sprocket tooth shape

a Duplicate the drawing onto an OHP viewgraph at a magnification that restores the scale to the full-size.

HB205-1, HB215LC-1 60-15

 16
Undercarriage and frame
Track frame and idler cushion

Undercarriage and frame 16

Track frame and idler cushion 16

60-16 HB205-1, HB215LC-1

 17
Undercarriage and frame
Track frame and idler cushion

Unit: mm
No. Item Criteria Remedy
Standard
Tolerance Repair limit
dimension
Vertical width of +3
1 Track frame 107 111
idler guide 1
Build-up welding
Idler support 105 0.5 103 for rebuilding or
replace
+4
Track frame 250 1 255
Horizontal width of
2 idler guide
Idler support 247.4 245.4
Standard dimension Repair limit
Free length
x Outside Installed Installed Free length Installed
length load load
diameter
3 Recoil spring Replace
109.3 kN 87.4 kN
HB205-1 558 x 238 417 531.4
{11,150 kg} {8,920 kg}
HB215LC-1 561.4 x 237 433 126.5 kN 534 101 kN
{12,900 kg} {10,300 kg}

HB205-1, HB215LC-1 60-17

 18
Undercarriage and frame
Idler

Idler 18

60-18 HB205-1, HB215LC-1

 19
Undercarriage and frame
Idler

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Outside diameter of protrusion
538

2 Outside diameter of tread 500 488

Build-up welding
3 Thickness of tread 26 20
for rebuilding or
replace
4 Difference of tread 19 25

5 Overall width 159

6 Width of tread 37.5

Standard Tolerance Standard Allowable
Clearance between shaft and dimension Shaft Hole clearance clearance
7 bushing
65 0.250 +0.164 0.176
0.350 0.074 0.514
Standard Tolerance Standard Allowable
Interference between idler and dimension Shaft Hole interference interference Replace bushing
8 bushing +0.108 0.032 0.040
72
+0.008 0.062 0.170
Clearance between bushing and Standard dimension Repair limit
9 support
(Total of both sides) 0.5 1.0

HB205-1, HB215LC-1 60-19

 20
Undercarriage and frame
Track roller

Track roller 20

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Outside diameter of flange
188

2 Outside diameter of tread 156 144

Build-up welding
3 Thickness of tread 44.5 38.5
for rebuilding or
replace
4 Overall width 225

5 Width of tread 44.5

6 Width of flange 25.5

Standard Tolerance Standard Allowable
Clearance between shaft and dimension Shaft Hole clearance clearance
7 bushing 0.215 +0.195 0.215
60 0.315 0 0.510
Replace bushing
Standard Tolerance Standard Allowable
Interference between roller and dimension Shaft Hole interference Interference
8 bushing +0.153 +0.030 0.023
67
+0.053 0 0.153
Clearance between bushing and Standard dimension Repair limit
9 collar Replace
(Total of both sides) 0.5 1.0

60-20 HB205-1, HB215LC-1

 21
Undercarriage and frame
Carrier roller

Carrier roller 21

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Outside diameter of flange
145

2 Outside diameter of tread 120 106

3 Width of tread 43

4 Thickness of tread 23 16

5 Width of flange 14
Tolerance Replace
Standard Standard Allowable
Clearance between shaft and dimension Shaft Hole clearance clearance
6 bushing
40 0.170 +0.301 0.338
0.190 +0.168 0.491
Standard Tolerance Standard Allowable
Interference between roller and dimension Shaft Hole interference interference
7 bushing +0.061 0 0.016
47
+0.016 0.040 0.101
Standard clearance Allowable clearance
8 End play in axial direction
0.44 0.76

HB205-1, HB215LC-1 60-21

 22
Undercarriage and frame
Track shoe

Track shoe 2

a P portion shows the link of bushing press fitting end.

*1. Triple grouser shoe q Number of shoes

*2. Road liner Machine model Qty (each side)
*3. Swamp shoe
HB205-1 45
*4. Flat shoe
HB215LC-1 49

60-22 HB205-1, HB215LC-1

 23
Undercarriage and frame
Track shoe

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Link pitch
190.3 193.3
Standard dimension Reverse
Reverse or replace
2 Outside diameter of bushing
59.3 54.3

3 Thickness of bushing 10.4 5.4

Standard dimension Repair limit
4 Link height
105 97
Repair or replace
Thickness of link (bushing press-fit
5 part)
28.5 20.5

6 160.4

7 Shoe bolt pitch 124.4

8 62
Inside
9 width
84.8
Overall
10 Link width
45.4
Tread
11 width
39.6

Regular 2.5
12 Protrusion of pin
Master 2.5 Adjust or replace

Regular 4.85
13 Protrusion of bushing
Master 0.0

Regular 212
14 Overall length of pin
Master 212

Regular 138.5
15 Overall
bushing
length of
Master 128.7

16 Thickness of spacer

17 Bushing 88.2 245 kN {9 25 ton}

18 Press-fitting force Regular pin 127.4 274.4 kN {13 28 ton}

19
Master pin 78.4 147 kN {8 15 ton}
(*)
* Dry type track link

HB205-1, HB215LC-1 60-23

 24
Undercarriage and frame
Track shoe

Unit: mm
No. Item Criteria Remedy
Tightening torque Retightening angle
(Nm {kgm}) (deg.)
a. Regular Triple grouser 490 49 120 10
link shoe {50 5}
Road liner 549 59
20 Shoe bolt (Rubber pad type) {56 6}
Retighten
Tightening torque Retightening angle Lower limit torque
b. Master (Nm {kgm}) (deg.) (Nm {kgm})
link

Standard Tolerance Standard
dimension interference
21 Interference
link
between bushing and Shaft Hole
+0.434 +0.074
59 0.320 0.434
+0.394 0
22 Interference
and link
between regular pin
38
+0.222
+0.162
0.138
0.200
0.300 0.422
Standard Tolerance Standard
dimension clearance
23 Clearance between regular pin
and bushing
Shaft Hole
+0.222 +0.902
38 0.180 0.740 Adjust or replace
+0.162 +0.402
Standard Tolerance Standard
24 Interference between master pin dimension Shaft Hole interference
(*) and link +0.280 +0.062
37.8 0.188 0.280
+0.250 0
Standard Tolerance Standard
25 Clearance between master pin dimension Shaft Hole clearance
(*) and bushing 0.150 +0.902
38 0.552 1.252
0.350 +0.402
* Dry type track link

60-24 HB205-1, HB215LC-1

 25
Undercarriage and frame
Track shoe

HB205-1, HB215LC-1 60-25

 26
Undercarriage and frame
Track shoe

Triple grouser shoe

Swamp shoe

Road liner

60-26 HB205-1, HB215LC-1

 27
Undercarriage and frame
Track shoe

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Height
26 16

10
2 Thickness
(*) 8.5

3 Length of base 26

4 Length of base 19

5 Length at tip 20
Build-up welding
or replace
6 Length at tip 14

7 Length at tip 19
Standard dimension Repair limit
36 26
8 Thickness
(*) 34.5 24.5

9 Height 102.5 90.5

10 Thickness 17 5

11 Height 70 Replace

*: HB205-1, HB215LC-1: 600 mm width shoe

HB205-1, HB215LC-1 60-27

 28
Hydraulic system
Main pump

Hydraulic system 28

Main pump 28

Type: HPV95+95

60-28 HB205-1, HB215LC-1

 29
Hydraulic system
Main pump

HB205-1, HB215LC-1 60-29

 30
Hydraulic system
Main pump

LS (PC)-EPC valve

60-30 HB205-1, HB215LC-1

 31
Hydraulic system
Main pump

HB205-1, HB215LC-1 60-31

 32
Hydraulic system
Control valve

Control valve 32

General view
(If equipped with one attachment)

60-32 HB205-1, HB215LC-1

 33
Hydraulic system
Control valve

Sectional view
(1/5)

HB205-1, HB215LC-1 60-33

 34
Hydraulic system
Control valve

Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
x Outside Free length
1 Spool return spring
diameter
length load load

55.2 x 34.4 51.2 407 N 326 N

{41.5 kg} {33.2 kg} If damaged or
deformed, replace
393 N 315 N spring.
2 Spool return spring 54.5 x 34.8 51.2
{40.1 kg}

{32.1 kg}
375 N 300 N
3 Spool return spring 54.4 x 34.8 51.2
{38.2 kg}

{30.6 kg}
421 N 336 N
4 Spool return spring 54.6 x 34.8 51.2
{42.9 kg}

{34.3 kg}

60-34 HB205-1, HB215LC-1

 35
Hydraulic system
Control valve

(2/5)

Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
x Outside Free length
1 Suction valve spring
diameter
length load load If damaged or
deformed, replace
46.8 x 7.5 40.6 5.5 N 4.4 N spring.
{0.56 kg} {0.45 kg}
1.5 N 1.2 N
2 Check valve spring 11.5 x 4.6 8.5
{0.15 kg}

{0.12 kg}

HB205-1, HB215LC-1 60-35

 36
Hydraulic system
Control valve

(3/5)

60-36 HB205-1, HB215LC-1

 37
Hydraulic system
Control valve

Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
x Outside Free length
1 Check valve return spring
diameter
length load load

59.3 x 14.4 43 14.7 N 11.8 N

{1.5 kg} {1.2 kg}
13.7 N 11 N
2 Check valve spring 33.8 x 6 29
{1.4 kg}

{1.12 kg} If damaged or
deformed, replace
170 N 135 N spring.
3 Piston return spring 60.2 x 20 36
{17.3 kg}

{13.8 kg}
5.9 N 4.71 N
4 Check valve spring 31.5 x 10.3 19.5
{0.6 kg}

{0.48 kg}
157 N 126 N
5 Piston return spring 88.2 x 28.4 65
{16 kg}

{12.8 kg}
36.1 N 28.8 N
6 Piston return spring 18.0 x 9.3 13.4
{3.68 kg}

{2.94 kg}

HB205-1, HB215LC-1 60-37

 38
Hydraulic system
Control valve

(4/5)

60-38 HB205-1, HB215LC-1

 39
Hydraulic system
Control valve

Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
x Outside Free length
1 Spool return spring
diameter
length load load

36.4 x 21.8 33.0 121 N 96.5 N

{12.3 kg} {9.84 kg}
250 N 200 N
2 Check valve spring 70.9 x 18.0 56.0
{25.5 kg}

{20.4 kg}
If damaged or
178 N 142 N
3 Spool return spring 64.5 x 32.3 63.0
{18.1 kg}

{14.5 kg}
deformed, replace
spring.
35.3 N 28.2 N
4 Check valve spring 33.0 x 12.0 26.0
{3.6 kg}

{2.88 kg}
13.7 N 11.0 N
5 Check valve spring 33.8 x 6.0 29.0
{1.4 kg}

{1.12 kg}
5.9 N 4.71 N
6 Piston return spring 31.5 x 10.3 19.5
{0.6 kg}

{0.48 kg}
50.0 N 40.0 N
7 Piston return spring 30.7 x 20.5 23
{5.1 kg}

{4.08 kg}

HB205-1, HB215LC-1 60-39

 40
Hydraulic system
Control valve

(5/5)

60-40 HB205-1, HB215LC-1

 41
Hydraulic system
Travel motor

Travel motor 41

Type: HMV110ADT-2

HB205-1, HB215LC-1 60-41

 42
Hydraulic system
Travel motor

60-42 HB205-1, HB215LC-1

 43
Hydraulic system
Travel motor

Unit: mm
No. Check item Criteria Remedy
Free length
Installed Installation Installation
x Outside Free length
length load load
1 Check valve spring diameter
7.16 N 5.69 N
32.5 6.5 24.2
{0.73 kg} {0.58 kg} If damaged or
1.96 N 1.57 N deformed, replace
2 Check valve spring 13.0 6.5 9.5
{0.2 kg}

{0.16 kg} spring
427 N 341 N
3 Spool return spring 58.4 30 42
{43.5 kg}

{34.8 kg}
54.9 N 43.9 N
4 Regulator valve spring 21.5 11.1 17.1
{5.6 kg}

{4.48 kg}

HB205-1, HB215LC-1 60-43

 44
Hydraulic system
PPC valve

PPC valve 4

Work equipment and swing PPC valve

60-44 HB205-1, HB215LC-1

 45
Hydraulic system
PPC valve

HB205-1, HB215LC-1 60-45

 46
Hydraulic system
PPC valve

Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
Centering spring x Outside Free length
1 (for ports P3 and P4) diameter
length load load
If damaged or
42.5 15.5 34.0 17.7 N 14.1 N deformed, replace
{1.80 kg} {1.44 kg}
spring
Centering spring 29.4 N 23.5 N
2 (for ports P1 and P2)
44.5 15.5 34.0
{3.0 kg}

{2.40 kg}
16.7 N 13.3 N
3 Metering spring 26.5 8.15 24.9
{1.70 kg}

{1.36 kg}

60-46 HB205-1, HB215LC-1

 47
Hydraulic system
PPC valve

Travel PPC valve

HB205-1, HB215LC-1 60-47

 48
Hydraulic system
PPC valve

60-48 HB205-1, HB215LC-1

 49
Hydraulic system
PPC valve

Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
x Outside Free length
1 Centering spring
diameter
length load load
If damaged or
48.6 15.5 32.5 108 N 86.3 N deformed, replace
{11.0 kg} {8.8 kg}
spring
16.7 N 13.3 N
2 Metering spring 26.5 8.15 24.9
{1.7 kg}

{1.36 kg}
8.83 N 7.06 N
3 Steering signal spring 12.8 7.3 8.5
{0.9 kg}

{0.72 kg}

HB205-1, HB215LC-1 60-49

 50
Hydraulic system
PPC valve

Service PPC valve (with EPC valve)

Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installation Installation Installation
x Outside Free length
1 Centering spring
diameter
length load load If damaged or
deformed, replace
33.9 x 15.3 28.4 125 N 100 N spring.
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0
{1.70 kg}

{1.36 kg}

60-50 HB205-1, HB215LC-1

 51
Hydraulic system
PPC valve

EPC valve

Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
If damaged or
Installation Installation Installation
Free length Free length deformed, replace
1 Return spring length load load
EPC valve
3.1 N assembly.
9.0 8.4
{0.32 kg}

HB205-1, HB215LC-1 60-51

 52
Hydraulic system
PPC valve

Service PPC valve

Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installation Installation Installation
x Outside Free length
1 Centering spring
diameter
length load load If damaged or
deformed, replace
33.9 x 15.3 28.4 125 N 100 N spring.
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0
{1.70 kg}

{1.36 kg}

60-52 HB205-1, HB215LC-1

 53
Hydraulic system
PPC valve

HB205-1, HB215LC-1 60-53

 54
Hydraulic system
Solenoid valve

Solenoid valve 54

For PPC lock, travel junction, travel speed, swing brake, and 2-stage relief solenoid valves

60-54 HB205-1, HB215LC-1

 55
Hydraulic system
Attachment circuit selector valve

Attachment circuit selector valve 5

Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installation Installation Installation If damaged or
x Outside Free length
1 Spool return spring diameter length load load deformed, replace
spring.
834 N 667 N
132 x 29 114.5 {85.0 kg} {68.0 kg}

HB205-1, HB215LC-1 60-55

 56
Hydraulic system
Center swivel joint

Center swivel joint 56

Unit: mm
No. Item Criteria Remedy
Standard dimension Standard clearance Allowable clearance
Clearance between rotor and
1 shaft
Replace
80

60-56 HB205-1, HB215LC-1

 57
Hydraulic system
Center swivel joint

HB205-1, HB215LC-1 60-57

 58
Work equipment
Work equipment

Work equipment 58

Work equipment 58

60-58 HB205-1, HB215LC-1

 59
Work equipment
Work equipment

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between pin connecting dimension clearance clearance
Shaft Hole
1 "boom and revolving frame" and
bushing 0.036 +0.135 0.110
90 1.0
0.071 +0.074 0.206
Clearance between pin connecting 0.036 +0.137 0.113
2 "boom and arm" and bushing
90
0.071 +0.077 0.208
1.0
Clearance between pin connecting 0.030 +0.158 0.108 Replace
3 "arm and link" and bushing
70
0.076 +0.078 0.234
1.0
Clearance between pin connecting 0.030 +0.137 0.104
4 "arm and bucket" and bushing
80
0.076 +0.074 0.213
1.0
Clearance between pin connecting 0.030 +0.166 0.116
5 "link and bucket" and bushing
80
0.076 +0.086 0.242
1.0
Clearance between pin connecting 0.030 +0.154 0.104
6 links and bushing
70
0.076 +0.074 0.230
1.0

HB205-1, HB215LC-1 60-59

 60
Work equipment
Dimension of work equipment

Dimension of work equipment 60

Arm

60-60 HB205-1, HB215LC-1

 61
Work equipment
Dimension of work equipment

Unit: mm
HB205-1, HB215LC-1
No.
Standard dimension Tolerance
+0.1
1 f80
0
+1.5
2 109.3
0
0
3 305.5
0.5
+0.054
4 f90
0
5 402.1 1

6 187.2 0.5

7 829.1 1

8 2,919

9 2,630.5 1

10 410 1

11 640 0.2

12 600 0.5

13 458.1

14 1,486
+0.1
15 f80
0
16 325 0.5
+0.1
17 f80
0
0
Arm boss (without bushing) 311
0.5
18
When press-fitting bushing
325
(with bushing)
Min. 1,680
19
Max. 2,800

HB205-1, HB215LC-1 60-61

 62
Work equipment
Dimension of work equipment

Bucket

60-62 HB205-1, HB215LC-1

 63
Work equipment
Dimension of work equipment

Unit: mm
HB205-1, HB215LC-1
No.
Standard dimension Tolerance

1 457.6 0.5

2 22 0.5

3 9245'

4 458.1

5 1,477.3

6 158.6

8 1554'
+0.1
9 f80
0
10 326.5 1

11 56

12 106

13 470

14 f23.5

15 f140

16 f190

17 133.2

18 131.6

19 107

20 85
+2
21 348.5
0
22 38

HB205-1, HB215LC-1 60-63

 64
Work equipment
Work equipment cylinder

Work equipment cylinder 64

Boom cylinder

Arm cylinder

Bucket cylinder

60-64 HB205-1, HB215LC-1

 65
Work equipment
Work equipment cylinder

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Cylinder
dimension Shaft Hole clearance clearance
0.036 +0.222 0.083
Boom 85 0.412
Clearance between 0.090 +0.047 0.312
1 piston rod and bushing
Replace bushing
0.036 +0.222 0.083
Arm 95 0.412
0.090 +0.047 0.312
0.030 +0.222 0.077
Bucket 80 0.398
0.076 +0.047 0.298
0.030 +0.190 0.100
Boom 80 1.0
0.060 +0.070 0.250
Clearance between
0.030 +0.190 0.100
2 piston rod support Arm 80
0.076 +0.070 0.266
1.0
shaft and bushing
0.030 +0.170 0.100
Bucket 70 1.0
0.076 +0.070 0.246 Replace pin or
0.030 +0.165 0.075 bushing
Boom 70 1.0
Clearance between 0.060 +0.045 0.225
cylinder bottom 0.030 +0.190 0.100
3 support shaft and
Arm 80
0.076 +0.070 0.266
1.0
bushing 0.030 +0.165 0.075
Bucket 70 1.0
0.060 +0.045 0.225

HB205-1, HB215LC-1 60-65

 66
Work equipment
Work equipment cylinder

60-66 HB205-1, HB215LC-1

SEN0537731-00 80-1

HB205-1

HYDRAULIC EXCAVATOR
Shop Manual 8-01

HB205-1
HB215LC-1

Machine model Serial number

HB205-1 1001 and up
HB215LC-1 1001 and up

80 Appendix 80-1

HB205-1, HB215LC-1 80-1

(01)
Contents

Contents 80-2
80 Appendix
Air conditioner ......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Air conditioner component ................................................................................................... 80- 4
Configuration and function of refrigeration cycle.................................................................. 80- 6
Outline of refrigeration cycle ................................................................................................ 80- 7
Air conditioner unit ............................................................................................................... 80- 10
Air conditioner controller ...................................................................................................... 80- 15
Compressor ......................................................................................................................... 80- 16
Condenser and Modulator ................................................................................................... 80- 17
Procedure for testing and troubleshooting ........................................................................... 80- 18
Circuit diagram and arrangement of connector pins ............................................................ 80- 20
System diagram ................................................................................................................... 80- 22
Detail of air conditioner unit ................................................................................................. 80- 24
Parts and connectors layout ................................................................................................ 80- 26
Testing air leakage (duct) .................................................................................................... 80- 30
Testing with self-diagnosis function ..................................................................................... 80- 31
Testing temperature control ................................................................................................. 80- 34
Testing vent (mode) changeover ......................................................................................... 80- 36
Testing FRESH/RECIRC air changeover ............................................................................ 80- 39
Testing inner sensor ............................................................................................................ 80- 41
Testing evaporator temperature sensor............................................................................... 80- 42
Testing sunlight sensor ........................................................................................................ 80- 44
Testing (dual) pressure switch for refrigerant ...................................................................... 80- 45
Testing relays....................................................................................................................... 80- 47
Troubleshooting chart 1 ....................................................................................................... 80- 48
Troubleshooting chart 2 ....................................................................................................... 80- 50
Information in troubleshooting table..................................................................................... 80- 52
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
............................................................................................................................................. 80- 53
Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80- 57
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ......... 80- 60
Troubleshooting for temperature control.............................................................................. 80- 63
Troubleshooting for vent (mode) changeover ...................................................................... 80- 66
Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 68
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 ....................................................................................... 80- 80

80-2 HB205-1, HB215LC-1

(01)
 Air conditioner
Precautions for refrigerant

Air conditioner 80-3

Precautions for refrigerant 80-3

k Collect the refrigerant (Air conditioner gas:

R134a) from air conditioner circuit before
disconnecting air conditioner hose to re-
place air conditioner unit, air conditioner
compressor or receiver drier and so on.
a Ask a qualified person for collecting, adding and
filling operations of the refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmo-
sphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skin, you may suffer from frostbite. Ac-
cordingly, put on protective eyeglasses,
gloves and working cloth with long sleeves
while collecting the refrigerant or filling the
air conditioner circuit with the refrigerant.

HB205-1, HB215LC-1 80-3

(01)
Air conditioner
Air conditioner component

Air conditioner component 80-4

80-4 HB205-1, HB215LC-1

(01)

1. Compressor
2. Condenser
3. Receiver drier
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
9. Air conditioner controller
10. Air conditioner unit
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
HB205-1, HB215LC-1
(01)
Air conditioner
Air conditioner component
A: Front warm/cool air vent
B: Rear warm/cool air vent
C: Foot warm/cool air vent
D: Defroster warm
E: Recirculation air inlet
F: Fresh air inlet
Specifications 80-5
Refrigerant R134a
Refrigerant refilling level (g) 870 50
80-5
Air conditioner
Configuration and function of refrigeration cycle

Configuration and function of refrigeration cycle 80-6

Cycle Compression Condensation Expansion Evaporation
(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator cab In operator cab
Location Engine compartment Front of radiator (Built in air conditioner (Built in air conditioner
unit) unit)
Circulates refrigerant
gas and increases its Lowers temperature and Evaporates refrigerant to
Condenses refrigerant
temperature and pres- pressure of refrigerant liq- absorb heat from air
to discharge heat
sure so that it can be uid and gas for easy evap- around evaporator, and
Function absorbed in evaporator.
liquefied easily in con- oration with throttle. cool the air.
(condensation of refrig-
denser. Controls flow rate, too. (Evaporation of refriger-
erant)
(Compression of (Throttle of refrigerant) ant)
refrigerant)
Gas o Gas Gas o Liquid
Liquid o Liquid and gas Liquid and gas o Gas
State of refriger-
ant Adiabatic compres- Cnstant pressure
Adiabatic expansion Cnstant pressure change
sion change

80-6 HB205-1, HB215LC-1

(01)

Outline of refrigeration cycle
The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly vaporizing and
liquefying.
1. Compression (Compressor)
The compressor sucks in the refrigerant that has
been vaporized in the evaporator and
compresses it into a state where it can be easily
liquefied at the ambient temperature.
The gaseous refrigerant sucked into the
compressor cylinder is compressed to a temper-
ature and pressure at which it can be easily
liquefied when cooled to the ambient tempera-
ture.
2. Condensation (Condenser)
The condenser cools and liquefies the high pres-
sure and high-temperature gaseous refrigerant
sent from the compressor.
The heat released to the outside from the
condenser is called condensation heat.
The amount of condensation heat is the sum
total of the heat absorbed by the evaporator from
the air in the cab and the quantity of the work
applied (the value converted into a heat quantity)
by compression of the compressor.
The refrigerant liquefied in the condenser is sent
to the receiver drier, where moisture is removed.
In the compression cycle, the gaseous refrig-
erant and liquid refrigerant coexist.
The temperature (condensation temperature)
and the pressure (condensation pressure) at
which the gaseous refrigerant is liquefied are
proportional to each other.
Reference: The pressure varies depending on
the condensation temperature of the refrigerant.
3. Expansion (Expansion valve)
The expansion valve reduces the liquid refrig-
erant pressure to a level where liquid refrigerant
can be easily evaporated by the throttle action
(*1).
The action of reducing the liquid refrigerant pres-
sure to a level where it can be easily evaporated
before it is sent to the evaporator is called
expansion.
The expansion valve, which reduces the refrig-
erant pressure, also adjusts the refrigerant flow
rate simultaneously.
The quantity of the liquid refrigerant that can be
evaporated in the evaporator depends on the
amount of heat (refrigeration load) to be
removed under the specific evaporation temper-
ature (evaporation pressure).
HB205-1, HB215LC-1
(01)
Air conditioner
Outline of refrigeration cycle
80-7
The expansion valve controls the refrigerant
feed rate so that the optimum quantity of liquid
refrigerant is supplied to the evaporator.
(*1) Throttle action
If there is a narrow section in the passage
through which liquid is flowing at a constant rate,
a resistance to the flow will be generated.
The liquid expands when it passes through the
narrow section and rushes into the passage
where the sectional area is larger, and conse-
quently, its pressure and temperature are
reduced.
No heat is transferred from or to the outside
during the throttle action.
4. Evaporation (Evaporator)
The evaporator evaporates the liquid refrigerant
(superheated vapor).
The refrigerant evaporates, while absorbing an
amount of heat necessary for evaporation (evap-
oration heat) from the air around the cooling fins
(air in the cab).
After the heat has been removed, the cooled air
is sent into the cab by the blower fan, reducing
the temperature inside the cab.
The mist refrigerant that has been sent from the
expansion valve coexists with the evaporated
refrigerant in the evaporator
The temperature (evaporation temperature) and
the pressure (evaporation pressure) at which the
liquid refrigerant is evaporated are proportional
to each other.
The compressor sucks in the evaporated refrig-
erant in order to keep the pressure level in the
evaporator as low as possible so that the liquid
refrigerant can be evaporated at a much lower
temperature.
Relationship between refrigerant and defective
air conditioning 80-7
q The refrigerant circulates in the refrigeration cir-
cuit while repeating the refrigeration cycle to ex-
pel the heat from inside the cab.
q If there is an insufficient quantity of refrigerant,
all of it will be evaporated while it is passing
through the evaporator. This causes evaporator
efficiency to deteriorate, which will result in de-
fective air conditioning.
80-7
Air conditioner
Outline of refrigeration cycle

q If there is excessive refrigerant, not all of it will be

evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the
compressor to compress the liquid and may
damage the components.
q If water gets into the refrigeration circuit, it will
freeze at a small hole in the expansion valve,
lower the refrigerant flow, and may result in de-
fective air conditioning.

80-8 HB205-1, HB215LC-1

(01)
 Air conditioner
Outline of refrigeration cycle

HB205-1, HB215LC-1 80-9

(01)
Air conditioner
Air conditioner unit

Air conditioner unit 80-10

a This air conditioner unit is auto temperature control type.

80-10 HB205-1, HB215LC-1

(01)
 Air conditioner
Air conditioner unit

A: Refrigerant inlet (from condenser) Air flow adjustment 80-1

B: Refrigerant outlet (to compressor) q Whenever an air flow control switch is operated
C: Hot water inlet on the machine monitor, air flow setting data is
D: Hot water outlet sent to the air conditioner controller. The air con-
ditioner controller controls blower motor (4) us-
1. Evaporator ing power transistor (11) in order to adjust the air
2. Heater core flow.
3. Expansion valve
4. Blower fan, blower motor Vent (mode) changeover 80-1
5. Air mix servomotor q Whenever a vent switch is operated on the ma-
Air mix door chine monitor, mode data is sent to the air con-
6-1. Cool door ditioner controller. The air conditioner controller
6-2. Hot door controls mode changeover servomotor (7) to ad-
6-3. Sub-hot door just the opening angle of mode changeover
7. Vent (mode) changeover servomotor (MODES) doors (8-1) to (8-4) and thus perform vent
Vent (mode) changeover door changeover.
8-1. Differential door
8-2. Foot door FRESH/RECIRC air changeover 80-1
8-3. Front door q Whenever a FRESH/RECIRC air changeover
8-4. Rear door switch is operated on the machine monitor,
9. FRESH/RECIRC air changeover servomotor FRESH/RECIRC air changeover setting data is
(R/FS) sent to the air conditioner controller. The air con-
10. FRESH/RECIRC air changeover door ditioner controller controls FRESH/RECIRC air
11. Power transistor changeover servomotor (9) to open and close
12. Evaporator temperature sensor FRESH/RECIRC air changeover door (10).
13. Insidel air temperature sensor
14. Holder Automatic air conditioner 80-1
q Inside air temperature sensor (13) detects the in-
Outline 80-1 side temperature based on changes in resis-
q The air conditioner unit consists of the evapora- tance. The air conditioner controller detects the
tor (1) and heater core (2), and is used to cool inside temperature by converting the changes in
down or warm up the air in the cab. the resistance of inside air temperature sensor
(13) into voltage changes.
Temperature control 80-1 The air conditioner controller checks the voltage
q Operating the temperature control switch on the of inside air temperature sensor (13) and
machine monitor sends the temperature setting controls the inside air temperature so that it
data to the air conditioner controller located in matches the setting made on the machine
the rear side of the operator seat. The air condi- monitor.
tioner controller controls air mix servomotor (5) Data from sunlight sensor is also taken into
and change the angle of air mix doors (6-1), (6-2) consideration when adjusting the inside temper-
and (6-3) in order to adjust the temperature. ature.

Over-cooling (Freezing) prevention 80-1 a 5 A fuse for the air conditioner unit is attached to
q The resistance of the evaporator temperature the wiring harness.
sensor (12) changes in response to tempera- a The door is the same as the damper.
ture.
q The air conditioner controller detects the temper-
ature of the evaporator (1) by converting the
changes in the resistance of the evaporator tem-
perature sensor (12) into voltage changes.
q The air conditioner controller performs control to
prevent freezing of the evaporator (1) by operat-
ing the compressor clutch relay (*) to stop the
compressor.
*: See "Parts and connectors layout" for details re-
garding the compressor clutch relay.

HB205-1, HB215LC-1 80-11

(01)
Air conditioner
Air conditioner unit

Functions of major components 80-12 q When the potential difference fails to reach a
Evaporator 80-12 predefined voltage for control of the servomotor,
q Evaporator (1) is cooled by the low-pressure, the air conditioner controller notifies the machine
low-temperature refrigerant gas being sent from monitor of an abnormality. "A/C Controller Error"
expansion valve (3). Air from blower motor (4) is is displayed in red on the air conditioner opera-
cooled and dehumidified when passing through tion screen of machine monitor.
the evaporator fins. a FRESH/RECIRC air changeover servo motor
does not feature a variable resistance, and
Heater core 80-12 therefore, does not have a self-diagnosis
q Heater core (2) is warmed by the hot water (en- function.
gine coolant) being sent from the engine. Air a When attempting to operate a servomotor during
from blower motor (4) is warmed when passing inspecting, do not supply power directly between
through the heater core fins. servomotor terminals (6) and (7).

Evaporator temperature sensor 80-12

q Evaporator temperature sensor (12) is installed
to evaporator (1) with holder (14). Its resistance
changes in response to the temperature change
of the evaporator. The air conditioner controller
monitors the evaporator temperature to prevent
its freezing.

Servomotors 80-12

a Servomotors are used to adjust the temperature

(air mix) and to perform vent (mode)
changeover.

q Whenever a switch on the machine monitor is

operated, the air conditioner controller delivers
power to the servomotor by raising the voltage
between terminals (6) and (7) to 24 V. (The rota-
tion direction changes based on the supply po-
larity.)

q The servomotor contains a variable resistance,

and its resistance value changes as the motor
turns.
q The air conditioner controller delivers voltage at
5 V to the variable resistance and detects motor
rotation angle based on the potential difference.
q When the door (damper) reaches the position
specified by each switch, the air conditioner con-
troller stops the supply of current to the servomo-
tor, then the corresponding door stops.

80-12 HB205-1, HB215LC-1

(01)

Expansion valve
A: When evaporator outlet temperature is high
B: When evaporator outlet temperature is low
C: From receiver drier (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Outline
q The expansion valve converts high-pressure
and high-temperature liquid refrigerant from the
receiver drier to low-pressure, low-temperature
misty refrigerant through the throttle action.
q It controls the flow rate of refrigerant by changing
the level of throttling depending on the tempera-
ture in the cab.
q The temperature of the air blown out of the air
vent is adjusted depending on the volume of re-
frigerant circulating in the evaporator (3).
HB205-1, HB215LC-1
(01)
Air conditioner
Air conditioner unit
80-13
Structure 80-13
q Box-type expansion valve (1) consists of needle
valve (1a), spring (1b), etc.
q Refrigerant gas (2) is sealed in the diaphragm
chamber (hatched area) outside diaphragm
(1a-1) of needle valve (1a).
q The opening level of needle valve (1a) is deter-
mined based on the balance between the reac-
tion force exerted by spring (1b) in a rightward
direction, and force (Fg) of refrigerant gas (2)
pushing needle valve (1a) through diaphragm
(1a-1) in a leftward direction.
q The refrigerant flow rate flowing from the receiv-
80-13 er drier to evaporator (3) is determined based on
the opening level of needle valve (1a).
80-13
Air conditioner
Air conditioner unit

Operation 80-14 Dual pressure switch 80-14

q Thermoprobe (1a-2) senses the refrigerant tem- a The dual pressure switch is mounted on the air
perature after it passes through the evaporator conditioner hose under the floor.
(3). q The dual pressure switch turns "OFF" when the
q After the refrigerant passes through evaporator refrigerant circuit pressure becomes abnormally
(3), its temperature is transferred to the refriger- low or abnormally high.
ant gas (2) in the diaphragm chamber (hatched q When the dual pressure switch turns "OFF", the
area) through the thermoprobe (1a-2). air conditioner controller turns the compressor
q The pressure of the refrigerant gas (2) sealed in clutch relay "OFF". As a result, the compressor's
the diaphragm chamber (hatched area) changes magnet clutch is released and air conditioner
in response to the temperature change of the components are protected.
thermoprobe (1a-2), which therefore changes
the force (Fg) pushing the needle valve (1a).
q The opening level of the needle valve (1a) is de-
termined based on the balance between the re-
action force exerted by the spring (1b) in a
rightward direction, and the force (Fg) of the re-
frigerant gas (2) pushing the needle valve (1a)
through the diaphragm (1a-1) in a leftward direc-
tion.

When evaporator (3) outlet temperature is high: 80-14

[When not cooled yet: Condition (A) in the fig-
ure] 80-14
q The pressure of the refrigerant gas (2) in the di-
aphragm chamber is high and the volume is in- a LA or lower: Abnormally low pressure
creased. a HA or higher: Abnormally high pressure
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is increased, and the nee- LA: 0.20 MPa {2 kg/cm2}
dle valve (1a) moves leftward. LB: 0.02 MPa {0.2 kg/cm2}
q As a result, the opening level of the needle valve HA: 3.14 MPa {32 kg/cm2}
(1a) is increased and the refrigerant flow rate to HB: 0.59 MPa {6 kg/cm2}
the evaporator (3) is increased to improve cool-
ing capacity.

When evaporator (3) outlet temperature is low: 80-14

[When cooled already: Condition (B) in the fig-
ure] 80-14
q The pressure of the refrigerant gas (2) in the di-
aphragm chamber is low and the volume is de-
creased.
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is reduced, and the needle
valve (1a) is moved rightward by the spring force
(1b).
q The opening level of the needle valve (1a) is re-
duced and the refrigerant flow rate to the evapo-
rator (3) is reduced to lower the cooling capacity.

80-14 HB205-1, HB215LC-1

(01)
 Air conditioner
Air conditioner controller

Air conditioner controller 80-15

a See "System Diagrams" for details regarding in-

put/output signals.

HB205-1, HB215LC-1 80-15

(01)
Air conditioner
Compressor

Compressor 80-16

A: Refrigerant inlet (from air conditioner unit) Function 80-16

B: Refrigerant outlet (to condenser) q The compressor circulates the refrigerant and
compresses the gaseous refrigerant from the
1. Pulley evaporator into a misty refrigerant at high pres-
2. Magnetic clutch sure and high temperature so that it will be easily
3. Relief valve regenerated (liquefied) at the normal tempera-
ture.
q Calling into account of the evaporator tempera-
ture and refrigerant pressure, the air conditioner
controller activates magnetic clutch (2) built in
the compressor.
q When the magnetic clutch is engaged, the power
of the engine rotates the compressor shaft along
with pulley (1) to drive the compressor.

Specifications 80-16
Number of cylinder Bore x
Stroke 10 - 32 x 20.8
(mm)
Piston capacity
157.3
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Denso: ND-OIL8 (For
Compressor oil
R134a)
Compressor oil refill capacity
180
(cc)

80-16 HB205-1, HB215LC-1

(01)
 Air conditioner
Condenser and Modulator

Condenser and Modulator 80-17

A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to air conditioner unit)

Function 80-17 Function 80-17

q Condenser (1)
It cools and liquefies the high-pressure,
high-temperature misty refrigerant from the
compressor.
a If the fin is crushed or is clogged with dust, heat
exchange efficiency is reduced and complete liq-
uefaction of refrigerant becomes impossible. As
a result, pressure in refrigerant circulation circuit
is increased, applying extra load to the engine or
reducing cooling effect. Take extreme care not
to crush or damage the fins when handling them
or checking them in daily inspection.
q Modulator (2)
a This has desiccant in it. See "Desiccant replace-
ment procedure".
It is used to store liquefied high-pressure,
high-temperature misty refrigerant from the
condenser. It is capable of completely liquefying
the refrigerant even when bubbles are contained
in the refrigerant due to the condenser condition
in heat dissipation.
It eliminates foreign substances in the circulation
line and moisuture in the refrigerant by use of the
built-in filter and desiccant.

Specification 80-17 Specification 80-17

Fin pitch (mm) 4.0 Weight of desiccating 290
Height x Width x Thickness agent (g)
421 x 540 x 16
(mm)
Weight (kg) 3.2

HB205-1, HB215LC-1 80-17

(01)
Air conditioner
Procedure for testing and troubleshooting

Procedure for testing and troubleshooting 80-18

The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.

1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See Check with self-diagnosis).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air condi-
tioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air condi-
tioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.

Basic testing and troubleshooting sequence

80-18 HB205-1, HB215LC-1

(01)
 Air conditioner
Procedure for testing and troubleshooting

*1: By error display or abnormal display on "Abnormality Record" screen on machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding
with the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant
or no refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.

S: Sight glass condition

R: Receiver drier internal condition
LR: Liquid refrigerant

*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for discon-
necting and connecting air conditioner piping."

*4: Start the engine and perform the check with the air conditioner switch set to ON.

HB205-1, HB215LC-1 80-19

(01)
Air conditioner
Circuit diagram and arrangement of connector pins

Circuit diagram and arrangement of connector pins 80-20

80-20 HB205-1, HB215LC-1

(01)
 Air conditioner
Circuit diagram and arrangement of connector pins

a BLOW OUT (MODE) SERVOMOTOR means BLOW OUT (MODE) CHANGEOVER SERVOMOTOR.

HB205-1, HB215LC-1 80-21

(01)
Air conditioner
System diagram

System diagram 80-2

a This air conditioner unit is auto temperature control type.

80-22 HB205-1, HB215LC-1

(01)
 Air conditioner
System diagram

Input/output signals of the air conditioner con- q Operation of air conditioner controller
troller (CNT) 80-23 1. Performing CAN communication with the
Controller side connector: AMP 040 - 36PM machine monitor, the air conditioner controller
Harness side connectors: [1], [2] controls the air conditioner unit by inputting
[1] AMP040 - 16PF switches associated with air conditioning.
Pin Input/o 2. The air conditioner controller controls three
Symbol Signal name servomotors located inside the air conditioner
No. utput
1 unit in order to adjust the temperature (airmix),
A/M servo potentiometer volt- perform vent (mode) changeover, and perform
2 A/MP Input
age FRESH/RECIRC air changeover.
Servo potentiometer 5 V 3. The air conditioner controller controls the
3 POT 5 V Output
power supply ON/OFF condition of the blower main relay (i.e.,
PRESS (Dual) pressure switch
4 Input a switch for blowing air) and of the compressor
SW (Refrigerant pressure)
5 clutch relay (i.e., a switch for activating the
6 +24 V Power supply Input compressor).
7 BLOW F/B Blower feedback signal Input 4. The air conditioner controller controls the air flow
Power transistor control sig- volume using the power transistor.
8 PTR B Output
nal a The power transistor has an overcurrent pre-
Blow out (mode) servo poten- vention fuse in it.
9 MODE P Input
tiometer voltage 5. The air conditioner controller detects the evapo-
10
11 THI Inside air temperature sensor Input
rator temperature using the evaporator tempera-
Evaporator temperature sen- ture sensor.
12 THEVA Input 6. In order to prevent freezing of the evaporator,
sor
13 the air conditioner controller controls the
14 compressor by turning the compressor clutch
15 SS Sunlight sensor Input relay ON and OFF.
16 GND GND Input a When the dual pressure switch detects a
[2]AMP040 - 20PF pressure abnormality (i.e., turns OFF), the air
Pin Input/o conditioner controller turns the compressor
Symbol Signal name clutch relay OFF, and therefore, the com-
No. utput
Input/ pressor stops operating.
17 CAN (+) CAN communication +
output 7. When performing automatic air conditioning, the
Input/ air conditioner controller controls the inside air
18 CAN (-) CAN communication -
output temperature to the set temperature based on
Fresh/Recirculated air servo data from the sunlight sensor and the inner
19 F/RA Output
terminal A sensor (inside air temperature sensor).
Fresh/Recirculated air servo
20 F/RB Output 8. The air conditioner controller has the self-diag-
terminal B
21 A/MA A/M servo terminal A Output nosis function. If any abnormality is detected, the
22 A/MB A/M servo terminal B Output control amplifier notifies it to the machine
Blow out (mode) servo termi- monitor by the CAN communication. Then, the
23 MODE A Output
nal A letters of "A/C Controller Error" are displayed in
Blow out (mode) servo termi- red on the air conditioner operation screen of the
24 MODE B Output
nal B machine monitor.
25
26
27 GND S Sensor GND Input
28
29
30
31
32
33
34
35 CCRL Compressor clutch relay Output
36 BLOW RL Blower main relay Output
q A/M: Air mix
q F/B: Feedback
q F/R: Fresh/Recirculated air

HB205-1, HB215LC-1 80-23

(01)
Air conditioner
Detail of air conditioner unit

Detail of air conditioner unit 80-24

1. Foot door [8]: Inner sensor (inside air temperature sensor)

2. Defroster door connector
3. Front face door [9]: Evaporator temperature sensor connector
4. Rear face door
5. FRESH/RECIRC air changeover door A: Recirculation air port
6. Insidel air temperature sensor B: Fresh air port

[1], [2]: Control amplifier connector EXPV: Expansion valve

[3]: Blower (fan) motor connector Fu5A: Fuse (5 A)
[4]: Power transistor (PTR) connector PTR: Power transistor
[5]: Vent (mode) servomotor connector A/MS: Air mix servomotor
[6]: Temperature control (air mix) servomotor con- MODES: Vent (mode) servomotor
nector R/FS: FRESH/RECIRC air changeover servomotor
[7]: FRESH/RECIRC air changeover servomotor
connector

80-24 HB205-1, HB215LC-1

(01)
 Air conditioner
Detail of air conditioner unit

q Evaporator
Temperature sensor installation position

HB205-1, HB215LC-1 80-25

(01)
Air conditioner
Parts and connectors layout

Parts and connectors layout 80-26

a There are two fuses. One is in the fuse box at 3. Remove cover (3).
the right rear of the operator seat and the other
is wound onto the wiring harness between the air
conditioner unit and control amplifier.
a The air conditioner unit is located at the bottom
in the rear side of the operator's seat.
1. Open the cover of the fuse box located at the
bottom in the rear right side of the operator's
seat.
(See fuse mounting positions in "Trouble-
shooting.")
q No. 11 (20 A) from fuse box:
For power supply of blower (fan), air condi-
tioner compressor and air conditioner unit (all
components related to the air conditioner)
q Part No. of fuse
q Fu5A: Fuse 5 A
20 A: 08041-02000 For power supply of air conditioner unit
(including primary side of relays for blower
(fan) and air conditioner compressor)
q Part No. of fuse
Fu5A: ND93950-05003
q CNT: Air conditioner controller
q [1], [2]: Air conditioner controller connectors
q BRL: Blower main relay
q R20: Blower main relay connector
q CCRL: Compressor clutch relay
q R21: Compressor clutch relay connector
q N10: Air conditioner unit connector for 24 V
power supply and CAN communication with
the machine monitor (communication lines
shared with engine controller and pump con-
2. Remove covers (1) - (3). troller)
a Disconnect connector (M04) for the cigarette q AC01: Connector to air conditioner unit for
lighter from the rear of cover (3). GND, compressor, pressure switch, relay
and sunlight sensor

a State with cover (3) removed

q A/CU: Air conditioner unit
q CNT: Air conditioner controller

80-26 HB205-1, HB215LC-1

(01)
 Air conditioner
Parts and connectors layout

a Fu5A is installed inside the holder. a Bottom of the air conditioner unit
Part No. of fuse [4]: Power transistor (PTR) connector
Fu5A: ND93950-05003 [7]: FRESH/RECIRC air changeover servo-
motor (R/FS) connector
[8]: Inner sensor (inside air temperature
sensor) connector
H: Air conditioner unit wiring harness
PTR: Power transistor

q A/CU: Air conditioner unit

q CNT: Air conditioner controller
q [1], [2]: Air conditioner controller connectors
q MODES: Vent (mode) servomotor
q [5]: Vent (mode) servomotor connector
q A/MS: Temperature control (air mix) servo-
motor 4. Turn 90 degrees to remove cover (5).
q [6]: Temperature control (air mix) servomotor
connector
q [9]: Evaporator temperature sensor connec-
tor

q P17: Pressure switch connector

q [3]: Blower (fan) motor connector

q [9]: Evaporator temperature sensor connec-
tor

HB205-1, HB215LC-1 80-27

(01)
Air conditioner
Parts and connectors layout

5. Open the engine hood.

q ACC: Air conditioner compressor
q AC02: Air conditioner compressor connector
q E: Ground

4) Check connector CM02.

a CM02 and CM03 can be installed in re-
verse, so take care not to install them in
reverse. CM03 is a green connector.
6. Testing sunlight sensor connector P31 and a The connector CN-5 is connected on
machine monitor connector CM02 (CAN models with rear view camera specifica-
communication connector) tion.
a If machine monitor connector CM02 is dis-
connected, neither of the engine controller
and pump controller can carry out the CAN
communication and failure code [DAFRMC]
is displayed. If the screen changes to the air
conditioner operation screen at this time,
A/C Controller error is displayed in red. If
the above error is not displayed, no check is
necessary.
Note: "A/C Controller Error" is also displayed
on the air conditioner operation screen when
the vent changeover is not possible, when a
temperature control abnormality occurs, or
when the refrigerant's pressure switch is set
to OFF.
1) Remove cap (1).
2) Remove cover (2), and disconnect connector
P31 for the air conditioner sunlight sensor
(S).
3) Remove duct (3).

80-28 HB205-1, HB215LC-1

(01)
 Air conditioner
Parts and connectors layout

q Reference
Remove cover (4) as described below. [*1]
1] Insert a flat-head screwdriver into the slit
(SL) and lift it up.
2] Release lock (L) and remove cover (4).

3] Disconnect connector (HS01) for the

emergency stop switch wiring from the
back of cover (4).

5) Remove four mounting bolts and lift up

monitor assembly (5). [*2]
a Connectors can be disconnected from the
back of the machine monitor.

Caution about installation

[*1], [*2]
1. Tighten lightly the four mounting bolts for
machine monitor assembly (5), and install cover
(4).
2. With cover (4) installed, tighten the mounting
bolts for the monitor assembly.
q Perform the subsequent installation in the re-
verse order to removal.

HB205-1, HB215LC-1 80-29

(01)
Air conditioner
Testing air leakage (duct)

Testing air leakage (duct) 80-30

1. Remove front window (1).
2. Remove step plate (2).
3. Remove floor mat (3).
4. Referring to item 6 of parts and connectors
layout, remove cover (4) from machine monitor.
5. Remove covers (5) and (6).

8. Rear duct
Check ducts (12) and (13) for disconnection.

6. Remove rear covers (7) - (10).

a Disconnect connector (M04) for the cigarette
lighter from the back of cover (10).

9. Face duct and defroster duct

Check ducts (14) (20) for disconnection.
10. Fresh air duct
Check pin (P) and duct (21) for disconnection.
A: Packing

7. Foot duct
a Duct to under operator seat
1) Check duct (11) for disconnection.
2) Check the seal between duct (11) and cover
(11-1).
3) Remove duct (11) and cover (11-1).
4) Check that packing (A) is attached.
(See figure bottom)

80-30 HB205-1, HB215LC-1

(01)
 Air conditioner
Testing with self-diagnosis function

Testing with self-diagnosis function 80-31

Outline 80-31 How to enter air conditioner "Abnormality

On the air conditioner operation screen of the ma- Record" screen in service mode of machine
chine monitor, the system performs self-diagnosis monitor. 80-31
for the communication with the air conditioner unit,
temperature control, vent (mode) changeover and q Overview of machine monitor operating pro-
refrigerant pressure with the pressure switch, and if cedure
a problem is detected, the failure is displayed in red Normal screen
as "A/C Controller Error" O While pressing [4], press [1], [2], and [3] in this
order.
Service menu (Mode)
O Press [F3] once. Press [F6].
02 Abnormality Record
O Press [F3] twice. Press [F6].
03Air-conditioning System "Abnormality Record"
screen

q Detailed description of machine monitor op-

erating procedure
1. On the normal operation screen, while pressing
number key [4], press [1], [2], and [3] in this
order.
a Even if the cause of a detected problem is re-
stored to normal, the self-diagnosis failure condi-
tion will not automatically be reset. To reset the
failure condition, the starter switch must be set to
OFF.
a On the air-conditioning system abnormality
record screen that appears in service mode of
the machine monitor, the system performs
self-diagnosis for various sensors in addition to
the above items, and if a problem is detected,
screen displays it in red as "Abnormal."
a FRESH/RECIRC air changeover servomotor is
not checked with self-diagnosis function.

2. On the service menu screen, press [F3] (R)

once, and then select "02 Abnormality Record."

3. Press [F6] ( ) to confirm.

HB205-1, HB215LC-1 80-31

(01)
Air conditioner
Testing with self-diagnosis function
4. On the Abnormality Record screen, press [F3]
(R) twice, and then select "03 Air conditioning
System."
5. Press [F6] ( ) to confirm.
q Air Conditioning System Abnormality
Record screen: Information displayed in "03
Air Conditioning System"
(a): System or Component name
(b): Number of abnormality occurrence time
(c): Condition (Normal or abnormal)
(d): If the CAN communication condition is
displayed as being abnormal, it will indicate that
the air conditioner unit is disconnected and CAN
communication is not possible. Accordingly, the
display for the other (d) items will be cleared.
(e): If [E] is displayed to the left of the condition,
it indicates that the abnormality is ongoing or that
restoration to normal has not yet been detected.
[F2]: Clear "Abnormality Record"
[F5]: Return to Abnormality Record screen
q Clearing "Abnormality Record" on machine
monitor
While the "Abnormality Record" screen is
displayed, press [F2], and the number of occur-
rence time of abnormality is reset. If it is
confirmed at this time that the abnormality has
been reset, the trouble was resolved.
80-32
Caution
Inner Sensor means "inside temp. sensor" on
"system diagram " or "circuit diagram".
"Ventilating Sensor is abnormal" means that
evaporator temperature sensor is short circuit or
disconnected.
Sunlight Sensor is abnormal" meas that Sunlight
Sensor is short circuit only.
"Ventilation is abnormal" means servomotor for
vent changeover (mode) damper does not rotate
judging from the servomotor potentiometer
voltage.
a Damper is the same as door.
"Air Mix is abnormal" means servomotor for Air
Mix (temperature adjustment) damper does not
rotate judging from the servomotor potentiom-
eter voltage. "Refrigerant" means refrigerant
pressure from dual pressure switch. Namely,
"refrigerant is abnormal" means that dual pres-
sure switch of refrigerant is OFF.
1. CAN status: Abnormal
Normal communication is not possible between
the machine monitor and air conditioner
controller.
a Display of failure code [DAFRMC] CAN com-
munication failure (with engine controller) in-
dicates that the entire communication line
has failed. In this case, see failure code
[DAFRMC] in Chapter 40. If failure code
[DAFRMC] is not displayed, communication
failure is limited to between the controller and
the machine monitor alone.
In such a case, confirm whether connectors
AC01, CN-N10, [1], and [2] have been
disconnected. See item 2 from "Parts and
connectors layout." Alternatively, see "Trou-
bleshooting for power supply and CAN
communication system."
2. Setting : Abnormal
The air conditioner controller software and the
monitor software are not compatible. Confirm
the part number of each.
3. Inner sensor: Abnormal
a Inner Sensor is the same as inside temp.
sensor on "System diagram" or "circuit dia-
gram".
An open circuit or short circuit has been detected
between the air conditioner controller and the
inner sensor.
a Air conditioner controller remedy:
As it is not possible to use data from inner
sensor, control the air conditioner using only
the temperature setting in automatic air
conditioning mode.
HB205-1, HB215LC-1
(01)

a Trouble: Automatic air conditioner functions
do not work, but manual operations do.
a If an abnormality is detected in inner sensor,
see "Testing inner sensor."
4. Ventilating sensor: Abnormal
a Ventilating sensor means the evaporator
temperature sensor.
An open circuit or short circuit has been
detected between the air conditioner
controller and the evaporator temperature
sensor.
a Air conditioner controller remedy:
Output to the compressor is stopped.
a Trouble: The air conditioner does not
work.
a If an abnormality is detected in the venti-
lating sensor, see "Troubleshooting for
temperature sensor system."
5. Sunlight sensor: Abnormal
A short circuit has been detected between the air
conditioner controller and the sunlight sensor.
a Air conditioner controller remedy:
Control is carried out without referencing
sunlight sensor.
a Trouble: The automatic air conditioner does
not work when the machine is exposed to the
direct sunlight in the automatic air conditioner
mode.
a If an abnormality is detected in the sunlight
sensor, see "Testing sunlight sensor."
6. Ventilation: Abnormal
It has been determined based on the servo-
motor's potentiometer voltage that the servo-
motor for the vent (mode) changeover damper is
not operating.
a Damper is the same as door.
a Trouble: Vent is not changed over.
a Air conditioner controller remedy:
Output to the vent (mode) selection servo-
motor is stopped.
a Even if the link is disconnected and the
damper does not rotate, the self-diagnosis
system judges the damper normal since the
servomotor potentiometer voltage changes
normally.
a In the case of "Ventilation: Abnormal", see
"Testing vent (mode) changeover."
HB205-1, HB215LC-1
(01)
Air conditioner
Testing with self-diagnosis function
7. Air Mix: Abnormal
It has been determined based on the servo-
motor's potentiometer voltage that the servo-
motor for the air mix (temperature adjustment)
damper is not operating.
a Damper is the same as door.
a Trouble: The temperature control system
does not work.
a Air conditioner controller remedy:
Output to the air mix servomotor is stopped.
a Even if the link is disconnected and the
damper does not rotate, the self-diagnosis
system judges the damper normal since the
servomotor potentiometer voltage changes
normally.
a If an abnormality is detected in the Air Mix
(A/M) damper, repeat the temperature set-
ting 18.0 C (Max. cooling) io 32.0 C
(Max. heating) several times. If the A/M
damper abnormality count does not increase,
A/M damper is normal. (This abnormality po-
tentially happens at low temperature) When
the A/M damper abnormality count increas-
es, see "Troubleshooting for temperature
control."
8. Refrigerant: Abnormal
(Dual) pressure switch signal for refrigerant is
abnormal. Namely pressure switch for refrig-
erant is OFF.
a Trouble: The air conditioner does not work.
a Air conditioner controller remedy:
Output to the compressor is stopped.
k When replacing a pressure switch, refrig-
erant must be collected in advance. See
"Caution about refrigerant"
a If an abnormality is detected in the refriger-
ant, see "Testing (dual) pressure switch for
refrigerant."
80-33
Air conditioner
Testing temperature control

Testing temperature control 80-34

Outline 80-34 a State with cover (3) removed
q The air mix portion in air conditioner unit controls q A/C U: Air conditioner unit
temperature by changing the angle of four doors q CNT: Air conditioner controller
(dampers) and thereby changing the mixing ratio 2. Remove cover (4).
of hot air from heater and cold air from evapora- a Remove connectors H14 and H15 from clip
tor. The air mix servomotor changes the angle of on the back.
the doors (dampers) through plate (P1), lever 1
(L1) to lever 6 (L6) and rod (RODAM). Rod
(RODAM), lever 5 (L5) and lever 6 (L6) alone are
seen from outside. (See Item 5 for the figure)
a If lever 5 (L5) and lever 6 (L6) move smoothly
between COOLMAX and HOTMAX, you can
judge that plate (P1) and lever 1 (L1) to lever 4
(L4) are also operating normally.
a Control amplifier (CNTAMP) automatically con-
trols the temperature based on data from inner
sensor (inside air temperature sensor). There-
fore, movement between COOLMAX and HOT-
MAX is not available at the certain room
temperature.
a To reset the self-diagnosis system (to clear the 3. Check contact of connector [6] of air mix servo-
"A/C Controller Error" displayed on the air condi- motor (A/MS). (Check whether the connector is
tioner screen of the machine monitor), the start- coming off.)
ing switch must be turned OFF (While "A/C 4. Check rod (RODAM) for disconnection.
Controller Error" is displayed with self-diagnosis 5. Start the engine and turn the air conditioner
system, no signals are output to the servomo- power ON.
tor). 6. From the machine monitor's air conditioner oper-
1. Remove covers (1) - (3). ation screen, set the temperature to 18 C and
a Disconnect connector (M04) for the cigarette 32 C and visually check whether lever 5 (L5)
lighter from the back of cover (3). and lever 6 (L6) move smoothly between
COOLMAX and HOTMAX shown in the figure.
a See the next page for COOLMAX and HOTMAX.

80-34 HB205-1, HB215LC-1

(01)
 Air conditioner
Testing temperature control

a Plate (P1) and lever 1 (L1) to lever 4 (L4) are not
seen from outside.
q When lever 5 (L5) and lever 6 (L6) do not move
smoothly between the points shown in the figure:
1) Disconnect connectors (5) and [6] of the
servomotor.
2) Apply a match mark to the servomotors (5)
and (6) to identify later on which side they
were attached. (It might be required later to
install servomotors (5) and (6) after swapping
their mutual positions.)
3) Remove servo motors (5) and (6).
q MODES: Vent (mode) servomotor
q A/MS: Temperature control (air mix) ser-
vomotor
4) Remove cover (7).

5) Turn plate (P1) with your hand between

COOLMAX and HOTMAX to identify on
which of lever 1 (L1) to lever 6 (L6) hang-up
occurs, and correct the hang-up portion.
a If the levers do not move smoothly, clean
them and apply grease to the links.
2 Link: Molykote MH62 grease
(Toray, Dow Corning Corporation)
6) If movement of lever 1 (L1) to lever 6 (L6) is
normal when you have manually rotated
plate (P1) between COOLMAX and
HOTMAX, confirm whether the servomotors
are the cause of the trouble by installing
servomotors (5) and (6) swapping their
mutual positions and run them.
a For an electrical trouble, see "Trouble-
shooting for temperature control".

HB205-1, HB215LC-1 80-35

(01)
Air conditioner
Testing vent (mode) changeover

Testing vent (mode) changeover 80-36

Outline 80-36
The vent (mode) is selected by changing the angles
of the four doors (dampers) provided inside. The
servomotor changes the angles of the doors (damp-
ers) through plate (P2), rod for differential (RODD),
rod for front face (RODF) and lever 7 (L7) to lever 12
(L12). Rod for differential (RODD), rod for front face
(RODF), and levers 7 (L7) and 8 (L8) alone are seen
from outside. (See Item 5 for the figure.) Visually
check the opening and closing operation of the front
face and rear face doors (dampers) and the position
of these levers.
The servo motor changes the angle of the rear face
door (damper) through lever (13) and rod (RODR).
Lever (L11) of the front face, lever (13) of the rear
face and rod (RODR) are not seen from outside. Ac-
cordingly, remove the duct and check the rotation of
the door (damper) directly.
a To reset the self-diagnosis system (to clear the
"A/C Controller Error" displayed on the air condi-
tioner screen of the machine monitor), the start-
ing switch must be turned OFF (While "A/C
Controller Error" is displayed with self-diagnosis
system, no signals are output to the servomo-
tor).

1. Remove covers (1) - (4) by referring to "Testing

temperature control 1 and 2".
2. Check contact of connector [5] of the mode
servomotor (MODES). (Check whether the
connector is coming off.)
3. Check the defroster rod (RODD) and foot rod
(RODF) for disconnection.
4. Start the engine and turn the air conditioner
power ON.
5. Press the vent changeover switch on the air
conditioner operation screen of the machine
monitor and visually check that lever 7 (L7) and
lever 8 (L8) move smoothly between the foot
mode and differential mode.
6. Stop the engine.
7. Remove the rear face duct (RFD).
8. Referring to "Testing air leakage (duct)", remove
the ducts sequentially starting with the monitor
side up to the front face duct (FFD).

80-36 HB205-1, HB215LC-1

(01)
 Air conditioner
Testing vent (mode) changeover

9. Start the engine and turn the air conditioner

power ON.
10. Press the vent changeover switch on the air
conditioner operation screen of the machine
monitor, and visually check the opening and
closing movement of front face door (1) and rear
face door (damper) (2).

q When lever 7 (L7) and lever 8 (L8) do not move

smoothly between the points shown in the figure,
or when the front face door and rear face door do
not open:
1. Disconnect wiring connectors (5) and [6] of the
servomotor.
2. Apply a match mark to the servomotors (5) and
(6) to identify later on which side they were
attached. (It might be required later to install
servomotors (5) and (6) after swapping their
mutual positions.)
3. Remove servo motors (5) and (6).
4. Remove cover (7).

HB205-1, HB215LC-1 80-37

(01)
Air conditioner
Testing vent (mode) changeover

5. Turn plate (P2) with your hand to identify on

which lever 7 (L7) to lever 12 (L12) hang-up
occurs, and correct the hang-up portion.
a If the levers do not move smoothly, clean
them and apply grease to the links.
2 Link: Molykote MH62 grease (Toray,
Dow Corning Corporation)
6. If movement of lever 7 (L7) to lever 12 (L12) is
normal when you manually rotated plate (P2),
confirm whether the servomotor is the cause of
the trouble by installing servomotors (5) and (6)
swapping their mutual positions and run them.
a The figures in the foot mode and defroster
mode are shown before.
a For an electrical failure, see "Troubleshooting for
vent (mode) changeover."

a When increasing the set temperature from 18 C

to 32 C, position of the front face (F.Face) door
changes from "OPEN" to "HALF".

80-38 HB205-1, HB215LC-1

(01)
 Air conditioner
Testing FRESH/RECIRC air changeover

Testing FRESH/RECIRC air changeover 80-39

Outline 80-39 1) Remove covers (1) - (3) by referring to
FRESH/RECIRC air is selected by changing the "Testing temperature control 1".
door (damper) angle in the air conditioner unit with 2) Remove duct (4).
the servo motor. Check the opening and closing op- 3) Remove cover (5).
erations of the door (damper) visually. a Remove connectors H14 and H15 fixed
a The system does not have self-diagnosis func- on the back from the clip.
tion for FRESH/RECIRC air changeover servo
motor.
1. Remove recirculation air filter from behind the
operator seat.
2. Start the engine and turn the air conditioner
power ON.
3. Press the FRESH/RECIRC selector switch on
the air conditioner operation screen of the
machine monitor, and visually check the opening
and closing operation of the FRESH/RECIRC air
changeover door (damper) (F/RD).
4. If opening and closing of the FRESH/RECIRC
air changeover door (damper) (F/RD) is not
available, check the connection of connector [7] 4) Trace the routing of the air conditioner wiring
of the servomotor (F/RS) in the following way. harness (H) with your hand and check by
(Check whether the connector is coming off.) touch whether connector [7] of the
A: Recirculation air FRESH/RECIRC air changeover servomotor
B: Fresh air (F/RS) is connected. (Check whether the
connector is coming off.)
q [8]: Inside air temperature sensor connec-
tor
q [4]: Power transistor (PTR) connector

Reference
q How to remove fresh air duct.
1. Remove plate (6). (See the previous figure)

HB205-1, HB215LC-1 80-39

(01)
Air conditioner
Testing FRESH/RECIRC air changeover

2. Open fresh air filter cover (7).

3. Remove fresh air filter cover (8).

4. Remove pin (9) and remove fresh air duct (10).

a F/RD: FRESH/RECIRC air changeover door
(damper)

q FRESH/RECIRC air changeover servomotor

(F/RS) replacement procedure
a Remove the fresh air duct before starting the
replacement.
1. Disconnect connector [7]. (As mentioned earlier)
2. Disconnect connector [8] of inner sensor (inside
air temperature sensor) (12).
3. Remove box assembly (11).
4. Remove the FRESH/RECIRC air changeover
servomotor (F/RS) from box assembly (11).

a For an electrical trouble, see "Troubleshooting

for FRESH/RECIRC air changeover".

80-40 HB205-1, HB215LC-1

(01)

Testing inner sensor
a Inner sensor means inside (air) temperature
sensor.
q To reset the self-diagnosis system (detection of
abnormality), the starting switch must be turned
OFF.
1. Remove covers (1) - (4) by referring to "Testing
temperature control 1 and 2".
2. Check the contact of connector [8] of inner
sensor (12). (Check whether the connector is
coming off.)
3. Remove the fresh air duct by referring to "How to
remove fresh air duct" in "Testing
FRESH/RECIRC air changeover".
4. Remove box assembly (11) by referring to
"FRESH/RECIRC air changeover servomotor
(F/RS) replacement procedure" in "Testing
FRESH/RECIRC air changeover".
5. Standard resistance between terminals on
sensor side of connector [8]:
1.6 kz (at 0 C)
5 kz (at 25 C)
a Bottom of the air conditioner unit
[4]: Power transistor (PTR) connector
[7]: FRESH/RECIRC air changeover servo-
motor connector
[8]: Inner sensor (inside air temperature
sensor) connector
H: Air conditioner unit wiring harness
PTR: Power transistor
HB205-1, HB215LC-1
(01)
Air conditioner
Testing inner sensor
80-41
6. Disconnect connector [1] and [2] from the air
conditioner controller (CNT) by referring to 5 of
item 1 in "Testing evaporator temperature
sensor".
7. Ensure that the female terminals (on the wiring
harness side) of connector [8] are not being
shorted by each other. (If the terminals are
shorted, the wiring harness is defective.)
8. Confirm the resistance between the female
terminal of connector [8] (wiring harness side)
(2) (PB) and the terminal of connector [1] (wiring
harness side) (11) (PB): Max. 1 z. (If not, the
wiring harness is defective.)
9. Confirm the resistance between the female
terminal of connector [8] (wiring harness side)
(1) (BrR) and the terminal of connector [2] (wiring
harness side) (27) (BrR): Max. 1 z. (If not, the
wiring harness is defective.)
10. Connect all the connectors.
11. Turn the starting switch to ON position and if
"Inner sensor Abnormal" is still displayed with
self-diagnosis (on "03 Air conditioning System"
screen of "Abnormality Record" in the machine
monitor), replace the air conditioner controller.
80-41
Air conditioner
Testing evaporator temperature sensor

Testing evaporator temperature sensor 80-42

q When "Ventilating Sensor abnormal" is dis-
played by the self-diagnosis (on "03 Air-condi-
tioning System" screen of "Abnormality Record"
in the machine monitor), test the evaporator tem-
perature sensor.
q To reset the self-diagnosis system (detection of
abnormality), the starting switch must be turned
OFF.
1. Referring to testing temperature control 1,
remove covers (1) - (3).
2. Check the contact of connector (9). (Check
whether the connector is coming off.)
3. Remove connector (9).
4. Measure the resistance between the opponent
(female) of connector(9) and the terminal at
evaporator temperature sensor side. Standard
resistance:
4.8 kz (0 C)
2.3 kz (15 C)
a If error is detected with self-diagnosis and
evaporator temperature control sensor is
normal, air conditioner controller (CNT) or
wiring harness is defective.
5. Remove connectors [1], [2] from air conditioner
controller (CNT). (Connector [9] must be
connected.)
a If the evaporator temperature sensor is defec-
tive, replace it according to the following proce-
dure.
q Replacement of evaporator temperature sen-
sor
1. Referring to Shop Manual Chapter 50, "Removal
and installation of air conditioner unit assembly",
remove air conditioner unit assembly (A/CU).
2. Remove wiring harness. (For each connector,
see "Parts and connectors layout".)
3. Remove servo motors (2) and (3).
4. Remove cover (4).
5. Remove the link section. For details, see Shop
Manual, Chapter 80, Structure and function, "Air
conditioner unit".
6. Disconnect cases (5) and (6).

7. Remove the evaporator.

Standard resistance between terminal (11) (PB)

of connector [1] and terminal (27) (BrR) of
connector (2):
4.8 kz (0 C)
2.3 kz (15 C)
a If item 5 above is normal, the controller (CNT)
is defective. If item 5 above is abnormal and
item 4 is normal, wiring harness is defective.

80-42 HB205-1, HB215LC-1

(01)
 Air conditioner
Testing evaporator temperature sensor

8. Remove the holder from part (P) and remove the

evaporator temperature sensor.

Connection 80-43
1. Install the evaporator temperature sensor to the
position shown in the previous figure with the
holder.
2. Carry out the following installation in the reverse
order to removal.

HB205-1, HB215LC-1 80-43

(01)
Air conditioner
Testing sunlight sensor
Testing sunlight sensor
q When "Sunlight Sensor Abnormal" is displayed
by the self-diagnosis (on "03 Air conditioning
System" screen of "Abnormality Record" in the
machine monitor), test sunlight sensor connec-
tor P31.
q To reset the self-diagnosis system (detection of
abnormality), the starting switch must be turned
OFF.
a If sunlight sensor (S) is mesured with resistance
range of tester, sunlight sensor may be de-
stroyed, so do not measure with resistance
range of tester.
1. Remove cap (1).
2. Remove cover (2) and check the connector P31
(3) for sunlight sensor (S), which is located on
back side of the cover. (Check whether the
connector is coming off.)
3. Disconnect connector P31, and using a tester
set to the voltage range, measure the voltage
between the male side terminals on sunlight
sensor (S).
q Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
80-44
80-4
4. Referring to item 2 of "Parts and connectors
layout", disconnect connector [1] from the air
conditioner controller.
5. Ensure that the female terminals of the
connector P31 (wiring harness side) are not
being shorted. (If the terminals are shorted, the
wiring harness is defective.)
6. Confirm the resistance between the female
terminal of connector P31 (wiring harness side)
(2) (YW) and the terminal of connector [1] (wiring
harness side) (15) (YW): Max. 1 z.
(If not, the wiring harness is defective.)
a If the result of item 6 or item 7 is abnormal,
check the contact of connector CN-AC01.
(See "Parts and connectors layout".)
7. Confirm the resistance between the female
terminal of connector P31 (wiring harness side)
(1) (RB) and the terminal of connector [1] (wiring
harness side) (3) (RB): Max. 1 z. (If not, the
wiring harness is defective.)
8. Connect all the connectors.
9. Turn the starting switch to ON position, and if
"Sunlight Sensor Abnormal" is still displayed
with self-diagnosis (on "03 Air conditioning
System" screen of "Abnormal Record" in the
machine monitor), replace the air conditioner
controller.
HB205-1, HB215LC-1
(01)

Testing (dual) pressure switch for refrigerant
q When "Refrigerant Abnormal" is displayed by
the self-diagnosis (on "03 Air-conditioning Sys-
tem" screen of "Abnormality Record" in the ma-
chine monitor), test the dual pressure switch
connector P17.
q To reset the self-diagnosis system (detection of
abnormality), the starting switch must be turned
OFF.
q The dual pressure switch is ON when the refrig-
erant pressure is normal and OFF when it is ab-
normal.
a As the refrigerant pressure will drop when the
ambient temperature is below 0 C, there is a
possibility that the dual pressure switch is
OFF. In such a case, the dual pressure
switch is actually normal (I.e., not defective).
1. Remove cover (1).
2. Disconnect dual pressure switch connector P17.
HB205-1, HB215LC-1
(01)
Air conditioner
Testing (dual) pressure switch for refrigerant
80-45
3. Ensure that the resistance between the
switch-side terminals from connector P17 is
shorted (ON). (If not shorted (OFF), the dual
pressure switch will detect a refrigerant pressure
abnormality.)
a When the pressure switch is OFF, connect a
pressure gauge to the high pressure side of
the air conditioner compressor and check the
refrigerant pressure. See "Connection of ser-
vice tool" and "Troubleshooting with gauge
pressure."
a If refrigerant pressure is normal, the pressure
switch is defective.
q (Dual) pressure switch
LA: 0.20 MPa {2 kg/cm2}
LB: 0.20 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-45
Air conditioner
Testing (dual) pressure switch for refrigerant

k When replacing the pressure switch, refriger-

ant must be collected in advance.
q If resistance between the switch-side terminals
of connector P17 is shorted (ON): (See "Trouble-
shooting for the compressor and refrigerant sys-
tem" for the circuit diagram.)
1. Referring to item 1 and 5 of testing evaporator
temperature sensor, disconnect connector [1]
from air conditioner controller (CNT).
2. Confirm the resistance between the female
terminal of the connector P17 (wiring harness
side) (2) (B) and the machine ground: Max. 1 z.
(If not, the wiring harness is defective.)
3. Confirm the resistance between the female
terminal of the connector P17 (wiring harness
side) (1) (GB) and the terminal of connector [1]
(wiring harness side) (4) (GB): Max. 1 z. (If not,
the wiring harness is defective.)
a If the result of item 3 is abnormal, check the
contact of connector CN-AC01. (See "Parts
and connectors layout". )
4. Connect all the connectors.
5. Turn the starting switch ON and if "Refrigerant
abnormal" is still displayed with self-diagnosis
(on "03 Air-conditioning System" screen of
"Abnormality Record" in the machine monitor),
replace the air conditioner controller.

80-46 HB205-1, HB215LC-1

(01)

Testing relays
a If the air conditioner compressor is normal (air is
cooled) and air comes out, the relays are normal.
Accordingly, the test can be omitted.
a Listen closely to the relay to check whether or
not it is defective.
There are two relays.
q Blower main relay R20:
Turning the fan motor ON/OFF
q Compressor clutch relay R21:
Used to turn the air conditioner compressor
(clutch) ON/OFF
1. Remove covers (1) - (3) by referring to "Testing
temperature control 1".
2. Check the connections of connectors R20 and
R21. (Check whether the connectors are coming
off.)
3. Turn the starting switch ON (do not start the
engine) and turn the main power of the air condi-
tioner ON. If the blower main relay (BRL) is
normal, it is turned ON. Check its click.
4. If the air conditioner switch is turned ON at this
time, the compressor relay is turned ON if it is
normal. Check its click.
a The air conditioner controller (CNT) will not
turn on the compressor relay (CCRL) in the
following cases.
1) When the evaporator temperature is below
3 C (depending on the input voltage from
the evaporator temperature sensor).
2) When the pressure switch detects abnor-
mality (it is turned OFF).
a If the sound produced by the compressor relay
(CCRL) cannot be heard due to the sound of the
fan, turn the starting switch off temporarily and
disconnect the connector R20 before starting the
operation.
HB205-1, HB215LC-1
(01)
Air conditioner
Testing relays
80-47
q Checking relay unit
a Since no T-adapter is available, it is impossible
to check the relay while the voltage is applied to
the coil actually.
Blower main relay (BRL), connector (R20)
1) The coil resistance between terminals (1)
and (2) is 140 340 z.
2) While the voltage (20 - 30 VDC) is not applied
between terminals (1) (+) and (2), terminals
(3) and (4) are disconnected and terminals
(3) and (5) are connected.
3) While the voltage (20 - 30 VDC) is applied
between terminals (1) (+) and (2), terminals
(3) and (4) are connected and terminals (3)
and (5) are disconnected.
Compressor clutch relay (CCRL), connector (R21)
1) The coil resistance between terminals (1)
and (3) is 140 340 z.
2) While the voltage (20 - 30 VDC) is not applied
between terminals (1) (+) and (3), terminals
(2) and (4) are disconnected.
3) While the voltage (20 - 30 VDC) is applied
between terminal (1) (+) and (3), terminals
(3) and (4) are connected.
80-47
Air conditioner
Troubleshooting chart 1

Troubleshooting chart 1 80-48

The numbers in the boxes are the item numbers in the troubleshooting table.

1. Cooling trouble 80-48

80-48 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting chart 1

2. Heating trouble 80-49

HB205-1, HB215LC-1 80-49

(01)
Air conditioner
Troubleshooting chart 2

Troubleshooting chart 2 80-50

1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
a See "Troubleshooting of blower motor system (Air does not come out or air flow is abnormal)".
Probable cause Check method Remedy
Defective blower main relay See "Testing relays" Replace
Check connector of blower fan motor for disconnection. Repair broken parts
Wire breakage or defective con-
See "Detail of air conditioner unit" and "Parts and connectors and connect cor-
nection
layout". rectly
See "Troubleshooting of blower motor system" and "Parts and
Defective blower fan motor Replace
connector layout".
Operate the fan switches in order and check the fan speed.
Defective power transistor (PTR) Replace
See "Troubleshooting the blower motor system."

2. During cooling, the blower fan motor is normal but the flow of air is very light.
Probable cause Check method Remedy
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check duct joints.
Air leakage through duct joints Repair
See "Testing air leakage (duct)".
Remove obstruc-
Obstruction at evaporator inlet Check evaporator for stain and obstruction
tion and clean
Evaporator is frozen.
Defective evaporator tempera-
Sensor fixing clip inspection, sensor contaminated
ture sensor, defective contact of
Inspect the air conditioner hose around the pressure switch for Repair or replace
evaporator temperature sensor,
frost.
defective expansion valve*
(when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.

3. Pressure abnormality (high-pressure/low-pressure) during cooling.

Probable cause Check method Remedy
Repair leaking part,
then charge with
Insufficient refrigerant
proper quantity of
Check the refrigerant volume through sight glass.
refrigerant again
Specifically, perform checking with the gauge manifold con-
Collect refrigerant,
nected.
then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2} See Troubleshoot-
Judgment by pressure at
High pressure: Approx. 1.5 - 1.7 MPa {15 17 kg/cm2} ing with gauge pres-
inlet/outlet of compressor
Temperature in operator's cab: 30 to 35 C, Engine speed: sure
Approx. 1,500 rpm

80-50 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting chart 2

4. During cooling, the compressor cannot operate easily or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled part Probable cause Check method Remedy
Compressor
Slack of belt Deflection of belt is large. Adjust tension
belt
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling com-
Heating of compressor
Seizing on compressor pressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 - 20 z) Replace
Magnet clutch Check ground wire and connections
Wire breakage or defective con-
See "Troubleshooting for compressor and Repair
nection of ground wire
refrigerant system".
Relay Defective compressor clutch relay See "Testing relays" Replace
Refrigerant Low/high pressure (Operation of See "Troubleshooting
See "Troubleshooting with gauge pressure".
pressure pressure switch) with gauge pressure".
Pressure See "Troubleshooting for compressor and
Defective pressure switch Replace
switch refrigerant system".

5. During heating, blower fan motor is normal but air flow alone is insufficient.
Probable cause Check method Remedy
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check the duct joints by referring to "Testing air leakage
Air leakage through duct joints Repair
(duct)."
Clogging of heater core fins Check heater core fins for clogging Clean

6. Engine coolant temperature or volume abnormalities during heating or cooling

Probable cause
Low engine coolant tempera-
ture
Low engine coolant level
Insufficient circulation of engine
coolant
The connection of IN and OUT
heater hoses is in reverse.
Check method Remedy
Warm up engine, and then check engine coolant temperature Find out cause
Check coolant level in radiator Add coolant
Check engine coolant piping for clogging
Bleed air and correct
(Hose, pipe, and core)
Check the destination of heater hoses Correct

7. Fan speed abnormalities during cooling

Probable cause Check method Remedy
See "Testing and adjusting of Air conditioner compressor belt
Fan speed is low tension" in the "Testing and adjusting" of Chapter 30 of the Correct
shop manual.

8. Other abnormalities
Probable cause
Temperature cannot be con-
trolled
Vent (mode) changeover is not
possible.
FRESH/RECIRC air cannot be
changed over
Excessive compressor oil
Water leakage into the cab
Check method Remarks
See "Testing temperature control" and "Troubleshooting for
temperature control"
"Testing vent (mode) changeover" Common to cooling and
See "Troubleshooting vent (mode) changeover." heating
See "Testing FRESH/RECIRC air changeover" and "Trouble-
shooting for FRESH/RECIRC air changeover"
See "Handling compressor oil".
Cooling only
Clogging of drain hole

HB205-1, HB215LC-1 80-51

(01)
Air conditioner
Information in troubleshooting table

Information in troubleshooting table 80-52

Information in troubleshooting table 80-52
a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
Failure Problem on machine
Related information Information related to detected failure or troubleshooting
Cause Procedure, measuring location, criteria and remarks
<Information described>
q Procedure
q Measuring location
1 a "Between A B" means Measure voltage or resistance and so on between A and B".
Probable causes of q Standard value in normal condition to judge probable causes
failure q Remarks required for judgement
(Perform trouble-
shooting according <Notes on troubleshooting>
to these.) (1) Pin number description sequence and tester lead handling
2 For troubleshooting, connect the plus (+) and minus () tester leads as shown below unless
otherwise specified.
q Connect the plus (+) lead to a pin or harness indicated in the front.
q Connect the minus () lead to a pin or harness indicated in the rear.
(2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time - defective shown at left is applied
3 - defective

a If a wiring harness is burnt, replace it.

<Defective wiring harness>
q Open circuit
Connection of connector is defective or wiring harness is broken.
q Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
q Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
q Short circuit
An independent wire in the harness abnormally comes into contact with one of another wire. (Defective
insulation in connector or others)

Related circuit diagram 80-52

This is the excerpted circuit diagram related to failure
q Indicates connector No., and pin No.
q See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for connector location
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb:
Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
q N.C.: Normally closed (Normally ON)
q [1], [2], are numbers of unlabeled connectors.
q Arrow (?): Roughly indicates their mounting place on the machine.

80-52 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)

Troubleshooting for power supply and CAN communication system (Air

conditioner does not operate) 80-53
Air conditioner does not operate due to failure in power supply system or CAN communication sys-
Failure
tem.
Problem on q "A/C Controller Error" is displayed in red on air conditioner operation screen of machine monitor.
machine q No air blows out (Blower motor does not rotate).
q If a failure code or [DAFRMC] error is displayed on the machine monitor, see first of all Chapter 40
and troubleshoot it.
a The machine monitor, engine controller, pump controller, and air conditioner controller are connect-
ed via CAN communication.
q In the following cases, "A/C Controller Error" will be displayed in red on the machine monitor's air
conditioner operation screen. Of these, 1), 2), and 3) will be covered below.
1) The air conditioner controller is receiving no power.
2) The air conditioner controller is malfunctioning.
3) No communication is possible between the air conditioner controller and the machine monitor.
4) Vent (mode) door (damper) servomotor does not rotate.
5) Temperature control (Air Mix) door (damper) servomotor does not rotate.
6) Refrigerant pressure is abnormal.
Related infor- q Referring to "Testing with self-diagnosis function", display the air conditioning system abnormality
mation record screen on the machine monitor and check condition of CAN communication. Abnormality in
CAN communication denotes that CAN communication is disabled between the air conditioner con-
troller behind the air conditioner unit and the machine monitor.
CAN Status is indicated as abnormal in any case of 1), 2) and 3) above.
q Referring to "Parts and connectors layout", ensure that No. 11 fuse (20A) of fuse box F01 and Fu5A
fuse of the air conditioner wiring harness are not blown.
q Ground cable of air conditioner is connected in machine wiring harness together with electrical
equipment of machine.
q For each connector, see "Parts and connectors layout".
q In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for compres-
sor and refrigerant system."
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is not prepared for other connectors.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative () terminal of the battery.
3. Disconnect connector [1] from the air conditioner controller, and connect
1 Defective wiring harness (ground)
the T-adapter to the harness side.
Between (16) (black) on the harness side of connector
Resistance Max. 1 z
[1] and the chassis ground
1. Turn starting switch to OFF position.
2. Referring to "Parts and connectors layout", confirm that No. 11 fuse (20 A)
2 Blown fuse
of fuse box F01 and the Fu5A fuse of the air conditioner wiring harness are
not blown.

HB205-1, HB215LC-1 80-53

(01)
Air conditioner
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)

Cause Procedure, measuring location, criteria and remarks

3 Defective harness
Ground fault in wiring harness
4
(contact with ground circuit)
5 Open circuit in wiring harness
a If fuse described in related information is blown, replace it.
1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative () terminal of the battery.
3. Disconnect connector [1] from the air conditioner controller, and connect
the T-adapter on the wiring harness side.
4. Turn starting switch to ON position.
Between wiring harness side (6) (red) and
Voltage 20 30 V A
(16) (B) of connector [1]
a If fuse is blown again in test A above, perform following procedure.
(Replace blown fuse )
1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative () terminal of the battery.
3. Disconnect connector [1] of the air conditioner controller, and connect the
T-adapter on the wiring harness side.
a If the fuse is blown again in the above test A and both B and C below are
normal, it is likely that the cause of the problem lies within the blower motor
circuit. In such a case, see "Troubleshooting the blower motor system."
Between wiring harness side (6) (red) and
Resistance Min. 1 Mz B
(16) (black) of connector [1]
Between (6) (red) on the harness side of
Resistance Min. 1 Mz C
connector [1] and the chassis ground
a If fuse is blown again in test A for cause 3 and result of B or C is abnormal,
identify wiring harness having ground fault.
1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative () terminal of the battery.
3. Disconnect connectors AC01, N10, and [1].
4. Connect the T-adapter to the harness side of connector [1], and connect the
T-adapter to the harness side.
a Abnormality in D or E below: Short circuit in the air conditioner wiring har-
ness
a Abnormality in F or G below: Short circuit in the chassis wiring harness
Between wiring harness side (6) (red) and
Resistance Min. 1 Mz D
(16) (black) of connector [1]
Between (6) (red) on the harness side of
Resistance Min. 1 Mz E
connector [1] and the chassis ground
Between connector N10 (female) (4) and
Resistance Min. 1 Mz F
AC01 (female) (4) (black)
Between connector AC01 (female) (5)
Resistance Min. 1 Mz G
(red) and (4) (black)
a If none of the fuses described in the related information is blown and an ab-
normality is recorded for cause 3 A, check the circuit relating to circuit dia-
grams.

80-54 HB205-1, HB215LC-1

(01)

Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Cause
Open circuit in CAN communica- ness side of connector [2]
tion line
6 (Communication is not possible
between the machine monitor and
the air conditioner controller.)
7 Defective air conditioner controller
8 Defective machine monitor
HB205-1, HB215LC-1
(01)
Air conditioner
Procedure, measuring location, criteria and remarks
a When short circuit or ground fault occurs in CAN communication line, a
[DAFRMC] error is displayed.
a Terminating resistor: Terminating resistors of approximately 120 z are pro-
vided inside the machine monitor and engine. Since they are connected in
parallel, the combined resistance is approximately 60 z.
1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative () terminal of the battery.
3. Disconnect connectors [1] and [2] from the air conditioner controller, and
connect the T-adapter to the harness side.
Between (17) and (18) on the wiring har- Approx.
Resistance H
60 z
a If result H above is abnormal, perform following procedure.
a If an abnormality is recorded for H above and J below, the cab harness is
defective.
a If an abnormality is recorded for H above but J below is normal, the air con-
ditioner harness is defective.
a Terminating resistor: Terminating resistors of approximately 120 z are pro-
vided inside the machine monitor and engine. Since they are connected in
parallel, the combined resistance is approximately 60 z.
1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative () terminal of the battery.
3. Disconnect connectors [1] and [2] from the air conditioner controller, and
connect the T-adapter to the harness side.
Between (male) (1) and (2) of connector Approx.
Resistance J
N10 60 z
If results of cause 1 and cause 2, 3 A, and 6 H are normal, replace the air con-
ditioner controller.
If no abnormality is found in the checkup of potential causes 1 - 7, the machine
monitor is defective.
80-55
Air conditioner
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)

Circuit diagram related to power supply and CAN communication 80-56

80-56 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting for compressor and refrigerant system (Air is not cooled)

Troubleshooting for compressor and refrigerant system (Air is not

cooled) 80-57
Failure Air is not cooled due to compressor or refrigerant system failure.
q When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air
is not cooled as displayed on screen.
q Air conditioner compressor does not operate.
Problem on q A/C Controller Error may be displayed in red on air conditioner operation screen of machine mon-
machine itor.
There are 6 cases, items 1) to 6), of the information relevant to "Troubleshooting for power supply
and CAN communication system". As for 1) through 3), see "Troubleshooting for the power supply
and CAN communication system."
The following description deals with item 6), refrigerant pressure abnormality.
q Referring to "Testing with self-diagnosis function", display air conditioner abnormality record screen
on machine monitor and check to see if refrigerant pressure is abnormal. If refrigerant pressure is
abnormal, compressor is not turned ON and air is not cooled consequently.
Related infor- a Abnormal refrigerant pressure indicates that "Signal (connector [1] (4)) from pressure switch is not
mation grounded".
q In certain cases, the air conditioner will not turn on at 3 C or lower (normal).
q For each connector and fuse, see "Parts and connectors layout".
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is provided only for connectors [1], [2], and AC02.

Cause Procedure, measuring location, criteria and remarks

1 Defective pressure switch
Defective air conditioner com-
2
pressor
3 Open circuit in wiring harness
a When "A/C Controller Error" is displayed in red on air conditioner operation
screen of machine monitor, perform following procedure.
1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative () terminal of the battery.
3. Disconnect pressure switch connector P17.
a In certain cases, the pressure switch may be operating normally and set to
OFF, therefore, if a failure is recorded for the following (i.e., switch OFF), at-
tach a pressure gauge to the air conditioner compressor and check the re-
frigerant pressure. (See "Troubleshooting with gauge pressure.")
Between (1) and (2) of connector P17 (male) Resistance Max. 1 z
k Before replacing pressure switch, collect refrigerant.
1. Turn starting switch to OFF position.
2. Disconnect the connector AC02 from the air conditioner compressor and
connect a T-adapter to the male side.
a Ensure connection of air conditioner compressor ground cable (E).
(See "Parts and connectors layout".)
Between connector AC02 (male) (1) and the
Approx.
machine ground (i.e., air conditioner compressor Resistance
15 z
coil resistance)
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and R21, and troubleshoot in that condition.
a Ensure that test result for cause 1 (pressure switch ON) and cause 2 (air con-
ditioner compressor normal) are both normal.
Between connector [1] (4) and the chassis ground
Resistance Max. 1 z
(Pressure switch is turned ON)
Between connector R21 (female) (2) and the chas-
Approx.
sis ground Resistance
15 z
(Air conditioner compressor coil resistance)

HB205-1, HB215LC-1 80-57

(01)
Air conditioner
Troubleshooting for compressor and refrigerant system (Air is not cooled)

Cause Procedure, measuring location, criteria and remarks

q Referring to "Testing relays", check sound when compressor clutch relay is
turned ON.
a If blower sound is too large to hear the sound when compressor clutch relay
is turned ON, turn starting switch OFF temporarily and disconnect connector
R20.
Click is heard. A
a If A above and B below are abnormal and C is normal (relay is normal), go
to causes 7 and 8.
1. Turn starting switch to OFF position.
Defective compressor clutch relay
4 2. Disconnect connector R21.
(does not turn ON)
3. Use a wire to short-circuit (2) (white) and (4) (blue on red) of connector R21
(wiring harness side) . (This forces the compressor to operate without using
the relay.)
4. Turn starting switch to ON position.
Air is cooled. B
1. Turn starting switch to OFF position.
2. Disconnect connector R21 and troubleshoot in that condition.
Between (1) and (3) of connector R21 Approx. 140 -
Resistance C
(male) (i.e., coil resistance) 340 z
a If the fuse is not blown, skip troubleshooting.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors R21 and AC02, and connect a T-adapter to the
5
(contact with ground circuit) female side of AC02.
Between M34 (female) (1) and chassis ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors R21, [1] and [2], and then connect the T-adapter to
[1] and [2] on the wiring harness side.
6 Short circuit in wiring harness
a Ensure that test result for cause 2 is normal.
Between wiring harness side (6) of connector [1]
Resistance Min. 1 Mz
and wiring harness side (35) of connector [2]
7 Open circuit in wiring harness a See circuit diagram and inspect.
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter to the harness
side.
Defective air conditioner control- 3. Turn starting switch to ON position.
8
ler 4. Display the air conditioner operation screen on the machine monitor and
press the A/C switch.
Between connector [2] (35) and connector [1] (16) Voltage Max. 1 V
1. Turn starting switch to ON position.
Defective machine monitor 2. Display the air conditioner operation screen on the machine monitor.
9
(defective switch)
Press A/C switch. "A/C ON" is displayed

80-58 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting for compressor and refrigerant system (Air is not cooled)

Circuit diagram related to compressor and pressure switch for refrigerant 80-59

HB205-1, HB215LC-1 80-59

(01)
Air conditioner
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)

Troubleshooting for blower motor system (No air comes out or air flow
is abnormal) 80-60
Failure No air comes out or air flow is abnormal due to blower motor system failure.
q LCD of machine monitor on air conditioner operation screen lights up normally but air does not come
Problem on
out.
machine
q Air flow does not match fan switch setting on air conditioner operation screen.
q This failure is not checked with self-diagnosis function.
q In cases where the blown-air volume begins to behave in an unpredictable manner after a certain
while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1) Defective compressor clutch relay (i.e., stuck in ON position) (see item 4 A from "Trouble-
shooting for compressor and refrigerant system")
2) Evaporator temperature sensor mounting holder has come off. (Remove and disassemble air
conditioner unit.)
3) Incorrect adjustment of the expansion valve. (Remove air conditioner unit and replace expan-
sion valve.)
Related infor-
q If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
mation
q For each connector, relay, and power transistor, see "Parts and connectors layout".
a Since the power transistor is located at the bottom of the air conditioner unit, its troubleshooting or
troubleshooting by disconnecting connector (4) is not available as long as it is installed on the ma-
chine.
q In cases where air is discharged but with unpredictable volumes even during heating, the power
transistor has failed, and therefore, the air conditioner unit must be replaced.
a The power transistor and blower motor cannot be replaced unless the air conditioner unit is once
removed.
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is not prepared for other connectors.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector [3], and troubleshoot in that condition.
1 Defective blower (fan) motor
Between wiring harness terminals at blower motor
Continuity
side of connecter [3]
q Referring to "Testing relay", check sound when Click is
A
blower main relay is turned ON. heard.
a When A above is abnormal and B below is abnormal and C is normal (if relay
is normal), go to cause 3.
1. Turn starting switch to OFF position.
2. Disconnect connector R20.
3. Using a wire, cause short-circuit between (wiring harness side) (3)
(red/yellow) and (red/blue) of connector R20 (This forces ON without using
the relay.)
Defective blower main relay
2 4. Turn starting switch to ON position.
(Does not work)
Air comes
Operate fan on air conditioner operation screen. B
out.
a If air does not come out even when blower motor is turned ON forcibly without
using relay, cause is part other than relay.
1. Turn starting switch to OFF position.
2. Disconnect connector R20 and troubleshoot in that condition.
Between (1) and (2) of R20 (relay Approx. 140
Resistance C
side) (coil resistance) 340 z

80-60 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors [1], [2], and [3], and then connect T-adapter to [1] on
the wiring harness side.
Between (8) and (16) on the harness side of con- Approx.
Resistance
nector [1] (power transistor's internal resistance) 11 kz
Between connector [1] (wiring harness side) (7) and
Open circuit in wiring harness or Approx.
connector [3] (female) (2) (power transistor's inter- Resistance
3 defective power transistor 2.2 kz
nal resistance)
(replace the air conditioner unit)
Between connector [1] (wiring harness side) (8) and Approx.
Resistance
ground (power transistor's internal resistance) 11 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors R20 and [3].
Between R20 (female) (3) and [3] (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors R20, [1] and [2], and then connect T-adapter to [1] on
wiring harness side.
Between (16) and (7) on the wiring harness side of
Resistance Min. 1 Mz
connector [1]
4 Short circuit in wiring harness Between wiring harness side (16) of connector [1]
Resistance Min. 1 Mz
and wiring harness side (36) of connector [2]
Between (2) and (1) on wiring harness side of con-
Resistance Min. 1 Mz
nector R20.
Between (6) and (7) on the wiring harness side of
Resistance Min. 1 Mz
connector [1]
q Blower motor input voltage
1. Turn starting switch to OFF position.
2. Disconnect connector [3].
3. Turn starting switch to ON position.
4. Press fan switch on air conditioner operation screen. (Air flow may be set to
any position.)
a If abnormal, go to cause 7.
Between (1) (red/yellow) on the wiring harness side
Check of input and output volt- of connector [3] and the chassis ground Voltage Approx. 24 V
5
ages
q Power transistor voltage
1. Turn starting switch to OFF position.
2. Insert T-adapter to connector [1]
3. Turn starting switch to ON position.
4. Press fan switch on air conditioner operation screen. (Air flow may be set to
any position.)
Approx. 24 V
Between (7) and (16) of connector [1] Voltage D
*1
If no abnormality is found in the checkup of potential causes 5-D and 7 (motor
6 Defective blower (fan) motor
does not run though the voltage is normal), the blower (fan) motor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
Defective air conditioner control- 4. Press fan switch on air conditioner operation screen. (Air flow may be set to
7 any position.)
ler
Between (36) of connector [2] and (16) of connector
Voltage Max. 1 V
[1]
Between (8) and (16) of connector [1] Voltage Max. 2 V
1. Turn starting switch to ON position.
2. Display the air conditioner operation screen on the machine monitor.
Defective machine monitor
8
(defective switch) LCD display of air flow
Press the fan switches from MIN to MAX
changes from MIN to MAX.

*1: When Blower main relay is turned ON

HB205-1, HB215LC-1 80-61

(01)
Air conditioner
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)

Circuit diagram related to blower motor 80-62

80-62 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting for temperature control

Troubleshooting for temperature control 80-63

Failure q Temperature cannot be controlled
q "A/C Controller Error" may be displayed in red on air conditioner operation screen of the machine
Problem on monitor. (See "Troubleshooting for power supply and CAN communication system.")
machine q While air conditioner operation screen of machine monitor is displayed, temperature does not
change even if temperature control switch is operated.
a Temperature control means Air Mix of cooled air and hot air.
q Referring to "Testing with self-diagnosis function", display "03 Air conditioning system" screen of
"Abnormality Record" of the machine monitor and check whether an "Air Mix" or "Inner sensor" ab-
normality has occurred.
In the case of "Inner sensor Abnormal", see "Testing inner sensor".
q In the case of "Air Mix damper Abnormal", repeat the temperature setting 18.0 C (Max. cooling)
io32.0 C (Max. heating) several times. If the Air Mix damper Abnormal count does not increase,
Air Mix damper is normal. (This abnormality potentially happens only at low temperature.)
q When rod etc. is disconnected (See Testing temperature control (Air Mix)), if current is supplied
to air mix servomotor by operating switches and potentiometer in servomotor reaches normal volt-
age, self-diagnosis function judges system normal.
Related infor-
q Referring to Testing temperature control (Air Mix), check that there is not contact of connector [6]
mation
or mechanical trouble (coming off or interference of link, etc.)
q Air Mix servomotor and air vent (mode) servomotor are same part number. Operating angle of tem-
perature control (Air Mix) is less, however. Accordingly, do not test servomotor to see if it rotates
by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomo-
tor and vent (mode) servomotor to see if they are normal.
q Air Mix servomotor can be checked for failure by connecting new servomotor to connector [6] and
see if it operates normally.
q For each connector, see "Parts and connectors layout".
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a Since T-adapters are not prepared for other connectors, check the signals while the air conditioner
controller is in operation.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector [6], and troubleshoot in that condition.
Between (6) and (7) (servomotor side) of connector 400
Resistance
Defective air mix servomotor (unit [6] (There must not be open circuit or short circuit.) 3000 z
1
test) Between (1) and (3) (servomotor side) of connector
Resistance 4 - 8 kz
[6] (There must not be open circuit or short circuit.)
Between (1) and (5) (servomotor side) of connector
Resistance 4 - 8 kz
[6] (There must not be open circuit or short circuit.)

HB205-1, HB215LC-1 80-63

(01)
Air conditioner
Troubleshooting for temperature control

Cause Procedure, measuring location, criteria and remarks

Defective air mix servomotor or
2 defective air conditioner wiring har-
ness
Defective air conditioner wiring
3
harness
4 Defective air conditioner controller
Defective machine monitor
5
(defective switch)
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
Between connector [1] (3) and connector [2] (27) Voltage 5V
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
4. Operate the temperature control switch on air conditioner operation screen
and prepare by setting to COOL MAX.
5. Operate the temperature control switch on air conditioner operation screen
and set to HOT MAX.
a Voltage will be output between connector [2] (24) and [2] (23) for approxi-
mately 3 seconds (only while door moves).
a The voltage will be vary between connectors [1](2) and [2](27) for approxi-
mately 3 seconds (only while door moves). (When the door stops, the volt-
age will stabilize.)
Between (21) (+) and (22) () of connector [2]
Approx. 24
a If temperature is changed from HOT MAX to Voltage
V
COOL MAX, voltage polarities are reversed.
Between connector [1] (2) (+) and connector [2] (22) Variable
Voltage
(-) max. 5 V
a When test result for cause 1 is normal and that for cause 2 is abnormal, per-
form following procedure.
Check with circuit diagram.
a When test result for cause 1 is normal and that for cause 2 is abnormal and
that for cause 3 is normal, air conditioner controller is defective.
1. Turn starting switch to ON position.
2. Display the air conditioner operation screen on the machine monitor.
LCD display changes
Press temperature control switch.
from 18 to 32 C.

80-64 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting for temperature control

Circuit diagram related to temperature control 80-65

a Servomotors are common.

HB205-1, HB215LC-1 80-65

(01)
Air conditioner
Troubleshooting for vent (mode) changeover

Troubleshooting for vent (mode) changeover 80-6

Failure q Vent (mode) cannot be changed over.
q "A/C Controller Error" is sometimes displayed in red on the air conditioner operation screen of ma-
Problem on
chine monitor. (See "Troubleshooting for power supply and CAN communication system")
machine
q When vent selector switch of machine monitor is operated, vent does not change over.
q Referring to "Testing with self-diagnosis function", display Air Conditioning System Abnormality
Record screen on machine monitor and check to see if vent damper is abnormal.
q When rod etc. is disconnected (See Testing vent (mode) changeover), if current is supplied to
vent (mode) servomotor by operating switches and potentiometer in servomotor reaches normal
voltage, self-diagnosis function judges system normal.
q Referring to "Testing vent (mode) changeover", check that there is not contact of connector [5] or
mechanical trouble (coming off or interference of link, etc.).
q Air Mix servomotor and vent (mode) servomotor are same part number. Operating angle of temper-
Related infor-
ature control (Air Mix) is less, however. Accordingly, do not test servomotor to see if it rotates by
mation
connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor
and vent (mode) servomotor to see if they are normal.
q Vent servomotor can be checked for failure by connecting new servomotor to connector [5] and see
if it operates normally.
q For each connector, see "Parts and connectors layout".
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a Since T-adapters are not prepared for other connectors, check the signals while the air conditioner
controller is in operation.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector [5], and troubleshoot in that condition.
Between (6) and (7) (servomotor side) of connector 400
Resistance
Defective vent (mode) servomotor [5] (There must not be open circuit or short circuit.) 3000 z
1
(unit test) Between (1) and (3) (servomotor side) of connector
Resistance 4 - 8 kz
[5] (There must not be open circuit or short circuit.)
Between (3) and (5) (servomotor side) of connector
Resistance 4 - 8 kz
[5] (There must not be open circuit or short circuit.)
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
Between connector [1] (3) and connector [2] (27) Voltage 5V
1.
Turn starting switch to OFF position.
2.
Disconnect connectors [1] and [2] and insert the T-adapter.
3.
Turn starting switch to ON position.
4.
Operate the vent switch on air conditioner operation screen and prepare by
setting to FACE mode.
Defective vent (mode) servomotor 5. Operate the vent switch on air conditioner operation screen and set to
2 or defective air conditioner wiring DEFROST mode.
harness a Voltage will be output between connector [2] (24) and [2] (23) for approxi-
mately 3 seconds (only while door moves).
a The voltage will be vary between connectors [1] (9) and [2] (27) for approx-
imately 3 seconds (only while door moves). (When the door stops, the volt-
age will stabilize.)
Between (24) (+) and (23) () of connector [2]
Approx. 24
a If vent is changed from DEFROST to FACE, volt- Voltage
V
age polarities are reversed.
Between connector [1] (9) (+) and connector [2] (27) Variable
Voltage
(-) max. 5 V
a When test result for cause 1 is normal and that for cause 2 is abnormal, per-
Defective air conditioner wiring form following procedure.
3
harness
Check with circuit diagram.
a When test result for cause 1 is normal and that for cause 2 is abnormal and
4 Defective air conditioner controller
that for cause 3 is normal, air conditioner controller is defective.

80-66 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting for vent (mode) changeover

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to ON position.
2. Display the air conditioner operation screen on the machine monitor.
Defective machine monitor Operate air vent switch and change LCD display to
5
(defective switch) FACE, FACE and REAR, FOOT and FACE and LCD display changes to
REAR, FOOT, FOOT and DEFRSOT, and each mode
DEFROST.

Circuit diagram related to vent (mode) changeover 80-67

a Servomotors are common.

HB205-1, HB215LC-1 80-67

(01)
Air conditioner
Troubleshooting for FRESH/RECIRC air changeover

Troubleshooting for FRESH/RECIRC air changeover 80-68

Failure FRESH/RECIRC air cannot be changed over
qWhen FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or fresh air
Problem on
does not change over.
machine
(FRESH/RECIRC air changeover door (damper) does not rotate)
q FRESH/RECIRC air changeover is not checked with self-diagnosis function.
q Referring toTesting FRESH/RECIRC air changeover, operate FRESH/RECIRC air selector
switch and check that there is not mechanical trouble (coming off or interference of link, etc.) in
FRESH/RECIRC air changeover door.
Related infor-
q Operating angle of FRESH/RECIRC air changeover servo motor is 90 deg.
mation
q For each connector, see "Parts and connectors layout".
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a Since T-adapters are not prepared for other connectors, check the signals while the air conditioner
controller is in operation.

Cause Procedure, measuring location, criteria and remarks

a Since connector [7] is located at the bottom of air controller unit, check it on
the air conditioner controller side.
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter on the wiring
Defective FRESH/RECIRC air harness side.
changeover servo motor (unit test) 3. Perform troubleshooting without turning starting switch ON.
1 Between connector [1] (wiring harness side) (6) and
or defective air conditioner wiring 400
harness connector [2] (wiring harness side) (19) Resistance
3000 z
(There must not be open circuit or short circuit.)
Between connector [1] (wiring harness side) (6) and
400
connector [2] (wiring harness side) (20) Resistance
3000 z
(There must not be open circuit or short circuit.)

Defective air conditioner wiring
2
harness
Defective control amplifier or
3 defective FRESH/RECIRC air
changeover servo motor
Defective FRESH/RECIRC air
4 (If all test results for causes 1, 2 and 3 are normal, cause may be mechan-
changeover servo motor
5 Defective air conditioner controller
Defective machine monitor
6
(defective switch)
a When test result for cause 1 is abnormal, perform following procedure.
Check with circuit diagram.
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
4. Operate FRESH/RECIRC air selector switch on air conditioner operation
screen, and prepare by setting RECIRC.
5. Operate FRESH/RECIRC air selector switch on air conditioner operation
screen, and set to FRESH.
a Voltage will be output between connectors [1] (6) and [2] (20) for approxi-
mately 3 seconds (only while door moves to the fresh-air position).
Between connector [1] (6) (+) and connector [2] (20) Approx. 24
Voltage
(-) V
See1. 3. above.
4. Operate FRESH/RECIRC air selector switch on air conditioner operation
screen, and prepare by setting FRESH.
5. Operate FRESH/RECIRC air selector switch on air conditioner operation
screen to RECIRC.
a Voltage will be output between connectors [1] (6) and [2] (20) for approxi-
mately 3 seconds (only while door moves to the fresh-air position).
Between connector [1] (6) (+) and connector [2] (19) Approx. 24
Voltage
(-) V
a When test result for cause 1 is abnormal and that for cause 2 is normal.
ical trouble such as hitch.)
a When test result for cause 1 is normal and that for cause 2 is normal and
that for cause 3 is abnormal, air conditioner controller is defective.
1. Turn starting switch to ON position.
2. Display the air conditioner operation screen on the machine monitor.
Display of Recirc/Fresh
Press FRESH/RECIRC air selector switch.
changes.

80-68 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting for FRESH/RECIRC air changeover

Circuit diagram related to FRESH/RECIRC air changeover 80-69

HB205-1, HB215LC-1 80-69

(01)
Air conditioner
Troubleshooting for temperature sensor system

Troubleshooting for temperature sensor system 80-70

Air is not cooled or automatic air conditioner mode does not operate due to the failure of temper-
Failure
ature sensor system.
q Air conditioner does not operate even when its activation switch is pressed, or automatic air
Problem on machine
conditioner mode does not operate even when the AUTO switch is pressed.
q There are two types of temperature sensors: evaporator temperature sensor and inside air
temperature sensor.
q Referring to "Test with self-diagnosis function", perform troubleshooting if either of the follow-
ing two abnormalities is found. Abnormality of ventilating sensor (evaporator temperature
Related information sensor) or abnormality of inner sensor (inside air temperature sensor).
q Troubleshooting for inside air temperature sensor connector is not possible, when it is mount-
ed on the machine.
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
q For each connector and other parts, see "Parts and connectors layout".

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] from air conditioner controller, and
Defective evaporator temperature connect T-adapter to each connector on the wiring harness side.
1 sensor or open circuit in wiring har- Between connector [1] (12) and con- Approx.
ness 0 C Resistance
nector [2] (27) 4.8 kz
(Resistance of evaporator temperature Approx.
15 C Resistance
sensor) 2.3 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] from air conditioner controller, and
Defective inside air temperature connect T-adapter to each connector on the wiring harness side.
2 sensor or open circuit in wiring har- Between connector [1] (11) and con- Approx.
ness 0 C Resistance
nector [2] (27) 1.6 kz
(Resistance of inside air temperature Approx.
25 C Resistance
sensor) 5 kz
3 Open circuit in wiring harness Check with circuit diagram.
4 Defective air conditioner controller If cause is not found by above checks, air conditioner controller is defective.

Circuit diagram related to temperature sensor system 80-70

80-70 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting with gauge pressure

Troubleshooting with gauge pressure 80-71

Perform troubleshooting according to the high and <Measurement condition for pressure>
low gauge pressures of the cooling cycle. For de- Item Condition value
tails, see "Connection of service tool". Ambient temperature 25 50 C
a The gauge pressure varies largely with the Engine Speed 1,500 rpm
weather condition and operating condition of the Air conditioner switch ON
Fan switch HI
machine. Check the gauge pressure under the
Set temperature Full cool
pressure measurement conditions.
q High-pressure line pressure is too high: Above q Dual pressure switch
approx. 2.5 MPa {25 kg/cm2} a The swiths is normally "ON", and becomes
q High-pressure line pressure is too low: Below
"OFF" when it detects abnormal pressure for
compressor operation.
approx. 1 MPa {10 kg/cm2}
q Low-pressure line pressure is too high: Above

approx. 0.3 MPa {3 kg/cm2}

q Low-pressure line pressure is too low: Below ap-

prox. 0.05 MPa {0.5 kg/cm2}

a Dual pressure switch turns "OFF" to protect the
air conditioner circuit if the pressure of the
high-pressure or low-perssure line is abnormal.

LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}

HB205-1, HB215LC-1 80-71

(01)
Air conditioner
Troubleshooting with gauge pressure

Indicated gauge
Cause Check method Remedy
pressure
Air conditioner cycle is operating normally.
If there is any trouble (cooling trouble), there is another cause.
Pressure is normal
High-pressure: Approx. 1.5 - 1.7 MPa {15 - 17 kg/cm2}
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2}
Collect refrigerant, then
Bubble can be seen through sight glass. *1, fill up with proper quan-
Insufficient refrigerant
*3 tity of refrigerant again
*2
There is a temperature difference between
Replace
Clogging of receiver drier inlet and outlet pipes of receiver drier.
*2
Tank is frosty
Clean or replace
Both high-pressure Clogging of expansion valve Expansion valve is frosted
*2
and low-pressure
Gas leakage at thermoprobe of expan- Replace
are too low> Low-pressure gauge reads vacuum
sion valve *2
Repair or replace
Low-pressure gauge Evaporator is frozen
Replace receiver drier
reads vacuum Defective evaporator temperature sensor Flow rate of refrigerant is reduced due to
Collect refrigerant, then
or defective contact of sensor (coming off freezing.
fill up with proper quan-
of mounting clip) (At Cool Max. and HI speed of fan, later it
tity of refrigerant again
becomes not to cold.)
*2
Piping between receiver drier and com-
pressor is clogged or crushed. Clean or replace
Clogged or crushed piping
If clogged completely, low-pressure gauge *2
reads vacuum
Collect refrigerant, then
fill up with proper quan-
Filling too much with refrigerant Connect gauge manifold
tity of refrigerant again
*2
Clean, repair fins, or
Dirty condenser, clogging or crushing of repair or replace con-
<Both high-pres- Defective cooling of condenser
fins, or defective rotation of cooling fan denser
sure and low-pres-
*2
sure are too high>
Improper adjustment of expansion valve Replace
Bubble can be seen through sight glass. *3
(Valve is opened too wide) *2
Evacuate and then fill up
with proper quantity of
Air in cycle parts Bubble can be seen through sight glass. *3
refrigerant again
*2
<High-pressure is Clean inside of cycle or
Clogged or crushed piping between com- There is a remarkable temperature differ-
too high and low- replace
pressor and condenser ence across clogged part
pressure is too low> *2
<High-pressure is Both high-pressure and low-pressure are
too low and Defective compressor (Compression balanced while compressor is in operation. Replace
low-pressure is too trouble of compressor) Compressor has seized and is extremely *2
high> hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing a cooling cycle part, see Caution about refrigerant and collect refrigerant. After
replacing it, fill up the air conditioner system with refrigerant again.
*3: Sight glass is on the air conditioner hose near the condenser.

80-72 HB205-1, HB215LC-1

(01)
 Air conditioner
Troubleshooting with gauge pressure

HB205-1, HB215LC-1 80-73

(01)
Air conditioner
Connection of service tool

Connection of service tool 80-74

Sym- Part number Part name Connect the gauge manifold, hoses and other ser-
bol vice tools according to the following procedure.
X 799 - 703 - 1200 Service tool kit 1. Close high-pressure valve (6) and low-pressure
a Use the service tool kit for R134a. valve (7) of gauge manifold (1).
Service tool kit X 2. Connect the red charging hose (2) to the HI side
(1): Gauge manifold of the gauge manifold and the blue charging
(2): High-pressure charging hose (red) hose (3) to the LO side.
(3): Low pressure charging hose (blue) 3. Connect quick joints (4) and (5) to each hose.
(4): Quick joint for HI side (large diameter) 4. Connect quick joints (4) and (5) to service valves
(5): Quick joint for LO side (small diameter) (8) and (9) of high- and low-pressure piping
respectively.
(a): As the thread is coarse, care should be taken
with regard to loosening.

80-74 HB205-1, HB215LC-1

(01)
 Air conditioner
Connection of service tool

A: From Cab
B: To Condenser

HB205-1, HB215LC-1 80-75

(01)
Air conditioner
Precautions for disconnecting and connecting air conditioner piping
Precautions for disconnecting and connecting air conditioner piping
Precautions for disconnecting
k Collect the refrigerant (Air conditioner gas:
R134a) from air conditioner circuit before
disconnecting air conditioner hose to re-
place air conditioner unit, air conditioner
compressor or receiver drier and so on.
a Ask a gualified person for collecting, adding and
filling operations of the refrigerant (R134a).
a Never release the refrigerant (R134a) to the at-
mosphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skins, you may suffer from frostbite. Ac-
cordingly, put on the protective eyeglasses,
gloves and working suits with long sleeves
while you are collecting the refrigerant
(R134a) or filling the air conditioner circuit
with the refrigerant (R134a). Collecting and
filling work must be conducted by a qualified
person.
q When loosening the air conditioner hose nuts af-
ter collecting the refrigerant, be sure to use 2
wrenches; use one wrench to fix and use the oth-
er one to loosen the nuts.
80-76
80-76
80-76 Precautions for connecting 80-76
q When connecting piping, apply compressor oil
(ND-OIL8) for R134a to its O-rings. (See item 4
of "Handling compressor oil")
Do not apply oil to the threads of a bolt, nut or
union, however.
q Once an O-ring is used, it is deformed and dete-
riorated. Accordingly, do not reuse it. When re-
moving it, use a soft tool (such as a toothpick) so
that the piping will not be damaged.
q Push in each pipe to the stopper and tighten the
bolt or nut fully with your fingers.
q Be sure to use two wrenches to tighten each nut.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
HB205-1, HB215LC-1
(01)
 Air conditioner
Precautions for disconnecting and connecting air conditioner piping

Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
M6 x 1.0 8 to 12 {0.8 to 1.2}

1. Engine
2. Compressor
3. Condenser
4. Modulator
5. Air conditioner unit

HB205-1, HB215LC-1 80-77

(01)
Air conditioner
Handling of compressor oil

Handling of compressor oil 80-78

1. Compressor oil management (DENSO:
ND-OIL8 for R134a)
Although compressor oil differs from engine oil in
that it does not need regular checking or filling, the
following types of problem can occur if the amount
in the system is too high or too low.
Condition Content
Insufficiency of Lubrication trouble and seizure of com-
oil pressor
Cooling trouble
Excess of oil (Excessive oil stick to parts and lower
heat exchange performance)
Accordingly, compressor oil must be filled to the
specified level, similarly to refrigerant.
2. Filling compressor oil 80-78
80-78
k Refrigerant is potentially hazardous to health
and to the environment. Before disconnect-
ing air conditioner hoses, therefore, refriger-
ant should be collected in accordance with
"Precautions for connecting air conditioner
piping."
a If oil for CFC-12 (R-12) is used, lubrication trou-
ble will occur and the compressor may be broken
or seized.
Be sure to use an oil suitable for R134a
(DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic,
and therefore, the cap must be immediately
closed after use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into
contact with acrylic plastic or polystyrene
surfaces (except a baked finish) as it may
dissolve these plastics.
Check compressor oil in the following cases, and
then add new oil if necessary.
q When much refrigerant is discharged because of
leakage.
q When the compressor is troubled and replaced.
(See 3 below)
q When a cycle parts such as condenser, receiver
drier, evaporator unit, etc. is replaced.

q Quantity of oil to be added when cycle part is re-

placed
Quantity to be
Air conditioner part
added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser Approx. 40
Receiver drier Approx. 20
Hose (Compressor Cab) Approx. 40
Hose (Compressor Condenser) Approx. 30
Hose (Cab - Condenser) Approx. 10

80-78 HB205-1, HB215LC-1

(01)
 Air conditioner
Handling of compressor oil

3. Replacement of compressor 80-79 4. Applying compressor oil to O-rings 80-79

q In case of compressor seizure or breakage. Whenever connecting piping or hoses, the com-
Metal chips will circulate through the air condi- pressor oil (ND-OIL8) must be applied to O-rings in
tioner circuit and contaminate the compressor oil order to prevent the leakage of refrigerant.
extremely.
In this case, flush the air conditioner circuit and
replace the compressor and receiver drier.
The compressor oil is removed from the air
conditioner circuit by flushing. Accordingly,
install a new compressor with the oil of the spec-
ified quantity (180 cc) filled in it.

q Other cases
a New compressor contains compressor oil of 180
cc in it.
1) Prepare an oil container and drain oil from
the old compressor.
2) Measure the quantity of the drained oil with a
measuring cylinder, and note the quantity or
mark the level.

3) Drain below-mentioned quantity of oil from

the new compressor.
Quantity to be drained= 180 cc - "Noted
quantity"
Example:If 30 cc was drained from the
removed compressor, the amount to be
drained from the new compressor would be
150 cc (i.e., 180 - 30 cc).

HB205-1, HB215LC-1 80-79

(01)
Air conditioner
Desiccant replacement procedure

Desiccant replacement procedure 80-80

a Prepare desiccant replacement kit Taking out desiccant (D) 80-80
(20Y-810-1250). 1. Remove snap ring (SR) from receiver drier (2).
2. Remove cap (C) from receiver drier (2).
Hold boss (B) of cap (C) with pliers etc. to
remove.
a Cap (C) may be hard to remove. When re-
moving it, take care not to damage or deform
the seal or receiver drier (2).
3. Remove filter (F) from receiver drier (2)
4. Take desiccant (D) out of receiver drier (2).
a Removed snap ring (SR), cap (C), filter (F),
desiccant (D) will be replaced with the parts
of the drier (desiccant replacement kit) and
will not be necessary any more.

k When replacing the desiccant, be sure to col-

lect the refrigerant from the air conditioning
cycle. If the desiccant is replaced without
collecting the refrigerant, the refrigerant may
blind you or cap (C) may fly out and injure
you because of the refrigerant pressure in
the cycle.
1. Condenser
2. Receiver drier
a The desiccant is in receiver drier (2).

80-80 HB205-1, HB215LC-1

(01)
 Air conditioner
Desiccant replacement procedure

Installing new desiccant (D) 80-81

1. Apply ND-OIL 8 to the periphery of O-ring (OR)
of cap (C).
2. Install filter (F) to cap (C).

3. Insert desiccant (D) in receiver drier (2).

4. Install cap (C) with filter (F) to receiver drier (2).
5. Install snap ring (SR) to receiver drier (2).
a Install snap ring (SR) to the groove in receiv-
er drier (2) securely. If it is not installed se-
curely, cap (C) may come off.

HB205-1, HB215LC-1 80-81

(01)
Air conditioner
Desiccant replacement procedure

80-82 HB205-1, HB215LC-1

(01)
 0-1
HB205-1, HB215LC-1

HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1

Machine model Serial number

HB205-1 1001 and up
HB215LC-1 1001 and up

90 Diagrams and drawings 30-1

HB205-1, HB215LC-1 90-1

 2
Contents

Contents 0-1

90 Diagrams and drawings

Hydraulic circuit diagram......................................................................................................... 90- 3 3
Symbols used in hydraulic circuit diagrams ......................................................................... 90- 3 3
Hydraulic circuit diagram...................................................................................................... 90- 7 7
Electrical circuit diagram ......................................................................................................... 90- 9 7
Symbols used in electric circuit diagrams ............................................................................ 90- 9 7
Electrical circuit diagram ...................................................................................................... 90- 13 9

90-2 HB205-1, HB215LC-1

 3
Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams

Hydraulic circuit diagram 3

Symbols used in hydraulic circuit diagrams 3

(Rev. 2010/03)

HB205-1, HB215LC-1 90-3

 4
Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams

90-4 HB205-1, HB215LC-1

 5
Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams

HB205-1, HB215LC-1 90-5

 6
Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams

90-6 HB205-1, HB215LC-1

 7
Hydraulic circuit diagram Hydraulic circuit diagram 00-74

HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HB205-1, HB215LC-1 90-7

 7
Electrical circuit diagram
Symbols used in electric circuit diagrams

Electrical circuit diagram 9

Symbols used in electric circuit diagrams 9

(Rev. 2010/03)

HB205-1, HB215LC-1 90-9

 8
Electrical circuit diagram
Symbols used in electric circuit diagrams

90-10 HB205-1, HB215LC-1

 9
Electrical circuit diagram
Symbols used in electric circuit diagrams

HB205-1, HB215LC-1 90-11

 10
Electrical circuit diagram
Symbols used in electric circuit diagrams

90-12 HB205-1, HB215LC-1

 9
Electrical circuit diagram (1/6) Electrical circuit diagram (1/6) 00-134

(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HB205-1, HB215LC-1 90-13

 11
Electrical circuit diagram (2/6) Electrical circuit diagram (2/6) 00-34

(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HB205-1, HB215LC-1 90-15

 13
Electrical circuit diagram (3/6) Electrical circuit diagram (3/6) 00-34

(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HB205-1, HB215LC-1 90-17

 15
Electrical circuit diagram (4/6) Electrical circuit diagram (4/6) 00-34

(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HB205-1, HB215LC-1 90-19

 17
Electrical circuit diagram (5/6) Electrical circuit diagram (5/6) 00-34

(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HB205-1, HB215LC-1 90-21

 19
Electrical circuit diagram (6/6) Electrical circuit diagram (6/6) 00-34

(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

HB205-1, HB215LC-1 90-23

 1
Index

Index 0 -1

HB205-1, HB215LC-1

A Disassembly and assembly of track roller

Accumulator 10-143 assembly 50-169
Adjusting mirrors 30-62 Disassembly and assembly of travel PPC valve
Adjusting play of work equipment and assembly 50-205
swing PPC valves 30-53 Disassembly and assembly of work equipment
Adjusting valve clearance 30-13 cylinder assembly 50-211
Air conditioner component 80-4 Disassembly and assembly of work equipment
Air conditioner controller 80-15 PPC valve assembly 50-203
Air conditioner unit 80-10 Draining adding coolant and bleeding air for
Angle adjustment of rear view camera 30-65 hybrid system 50-89
Attachment circuit selector valve 10-138, 60-55 Draining and adding generator lubricating oil 50-108

B E
Bleeding air from each part 30-59 E-1 Engine does not start (Engine does not
Bleeding air from fuel circuit 30-28 crank) 40-434
E-2 Preheater does not operate 40-440
C E-3 When starting switch is turned to ON
Carrier roller 60-21 position, machine monitor displays nothing 40-445
Center swivel joint 10-142, 60-56 E-4 When starting switch is turned to ON
Checking cab tipping stopper 30-61 position (with engine stopped), basic check
Checking exhaust gas color 30-12 monitor lights up. 40-448
Checking parts which cause E-5 Precaution monitor lights up while engine
hydraulic drift of work equipment 30-54 is running 40-449
Checks before troubleshooting 40-12 E-6 Emergency stop monitor lights up while
Circuit diagram and arrangement of connector engine is running 40-451
pins 80-20 E-7 Fuel level gauge does not indicate properly 40-452
Classification and procedures for troubleshooting 40-41 E-8 Engine coolant temperature gauge does
Cleaning and replacement of not indicate properly 40-454
oil filter of swing electric motor 30-67 E-9 Hydraulic oil temperature gauge does not
CLSS 10-32 indicate properly 40-456
Coating materials list 50-7 E-10 HYB system temperature gauge does not
Compressor 80-16 indicate properly 40-458
Condenser and Modulator 80-17 E-11 Displays on machine monitor are different
Configuration and function of refrigeration cycle 80-6 from those for actual machine 40-460
Configuration and safety functions of E-12 Machine monitor does not display some
hybrid system 10-6 items 40-460
Connection of service tool 80-74 E-13 Function switch does not work 40-460
Connection table for connector pin numbers 40-70 E-14 Automatic warm-up system does not
Connector list and layout 40-59 operate (in cold season) 40-461
Control valve 10-58, 60-32 E-15 Auto-decelerator does not operate
Conversion table 00-50 normally 40-462
Cooling system 10-4, 60-5 E-16 Working mode does not change 40-463
Cooling system of hybrid component 10-10 E-17 Travel speed does not change 40-464
Cylinder cut-out test mode operation 30-23 E-18 Alarm buzzer does not stop sounding 40-465
E-19 When starting switch is at OFF position,
D service meter is not displayed 40-465
Desiccant replacement procedure 80-80 E-20 Machine monitor cannot be set in
Detail of air conditioner unit 80-24 service mode 40-465
Dimension of work equipment 60-60 E-21 All of work equipment, swing, and travel
Disassembly and assembly of carrier roller mechanism do not move or are not locked 40-466
assembly 50-171 E-22 Swing holding brake does not operate
Disassembly and assembly of center swivel properly 40-469
joint assembly 50-181 E-23 One-touch power max. function does not
Disassembly and assembly of control valve operate 40-472
assembly 50-199 E-24 Travel alarm does not sound or does not
Disassembly and assembly of final drive 50-131 stop sounding 40-476
Disassembly and assembly of idler assembly 50-164 E-25 Horn does not sound or does not stop
Disassembly and assembly of idler cushion sounding 40-478
assembly 50-167 E-26 Windshield wiper and window washer do
Disassembly and assembly of swing machinery not operate 40-480
assembly 50-145

HB205-1, HB215LC-1 1
(01)
 2
Index

E-27 "BOOM LOWER" indicator is not Failure code [CA154] Chg Air Temp Sensor
displayed properly with monitoring function 40-482 Low Error 40-136
E-28 "ARM OUT" indicator is not displayed Failure code [CA155] Chg Air Temp High
properly with monitoring function 40-484 Speed Derate 40-138
E-29 "ARM IN" indicator is not displayed Failure code [CA187] Sens Supply 2 Volt Low
properly with monitoring function 40-486 Error 40-140
E-30 "BOOM RAISE" indicator is not displayed Failure code [CA221] Ambient Press Sens
properly with monitoring function 40-486 High Error 40-142
E-31 "BUCKET CURL" indicator is not Failure code [CA222] Ambient Press Sens
displayed properly with monitoring function 40-486 Low Error 40-144
E-32 "BUCKET DUMP" indicator is not Failure code [CA227] Sens Supply 2 Volt High
displayed properly with monitoring function 40-487 Error 40-146
E-33 "SWING" indicator is not displayed Failure code [CA234] Eng Overspeed 40-146
properly with monitoring function 40-487 Failure code [CA238] Ne Speed Sens Supply
E-34 "TRAVEL" indicator is not displayed Volt Error 40-147
properly with monitoring function 40-488 Failure code [CA271] IMV/PCV1 Short Error 40-148
E-35 "TRAVEL STEERING" indicator is not Failure code [CA272] IMV/PCV1 Open Error 40-150
displayed properly with monitoring function 40-490 Failure code [CA322] Inj #1(L#1) Open/Short
E-36 "SERVICE" indicator is not displayed Error 40-152
properly with monitoring function 40-492 Failure code [CA324] Inj #3(L#3) Open/Short
E-37 Attachment hydraulic circuit cannot be Error 40-154
changed 40-494 Failure code [CA331] Inj #2(L#2) Open/Short
E-38 KOMTRAX system does not operate Error 40-156
properly 40-495 Failure code [CA332] Inj #4(L#4) Open/Short
Electric control unit 10-14 Error 40-158
Electrical circuit diagram 90-13 Failure code [CA342] Calibration Code Incom
Electrical control system 10-144 patibility 40-160
Engine and cooling system 50-20 Failure code [CA351] Injectors Drive Circuit
Engine mount 60-4 Error 40-161
Engine related parts 10-3 Failure code [CA352] Sens Supply 1 Volt Low
Explanation of terms for maintenance standard 00-11 Error 40-162
Failure code [CA386] Sens Supply 1 Volt High
F Error 40-164
Failure code [989L00] Engine Controller Lock Failure code [CA428] Water in Fuel Sensor
Caution 1 40-111 High Error 40-166
Failure code [989M00] Engine Controller Lock Failure code [CA429] Water in Fuel Sensor
Caution 2 40-111 Low Error 40-168
Failure code [989N00] Engine Controller Lock Failure code [CA435] Eng Oil Press Sw Error 40-170
Caution 3 40-111-1 Failure code [CA441] Battery Voltage Low
Failure code [AA10NX] Air Cleaner Clogging 40-111-2 Error 40-172
Failure code [AB00KE] Charge Voltage Low 40-112 Failure code [CA442] Battery Voltage High
Failure code [B@BAZG] Eng Oil Press Low 40-114 Error 40-174
Failure code [B@BAZK] Eng Oil Level Low 40-115 Failure code [CA449] Rail Press Very High
Failure code [B@BCNS] Eng Water Overheat 40-116 Error 40-175
Failure code [B@BCZK] Eng Water Level Low 40-118 Failure code [CA451] Rail Press Sensor High
Failure code [B@HANS] Hyd Oil Overheat 40-120 Error 40-176
Failure code [CA111] ECM Critical Internal Failure code [CA452] Rail Press Sensor Low
Failure 40-121 Error 40-178
Failure code [CA115] Eng Ne and Bkup Speed Failure code [CA488] Chg Air Temp High
Sens Error 40-121 Torque Derate 40-180
Failure code [CA122] Chg Air Press Sensor Failure code [CA553] Rail Press High Error 40-181
High Error 40-122 Failure code [CA559] Supply Pump Press
Failure code [CA123] Chg Air Press Sensor Low Error 1 40-182
Low Error 40-124 Failure code [CA689] Eng Ne Speed Sensor
Failure code [CA131] Throttle Sensor High Error 40-184
Error 40-126 Failure code [CA731] Eng Bkup Speed Sens
Failure code [CA132] Throttle Sensor Low Phase Error 40-186
Error 40-128 Failure code [CA757] All Continuous Data Lost
Failure code [CA144] Coolant Temp Sens Error 40-187
High Error 40-130 Failure code [CA778] Eng Bkup Speed Sensor
Failure code [CA145] Coolant Temp Sens Error 40-188
Low Error 40-132 Failure code [CA1633] KOMNET Datalink
Failure code [CA153] Chg Air Temp Sensor Timeout Error 40-191
High Error 40-134

2 HB205-1, HB215LC-1
(03)
 3
Index

Failure code [CA2185] Throt Sens Sup Volt Failure code [DHVBL8] HYB system swing
High Error 40-192 LEFT PPC pressure sensor signal
Failure code [CA2186] Throt Sens Sup Volt abnormality 40-260
Low Error 40-193 Failure code [DHVBMA] HYB system swing
Failure code [CA2249] Rail Press Very Low LEFT PPC pressure sensor malfunction 40-261
Error 40-194 Failure code [DHVCKZ] HYB Arm Dump PPC
Failure code [CA2311] IMV Solenoid Error 40-195 Pr. Sen. Opn/short Cir 40-262
Failure code [CA2555] Grid Htr Relay Open Failure code [DW43KA] Travel Speed Sol
Circuit Error 40-196 Open Circuit 40-264
Failure code [CA2556] Grid Htr Relay Short Failure code [DW43KB] Travel Speed Sol
Circuit Error 40-198 Short Circuit 40-266
Failure code [D19JKZ] Personal Code Relay Failure code [DW45KA] Swing holding brake
Abnormality 40-200 solenoid valve open circuit 40-268
Failure code [D862KA] GPS Antenna Open Failure code [DW45KB] Swing holding brake
Circuit 40-203 solenoid valve short circuit 40-271
Failure code [DA22KK] Pump Solenoid Power Failure code [DW45KK] Swing holding brake
Low Error 40-204 solenoid valve power voltage drop 40-274
Failure code [DA25KP] 5V Sensor1 Power Failure code [DW45KY] swing holding brake
Abnormality 40-206 Sol. Val. Pow. Short Cir 40-276
Failure code [DA26KP] 5V Sensor2 Power Failure code [DW4WKA] Cancel Bucket Dump
Abnormality 40-208 Open Circuit 40-278
Failure code [DA29KQ] Model Selection Failure code [DW4WKB] Cancel Bucket Dump
Abnormality 40-210 Short Circuit 40-280
Failure code [DA2RMC] CAN Discon (Pump Failure code [DW91KA] Travel Junction Sol.
Con Detected) 40-212 Disc. 40-282
Failure code [DAF8KB] Camera Power Supply Failure code [DW91KB] Travel Junction Sol.
Short Circuit 40-218 S/C 40-284
Failure code [DAFGMC] GPS Module Error 40-220 Failure code [DWA2KA] Attachment Sol Open
Failure code [DAFRMC] CAN Discon (Monitor Circuit 40-286
Detected) 40-221 Failure code [DWA2KB] Attachment Sol Short
Failure code [DGH2KB] Hyd Oil Sensor Short 40-228 Circuit 40-288
Failure code [DHPAMA] Pump Press Sensor Failure code [DWK0KA] 2-stage Relief Sol
Abnormality 40-230 Open Circuit 40-290
Failure code [DHPBMA] R Pump Press Sensor Failure code [DWK0KB] 2-stage Relief Sol
Abnormality 40-232 Short Circuit 40-292
Failure code [DHS3MA] Arm IN PPC Sen. Failure code [DXA8KA] PC-EPC (F) Sol Open
Abnormality 40-234 Circuit 40-294
Failure code [DHS4MA] Bucket CURL PPC Failure code [DXA8KB] PC-EPC (F) Sol Short
Press Sensor Abnormality 40-236 Circuit 40-296
Failure code [DHS8MA] Boom RAISE PPC Failure code [DXA9KA] PC-EPC (R) Sol Open
Press Sensor Abnormality 40-238 Circuit 40-298
Failure code [DHSAKZ] Swing RIGHT PPC Failure code [DXA9KB] PC-EPC (R) Sol Short
pressure sensor system open or short circuit 40-240 Circuit 40-300
Failure code [DHSAMA] Swing RH PPC Press Failure code [DXE0KA] LS-EPC Sol Open
Sensor Abnomality 40-244 Circuit 40-302
Failure code [DHSBKZ] Swing LEFT PPC Failure code [DXE0KB] LS-EPC Sol Short
pressure sensor system open or short circuit 40-242 Circuit 40-304
Failure code [DHSBMA] Swing LH PPC Press Failure code [DXE4KA] Service Current EPC
Sensor Abnomality 40-246 Disc. 40-306
Failure code [DHSDMA] Bucket Dump PPC Failure code [DXE4KB] Service Current EPC
Press Sensor Abnormality 40-248 S/C 40-308
Failure code [DHV3KZ] HYB system arm IN Failure code [DXE5KA] Merge-divider Main
PPC pressure sensor open or short circuit 40-250 Sol Open Circuit 40-310
Failure code [DHV9KZ] HYB Boom Lower Failure code [DXE5KB] Merge-divider Main
PPC Pr. Sen. Open/Shrt Cir 40-252 Sol Short Circuit 40-312
Failure code [DHVAKZ] HYB Swing-R PPC Failure code [DXE6KA] Merge-divider LS Sol
Pr. Sen. Opn/Short Cir 40-254 Open Circuit 40-314
Failure code [DHVAL8] HYB system swing Failure code [DXE6KB] Merge-divider LS Sol
RIGHT PPC pressure sensor signal Short Circuit 40-316
abnormality 40-256 Failure code [DY20KA] Wiper Working
Failure code [DHVAMA] HYB system swing Abnormality 40-318
RIGHT PPC pressure sensor malfunction 40-257 Failure code [DY20MA] Wiper Parking
Failure code [DHVBKZ] HYB Swing-L PPC Abnormality 40-320
Pr. Sen. Opn/short Cir 40-258 Failure code [DY2CKA] Washer drive discon 40-322

HB205-1, HB215LC-1 3
(03)
 4
Index

Failure code [DY2CKB] Washer drive short 40-324 Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt.
Failure code [DY2DKB] Wiper Drive (Fwd) Sens. Malfunction 40-385
Short Circuit 40-326 Failure code [GA1FKR] Swing Mot. Drv.
Failure code [DY2EKB] Wiper Drive (Rev) Communication Failure 40-385
Short Circuit 40-328 Failure code [GA1FMA] Abnormal Swing Motor
Failure code [GA----] Hybrid devices monitoring Driver 40-386
items list and check sheet 40-355 Failure code [GA1GKK] Low Sup. Volt. Swing
Failure code [GA00NS] HYB devices overheat 40-359 Motor Drv. Sub-CPU 40-386
Failure code [GA01KA] Power Cable Interlock Failure code [GA1GKR] Swing Mot. Driver
Open Circuit 40-360 Sub-CPU Comm. Failure 40-387
Failure code [GA02KZ] DC Line Open/Short Failure code [GA1GKT] Swing Mot. Drv.
Circuit 40-362 Sub-CPU Cont. Abnormal 40-387
Failure code [GA04KG] Abnormal DC HW Failure code [GA1GMA] Swing Motor Drv.
Volt. Before Booster 40-363 Sub-CPU Malfunction 40-388
Failure code [GA05KG] Abnormal DC SW Failure code [GA1GMB] Swing Mot. Drv.
Volt. Before Booster 40-364 Sub-CPU Funct. Degraded 40-388
Failure code [GA05KP] Low DC SW Output Failure code [GA1GMC] Swing Mot. Drv.
Volt. Bef. Booster 40-365 Sub-CPU Defect Op. 40-389
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Failure code [GA1GNA] Swing Mot. Drv.
Cir. Bef. Booster 40-366 Sub-CPU Start Disabled 40-389
Failure code [GA08KG] Abnormal. DC HW Failure code [GA1HKZ] Swg Mot. Dr. Ph-U
Volt. After Booster 40-367 Tem. Sens Opn/Shrt Cir. 40-390
Failure code [GA09KG] Abnormal. DC SW Failure code [GA1JKZ] Swg Mot. Dr. Ph-V
Volt. After Booster 40-368 Tem. Sens Opn/Shrt Cir. 40-390
Failure code [GA09KP] Low DC SW Output Failure code [GA1KKZ] Swg Mot. Dr. Ph-W
Volt. After Booster 40-369 Tem. Sens Opn/Shrt Cir 40-391
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt Failure code [GA1LKZ] Swg Mot. Dr. Current.
cir. Aft. Booster 40-370 Sens Opn/Shrt Cir. 40-391
Failure code [GA0BKZ] AC Line Open/Short Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt.
Circuit 40-371 Sen Opn/Shrt Cir. 40-392
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure code [GA1NNS] Swing Motor Driver
Failure 40-372 IGBT Overheat 40-393
Failure code [GA12NK] HYB Cont. Pow. Suppl. Failure code [GA1SFS] Contactor Locked 40-394
Not Turn. ON 40-373 Failure code [GA1SMC] Contactor Failure 40-394
Failure code [GA12NL] HYB Cont. Pow. Suppl. Failure code [GA1TKP] Capacitor Low Output
Not Turn. OFF 40-374 Voltage 40-395
Failure code [GA13MC] HYB Control. Sen. Failure code [GA1TNS] Capacitor Overheat 40-396
Power Sup. Failure 40-376 Failure code [GA1UKZ] Capacitor Temp.
Failure code [GA14KR] HYB Control. KOMNET Sensor Opn/Short Cir. 40-398
Comm. Failure 40-378 Failure code [GA1VFS] Capacitor Contactor
Failure code [GA15KZ] HYB Cont. Bad Insul. Locked 40-400
Sen. Opn/Short. Cir 40-379 Failure code [GA1VMC] Capacitor Contactor
Failure code [GA17KR] Gen. Mot. Drv. Failure 40-402
Communication Failure 40-379 Failure code [GA1XKZ] Boost. Ind. Temp.
Failure code [GA17KY] Gen. Mot Dr. Power Sens. Open/Shrt. Circ. 40-403
Line Short Circuit 40-380 Failure code [GA1YNS] Booster Inductor
Failure code [GA17KZ] Gen. Motor Driver Overheat 40-404
Open/Short Circuit 40-380 Failure code [GA1ZKZ] Booster IGBT Temp.
Failure code [GA17MB] Gen. Mot. Drv. Function Sens. Opn/Shrt. Circ. 40-404-1
Degraded 40-381 Failure code [GA1ZNS] Booster IGBT Temp.
Failure code [GA18MC] Gen.Mo. Dr. Excite. Sens. Overheat 40-404-2
Pow. Sup. Failure 40-381 Failure code [GA21KB] Booster IGBT Short
Failure code [GA19KK] Gen. Mot. Drv. Circuit 40-404-3
Sub-CPU Low Sup. Volt 40-382 Failure code [GA22NS] Booster IGBT Junction
Failure code [GA19KR] Gen. Motor Driver Overheat 40-405
Sub-CPU Comm. Failure 40-382 Failure code [GA23KZ] Gen. Mot. Dr. Temp.
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Sens.0 Opn/Short Cir. 40-406
Drv. Sub-CPU Con. 40-383 Failure code [GA24KZ] Gen. Mot. Dr. Temp.
Failure code [GA19MA] Gen. Mot. Drv. Sens.1 Opn/Short Cir. 40-406
Sub-CPU Malfunction 40-383 Failure code [GA25MA] Gen. Motor Driver
Failure code [GA19MC] Gen. Mot. Drv. IGBT0 Abnormality 40-407
Sub-CPU Defect. Operation 40-384 Failure code [GA25NS] Gen. Motor Driver
Failure code [GA19NA] Gen. Mot. Drv. IGBT0 overheat 40-407-1
Sub-CPU Start Disabled 40-384

4 HB205-1, HB215LC-1
(03)
 5
Index

Failure code [GA26MA] Gen. Motor Driver H-3 All work equipment and travel systems do
IGBT1 Abnormality 40-407-2 not work 40-502
Failure code [GA26NS] Gen. Motor Driver H-4 Unusual noise comes out from around
IGBT1 overheat 40-408 hydraulic pump 40-502
Failure code [GA27KZ] DC before boosting H-5 Auto-decelerator does not operate 40-503
sensor open or short circuit 40-409 H-6 Fine control performance or response is
Failure code [GA28KZ] DC after boosting low 40-503
sensor open or short circuit 40-409 H-7 Speed or power of boom is low 40-504
Failure code [GA60MC] Generator Motor H-8 Speed or power of arm is low 40-505
Failure 40-410 H-9 Speed or power of bucket is low 40-506
Failure code [GA60MD] Gen. Mot. Defective H-10 Work equipment does not move in its
Movement 40-411 single operation 40-506
Failure code [GA60N1] Generator Motor H-11 Hydraulic drift of work equipment is large 40-507
Overrun 40-412 H-12 Time lag of work equipment is large 40-509
Failure code [GA61KZ] Gen. Motor Temp. H-13 When part of work equipment is relieved
Sens. Open/Short Cir. 40-414 singly, other parts of work equipment move 40-509
Failure code [GA61NS] Generator Motor H-14 Power maximizing function does not work 40-510
Temp. Sensor Overheat 40-416 H-15 In combined operation of work equipment,
Failure code [GA62KY] Gen. Mot. Ph-A Cur. speed of part loaded more is low 40-510
Sen. Power Short Cir 40-417 H-16 When machine swings and travels
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. simultaneously, travel speed is low 40-510
Sen. Open/Short Cir 40-418 H-17 Machine deviates during travel 40-511
Failure code [GA62MA] Gen. Mot. Ph-A H-18 Travel speed is low 40-512
Current Sen. Malfunction 40-419 H-19 Machine is not steered well or sterring
Failure code [GA63KY] Gen. Mot. Ph-B Cur. power is low 40-513
Sen. Power Short Cir. 40-419 H-20 Travel speed does not shift or travel
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. speed is low or high 40-514
Sen. Open/Short Cir 40-420 H-21 Travel system does not work (only one
Failure code [GA63MA] Gen. Mot. Ph-B side) 40-515
Current Sen. Malfunction 40-420 H-22 Upper structure does not swing 40-516
Failure code [GA64KY] Gen. Mot. Ph-C Cur. H-23 Swing acceleration or swing speed of
Sen. Power Short Cir. 40-421 upper structure is low 40-516
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. H-24 Upper structure overruns remarkably
Sen. Open/Short Cir. 40-422 when it stops swinging 40-516
Failure code [GA64MA] Gen. Mot. Ph-C H-25 Large shock is made when upper
Current Sen. Malfunction 40-422 structure stops swinging 40-517
Failure code [GA70KB] HYB Swing Motor H-26 Large sound is made when upper
Short Circuit 40-423 structure stops swinging 40-517
Failure code [GA70MD] HYB Swing Motor H-27 Upper structure lowers largely by its own
Defective Stirr. Motion 40-423 weight 40-517
Failure code [GA70NS] HYB Swing Motor Handling fuel system parts 30-20
Overheat 40-424 Handling of compressor oil 80-78
Failure code [GA71KZ] HYB Swing Mot. Temp. Handling of controller high-voltage circuit 30-30
Sens. Opn/Shrt Cir. 40-426 Handling of electric equipment 00-18
Failure code [GA72MA] HYB Swing Motor Handling of hybrid devices and
Resolver Malfunction 40-428 high-voltage wirings 00-36
Failure code [GA72MC] HYB Swing Motor Handling of hydraulic components 00-13
Resolver Defect Op. 40-430 Handling voltage circuit of engine controller 30-132
Failure code [GA81KZ] Swing Motor Power High-voltage wiring (power cable) 10-15
Cable Opn/Shrt Circ. 40-430 How to read Disassembly and Assembly 50-4
Failure code [GAA100] Swing emergency stop How to read electric wire code 00-28
switch operated 40-431 How to read the shop manual 00-9
Failure code [GAA2KB] Swing Brake sol. How to read this manual 50-4
Supply Line short cir. 40-432 Hydraulic circuit diagram 90-7
Failure codes table 40-44 Hydraulic components layout drawing 10-28
Final drive 10-24, 60-12 Hydraulic tank 10-31
Functions and operation by valve 10-70
Fuse location table 40-109 I
Idler 60-18
H Information in troubleshooting table (H mode) 40-498
H-1 Speed or power of all work equipment and Information in troubleshooting table 40-55
travel is low 40-499 Information in troubleshooting table 80-52
H-2 Engine speed lowers significantly or engine
stalls 40-501

HB205-1, HB215LC-1 5
(03)
 6
Index

K Removal and installation of floor frame

KOMTRAX system 10-190 assembly 50-238
Removal and installation of front window
L assembly 50-231
List of Abbreviation 00-46 Removal and installation of fuel cooler
assembly 50-68
M Removal and installation of fuel injector
Machine monitor system 10-174 assembly 50-25
Main pump 10-36, 60-28 Removal and installation of fuel supply pump
Method of disconnecting and connecting assembly 50-20
push-pull type coupler 00-15 Removal and installation of fuel tank assembly 50-86
Method of using troubleshooting chart 40-518 Removal and installation of hybrid radiator
Motor-generator 10-12 assembly 50-93
Removal and installation of hydraulic oil cooler
N assembly 50-57
No injection cranking operation 30-23 Removal and installation of hydraulic tank
assembly 50-183
O Removal and installation of inverter and
Operation check of swing emergency stop switch 30-68 capacitor assembly 50-103
Outline of hybrid system 01-3 Removal and installation of inverter assembly 50-99
Outline of refrigeration cycle 80-7 Removal and installation of KOMTRAX terminal
assembly 50-253
P Removal and installation of machine monitor
Parts and connectors layout 80-26 assembly 50-251
Pm Clinic service 30-141 Removal and installation of main pump
Points to remember when troubleshooting 40-10 assembly 50-188
Power train 10-18 Removal and installation of main pump input
PPC valve 10-117, 60-44 shaft oil seal 50-193
Precaution in hybrid device troubleshooting, Removal and installation of motor-generator
and common troubleshooting procedures housing assembly 50-113
for high voltage devices 40-330 Removal and installation of operator's cab
Precautions for disconnecting and connecting assembly 50-217
air conditioner piping 80-76 Removal and installation of operator's cab glass
Precautions for refrigerant 80-3 (adhered window glass) 50-221
Precautions related to hybrid machine 40-540, 50-6 Removal and installation of pump controller
Precautions related to hybrid machines 30-133 assembly 50-248
Precautions when performing work 00-33 Removal and installation of radiator assembly 50-55
Preparation work for troubleshooting of Removal and installation of revolving frame
electrical system 30-134 assembly 50-175
Procedure for testing and troubleshooting 80-18 Removal and installation of sprocket 50-140
Procedure for testing diodes 30-140 Removal and installation of swing circle
assembly 50-160
R Removal and installation of swing electric
Releasing remaining pressure from fuel system 30-20 motor assembly 50-122
Releasing remaining pressure from Removal and installation of swing motor and
hydraulic circuit 30-56 swing machinery assembly 50-141
Removal (and installation) of engine, motor Removal and installation of tandem pump
generator, and main pump assembly 50-70 assembly 50-110
Removal and installation of aftercooler assembly 50-59 Removal and installation of water pump
Removal and installation of air conditioner unit assembly for hybrid system 50-96
assembly 50-243 Removal and installation of work equipment
Removal and installation of center swivel joint assembly 50-208
assembly 50-179 Replacement of fan belt 30-32
Removal and installation of control valve Return oil filter 10-140
assembly 50-194
Removal and installation of counterweight S
assembly 50-177 S-1 Engine startability is poor 40-522
Removal and installation of cylinder head S-2 Engine does not start 40-523
assembly 50-32 S-3 Engine does not pick up smoothly 40-526
Removal and installation of engine controller S-4 Engine stops during operations 40-527
assembly 50-246 S-5 Engine does not rotate smoothly 40-528
Removal and installation of engine front seal 50-62 S-6 Engine lacks output (or lacks power) 40-529
Removal and installation of engine rear seal 50-64 S-7 Exhaust gas is black (incomplete
Removal and installation of final drive assembly 50-129 combustion) 40-530

6 HB205-1, HB215LC-1
(03)
 7
Index

S-8 Oil consumption is excessive (or exhaust Testing oil leakage 30-57
gas is blue) 40-531 Testing PPC valve output pressure 30-51
S-9 Oil becomes contaminated quickly 40-532 Testing relays 80-47
S-10 Fuel consumption is excessive 40-533 Testing solenoid valve output pressure 30-48
S-11 Oil is in coolant (or coolant spurts or Testing source pressure of control circuit 30-40
coolant level goes down) 40-534 Testing sunlight sensor 80-44
S-12 Oil pressure drops 40-535 Testing swing circle bearing clearance 30-33
S-13 Oil level rises (coolant or fuel in oil) 40-536 Testing swing holding brake 30-66
S-14 Coolant temperature rises too high Testing temperature control 80-34
(overheating) 40-537 Testing vent (mode) changeover 80-36
S-15 Unusual noise is made 40-538 Testing with self-diagnosis function 80-31
S-16 Vibration is excessive 40-539 Tools for testing, adjusting and troubleshooting 30-4
Safety notice 00-4 Track frame and idler cushion 10-26, 60-16
Sensor 10-192 Track roller 60-20
Separation and connection of track shoe Track shoe 60-22
assembly 50-161 Travel motor 10-107, 60-41
Sequence of events in troubleshooting 40-11 Troubleshooting chart 1 80-48
Sketches of special tools 50-15 Troubleshooting chart 2 80-50
Solenoid valve 10-136, 60-54 Troubleshooting for blower motor system
Special functions of machine monitor 30-70 (No air comes out or air flow is abnormal) 80-60
Special tools list 50-10 Troubleshooting for compressor and refrigerant
Specification dimension drawing 01-4 system (Air is not cooled) 80-57
Specifications 01-6 Troubleshooting for FRESH/RECIRC air
Sprocket 60-14 changeover 80-68
Standard tightening torque table 00-42 Troubleshooting for power supply and CAN
Standard value table for engine 20-3 communication system (Air conditioner
Standard value table for machine 20-4 does not operate) 80-53
Swing brake 10-22, 60-10 Troubleshooting for temperature control 80-63
Swing circle 10-19, 60-7 Troubleshooting for temperature sensor system 80-70
Swing electric motor 10-13 Troubleshooting for vent (mode) changeover 80-66
Swing machinery 10-20, 60-8 Troubleshooting method for open circuit in
Symbols used in electric circuit diagrams 90-9 wiring harness of pressure sensor system 40-57
Symbols used in hydraulic circuit diagrams 90-3 Troubleshooting with gauge pressure 80-71
Symptom and troubleshooting numbers 40-52
System diagram 80-22 V
System diagram of hydraulic and mechanical Valve control 10-30
system 40-496
W
T Water pump 10-16
T- branch box and T- branch adapter table 40-106 Weight table 01-9
Table of contents 00-2 Work equipment 60-58
Table of fuel, coolant and lubricants 01-11 Work equipment cylinder 60-64
Testing (dual) pressure switch for refrigerant 80-45 Working range diagram 01-5
Testing air leakage (duct) 80-30
Testing and adjusting air conditioner compressor Y
belt tension 30-31 Y-1 Hybrid monitor does not go out 40-542
Testing and adjusting hydraulic oil pressure in Y-2 Upper structure does not swing 40-544
work equipment and travel circuits 30-37 Y-3 Swing acceleration or swing speed is low 40-546
Testing and adjusting oil pressure in pump Y-4 Upper structure overruns largely when
LS control circuit 30-44 stop swinging 40-547
Testing and adjusting oil pressure in pump Y-5 Large shock is made when upper structure
PC control circuit 30-41 stops swinging 40-548
Testing and adjusting track tension 30-34 Y-6 Large unusual noise is made when upper
Testing blowby pressure 30-18 structure stops swinging 40-548
Testing boost pressure 30-11 Y-7 Swing drift on a slope is large 40-549
Testing compression pressure 30-15 Y-8 Electric swing motor temperature increases
Testing engine oil pressure 30-19 abnormally 40-550
Testing engine speed 30-9 Y-9 Motor-generator temperature increases
Testing evaporator temperature sensor 80-42 abnormally 40-552
Testing FRESH/RECIRC air changeover 80-39 Y-10 Inverter overheats 40-553
Testing fuel circuit for leakage 30-29 Y-11 Capacitor overheats 40-554
Testing fuel delivery, return rate and leakage 30-24
Testing fuel system pressure 30-21
Testing inner sensor 80-41

HB205-1, HB215LC-1 7
(03)
HB205-1, HB215LC-1 HYDRAULIC EXCAVATOR

Form Number: SEN05393-04

2013 KOMATSU
All Rights Reserved
Printed in Japan 03-13 (01)

(04)