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Komatsu HB215LC-2 Hybrid Hydraulic Excavator Service Manual

1,838 pages · Publication SEN06488-01

$189.53
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Models
HB215LC-2 Hybrid
Serial coverage
50001 and up
Manual type
Service Manual
Pages
1,838
Publication
SEN06488-01
Condition
Brand new
Komatsu HB215LC-2 Hybrid Hydraulic Excavator Service Manual, publication SEN06488-01

What's inside

From the manual's own table of contents: 364 sections, 700 entries. See sample pages (PDF, 846 KB)

Index and foreword
Foreword, safety and general information
Important safety notice (Hybrid)
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code (Hybrid)
Precautions when performing operation
Practical use of KOMTRAX
Handling hybrid components and high voltage wiring harness
Standard tightening torque table
List of abbreviation
Conversion table
Specification
Specifications
Specification drawing
Working range drawings
Weight table
Table of fuel, coolant, and lubricants
Structure and function
Show all 364 sections
Engine and cooling system
Engine related parts
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDOC muffler
Cooling system
Hybrid system
Outline of hybrid system
Configuration of hybrid system
Protective function of hybrid component
Protection function for workers when disassembling hybrid component
Cooling system of hybrid component
Interlock function
Motor-generator
Electric swing motor
Electric control unit
High voltage wiring harness (power cable)
Water pump
Power train
Power train system
Swing circle
Swing machinery with swing brake
Final drive
Undercarriage and frame
Track frame and idler cushion
Hydraulic system13 topics
  • Hydraulic component layout
  • Valve control
  • Hydraulic tank
  • CLSS
  • Main pump
  • Control valve
  • Travel motor
  • PPC valve
  • Solenoid valve
  • Attachment circuit selector valve (for high pressure circuit)
  • Attachment circuit selector valve (for low pressure circuit)
  • Center swivel joint
  • Accumulator
Work equipment2 topics
  • Work equipment shim
  • Bucket play adjustment shim
Cab and its attachments2 topics
  • Cab mount and cab tipping stopper
  • ROPS cab
Electrical system4 topics
  • Electrical control system
  • Machine monitor system
  • KOMTRAX system
  • Sensor
Standard value tables
Standard service value table3 topics
  • Standard value table for engine
  • Standard value table for machine
  • Standard value table for electrical system
Testing and adjusting
Related information on testing and adjusting22 topics
  • Tools for testing and adjusting
  • Sketch of tools for testing and adjusting
  • Testing engine speed
  • Testing boost pressure
  • Testing exhaust gas color
  • Testing and adjusting valve clearance
  • Testing compression pressure
  • Testing blowby pressure
  • Testing engine oil pressure
  • Testing fuel pressure
  • Testing fuel discharge, return and leakage
  • Bleeding air from fuel system
  • Testing fuel circuit for leakage
  • Handling cylinder cutout mode operation
  • Handling no-injection cranking operation
  • Testing and adjusting air conditioner compressor belt tension
  • Replacing fan belt
  • Precautions related to hybrid equipment
  • Bleeding air from hybrid cooling system
  • Testing water pressure of hybrid coolant
  • Testing swing parking brake
  • Cleaning and replacing oil filter of electric swing motor
Testing swing circle bearing clearance
Testing and adjusting track tension
Releasing remaining pressure from hydraulic circuit
Testing oil pressure of control circuit
Testing and adjusting oil pressure in work equipment and travel circuits
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing outlet pressure of solenoid valve
Testing PPC valve outlet pressure
Adjusting play of work equipment and swing PPC valves
Testing pump swash plate sensor
Isolating the parts causing hydraulic drift in work equipment
Testing oil leakage
Bleeding air from hydraulic circuit
Testing cab tipping stopper
Adjusting mirrors
Special functions of machine monitor
KOMTRAX terminal start-up procedure
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service
Troubleshooting
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Checks before troubleshooting
Inspection procedure before troubleshooting
Preparation for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Diagnostic procedure for wiring harness open curcuit of pressure sensor system
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Fuse location table
Failure codes table
Troubleshooting by failure code (Display of code)
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
Failure code [989L00] Engine Controller Lock Caution1
Failure code [989M00] Engine Controller Lock Caution259 topics
  • Failure code [989N00] Engine Controller Lock Caution3
  • Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3
  • Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1
  • Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2
  • Failure code [AA10NX] Air Cleaner Clogging
  • Failure code [AB00KE] Charge Voltage Low
  • Failure code [B@BAZG] Eng Oil Press Low
  • Failure code [B@BAZK] Eng Oil Level Low
  • Failure code [B@BCNS] Eng Water Overheat
  • Failure code [B@BCZK] Eng Water Level Low
  • Failure code [B@HANS] Hyd Oil Overheat
  • Failure code [CA115] Eng Ne and Bkup Speed Sens Error
  • Failure code [CA122] Chg Air Press Sensor High Error
  • Failure code [CA123] Chg Air Press Sensor Low Error
  • Failure code [CA131] Throttle Sensor High Error
  • Failure code [CA132] Throttle Sensor Low Error
  • Failure code [CA144] Coolant Temp Sens High Error
  • Failure code [CA145] Coolant Temp Sens Low Error
  • Failure code [CA153] Chg Air Temp Sensor High Error
  • Failure code [CA154] Chg Air Temp Sensor Low Error
  • Failure code [CA187] Sensor 2 Supply Volt Low Error
  • Failure code [CA221] Ambient Press Sensor High Error
  • Failure code [CA222] Ambient Press Sens Low Error
  • Failure code [CA227] Sensor 2 Supply Volt High Error
  • Failure code [CA234] Eng Overspeed
  • Failure code [CA238] Ne Speed Sensor Supply Volt Error
  • Failure code [CA239] Ne Speed Sens Supply Volt High Error
  • Failure code [CA271] IMV/PCV1 Short Error
  • Failure code [CA272] IMV/PCV1 Open Error
  • Failure code [CA295] Ambient Press Sens In Range Error
  • Failure code [CA322] Inj #1(L#1) Open/Short Error
  • Failure code [CA324] Inj #3(L#3) Open/Short Error
  • Failure code [CA331] Inj #2(L#2) Open/Short Error
  • Failure code [CA332] Inj #4(L#4) Open/Short Error
  • Failure code [CA343] ECM Critical Internal Failure
  • Failure code [CA351] Injectors Drive Circuit Error
  • Failure code [CA352] Sensor 1 Supply Volt Low Error
  • Failure code [CA356] Mass Air Flow Sensor High Error
  • Failure code [CA357] Mass Air Flow Sensor Low Error
  • Failure code [CA386] Sensor 1 Supply Volt High Error
  • Failure code [CA428] Water in Fuel Sensor High Error
  • Failure code [CA429] Water in Fuel Sensor Low Error
  • Failure code [CA435] Eng Oil Press Sw Error
  • Failure code [CA441] Battery Voltage Low Error
  • Failure code [CA442] Battery Voltage High Error
  • Failure code [CA449] Rail Press Very High Error
  • Failure code [CA451] Rail Press Sensor High Error
  • Failure code [CA452] Rail Press Sensor Low Error
  • Failure code [CA466] KVGT Motor Driver Position Error
  • Failure code [CA488] Chg Air Temp High Torque Derate
  • Failure code [CA515] Rail Press Sens Sup Volt High Error
  • Failure code [CA516] Rail Press Sens Sup Volt Low Error
  • Failure code [CA553] Rail Press High Error
  • Failure code [CA555] Crankcase Press High Error 1
  • Failure code [CA556] Crankcase Press High Error 2
  • Failure code [CA559] Rail Press Low Error
  • Failure code [CA689] Eng Ne Speed Sensor Error
  • Failure code [CA691] Intake Air Temp Sens High Error
  • Failure code [CA692] Intake Air Temp Sens Low Error
Failure code [CA697] ECM Internal Temp Sensor High Error
Failure code [CA698] ECM Int Temp Sensor Low Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1117] Persistent Data Lost Error
Failure code [CA1695] Sensor 5 Supply Volt High Error
Failure code [CA1696] Sensor 5 Supply Volt Low Error
Failure code [CA1843] Crankcase Press Sens High Error
Failure code [CA1844] Crankcase Press Sens Low Error
Failure code [CA1896] EGR Valve Stuck Error
Failure code [CA1942] Crankcase Press Sens In Range Error
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error
Failure code [CA2185] Throt Sensor Sup Volt High Error
Failure code [CA2186] Throt Sensor Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2349] EGR Valve Solenoid Open Error
Failure code [CA2353] EGR Valve Solenoid Short Error
Failure code [CA2357] EGR Valve Servo Error
Failure code [CA2373] Exhaust Manifold Press Sens High Error
Failure code [CA2374] Exhaust Manifold Press Sens Low Error
Failure code [CA2375] EGR Orifice Temp Sens High Error
Failure code [CA2376] EGR Orifice Temp Sens Low Error
Failure code [CA2387] KVGT Servo Error
Failure code [CA2554] Exh Manifold Press Sens In Range Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [CA2961] EGR Orifice Temp High Error 1
Failure code [CA2973] Chg Air Press Sensor In Range Error
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error
Failure code [CA3741] Rail Press Valve Trip Error
Failure code [CA3918] KVGT Stuck Error
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error
Failure code [CA3921] KVGT Servo Error 2
Failure code [CA3922] KVGT Motor Driver Open Error
Failure code [CA3923] KVGT Motor Driver Short Error
Failure code [D110KB] Battery Relay Drive Short Circuit
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D811MC] KOMTRAX Error
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
Failure code [DA20MC] Pump Controller Malfunction
Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA25KP] 5V Sensor 1 Power Abnormality
Failure code [DA26KP] 5V Sensor 2 Power Abnormality
Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con)
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con)
Failure code [DA2QKR] CAN2 Discon (Pump Con)
Failure code [DA2RKR] CAN1 Discon (Pump Con)
Failure code [DAF0MB] Monitor ROM Abnormality
Failure code [DAF0MC] Monitor Error
Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAF9KQ] Model Selection Abnormality59 topics
  • Failure code [DAFGMC] GPS Module Error
  • Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor)
  • Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)
  • Failure code [DAFQKR] CAN2 Discon (Monitor)
  • Failure code [DAZ9KQ] A/C Model Selection Abnormality
  • Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
  • Failure code [DB2QKR] CAN2 Discon (Engine Con)
  • Failure code [DB2RKR] CAN1 Discon (Engine Con)
  • Failure code [DGH2KB] Hyd Oil Sensor Short Circuit
  • Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
  • Failure code [DHPAMA] F Pump Press Sensor Abnormality
  • Failure code [DHPBMA] R Pump Press Sensor Abnormality
  • Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
  • Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
  • Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
  • Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality
  • Failure code [DHSAKZ] Swing RH PPC Press Sensor Abnormality
  • Failure code [DHSBKZ] Swing LH PPC Press Sensor Abnormality
  • Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality
  • Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
  • Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality
  • Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality
  • Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality
  • Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality
  • Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt
  • Failure code [DHVAL8] HYB Swing-R PPC Pr. Sen. Signal Mismatch
  • Failure code [DHVAMA] HYB Swing-R PPC Sensor Malfunction
  • Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen. Opn/Short Cir
  • Failure code [DHVBL8] HYB Swing-L PPC Pr. Sen. Signal Mismatch
  • Failure code [DHVBMA] HYB Swing-L PPC Sensor Malfunction
  • Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality
  • Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality
  • Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
  • Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
  • Failure code [DV20KB] Travel Alarm Short Circuit
  • Failure code [DW43KA] Travel Speed Sol Open Circuit
  • Failure code [DW43KB] Travel Speed Sol Short Circuit
  • Failure code [DW45KA] Swing Brake Sol Open Circuit
  • Failure code [DW45KB] Swing Brake Sol Short Circuit
  • Failure code [DW45KK] Swing Brake Sol. Valve Low Sup. Voltage
  • Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir
  • Failure code [DW91KA] Travel Junction Sol Open Circuit
  • Failure code [DW91KB] Travel Junction Sol Short Circuit
  • Failure code [DWA2KA] Attachment Sol Open Circuit
  • Failure code [DWA2KB] Attachment Sol Short Circuit
  • Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit
  • Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit
  • Failure code [DWK2KA] Variable Back Press Sol Open Circuit
  • Failure code [DWK2KB] Variable Back Press Sol Short Circuit
  • Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
  • Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
  • Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
  • Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
  • Failure code [DXE0KA] LS-EPC Sol Open Circuit
  • Failure code [DXE0KB] LS-EPC Sol Short Circuit
  • Failure code [DXE4KA] Attachment Flow EPC Open Circuit
  • Failure code [DXE4KB] Attachment Flow EPC Short Circuit
  • Failure code [DXE5KA] Merge-divide Main Sol Open Circuit
  • Failure code [DXE5KB] Merge-divide Main Sol Short Circuit
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive Short Circuit
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit2 topics
  • voltage parts
    • components
Failure code [GA00NS] HYB Equipment Overheat
Failure code [GA01KA] Power Cable Interlock Open Circuit
Failure code [GA01KB] Power Cable Interlock Short Circuit
Failure code [GA02KZ] DC Line Open & Short Circuit
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster
Failure code [GA08KG] Abnorm. DC HW Volt. After Booster
Failure code [GA09KG] Abnorm. DC SW Volt. After Booster
Failure code [GA09KP] Low DC SW Output Volt. After Booster
Failure code [GA0AKZ] DC Vlt. Sen. Op./Shrt Cir. Aft. Booster
Failure code [GA0BKZ] AC Line Open & Short Circuit
Failure code [GA10MA] HYB Controller Malfunction
Failure code [GA10MC] HYB Controller Error
Failure code [GA12NK] High-Voltage Line Start-up Failure
Failure code [GA13KP] Low HYB Control. Sen. Power Sup
Failure code [GA13KY] HYB Control. Sen. Power Short Cir
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded
Failure code [GA18MC] Gen. Mo.Dr. Excite. Pow. Sup. Failure
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure
Failure code [GA1FMA] Abnormal Swing Motor Driver
Failure code [GA1GKR] Swg Mot. Driver Sub-CPU Comm. Failure
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens. Opn/Shrt Cir
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen. Opn/Shrt Cir
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat
Failure code [GA1SFS] Contactor Locked
Failure code [GA1SMC] Contactor Failure
Failure code [GA1TKP] Capacitor Low Output Voltage
Failure code [GA1TNS] Capacitor Overheat
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/short Cir
Failure code [GA1VFS] Capacitor Contactor Locked
Failure code [GA1VMC] Capacitor Contactor Failure
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ
Failure code [GA1YNS] Booster Inductor Overheat
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat
Failure code [GA22NS] Booster IGBT Junction Overheat39 topics
  • Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sen.0 Opn/Short Cir
  • Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sen.1 Opn/Short Cir
  • Failure code [GA25MA] Gen. Motor Driver IGBT 0 Abnormality
  • Failure code [GA25NS] Gen. Motor Driver IGBT 0 Overheat
  • Failure code [GA26MA] Gen. Motor Driver IGBT 1 Abnormality
  • Failure code [GA26NS] Gen. Motor Driver IGBT 1 Overheat
  • Failure code [GA27KZ] DC Cur. Sens. Bef. Booster Opn/Short Cir
  • Failure code [GA2QKR] CAN2 Discon (Hyb Con)
  • Failure code [GA2RKR] CAN1 Discon (Hyb Con)
  • Failure code [GA60KZ] Generator Motor Open/Short Circuit
  • Failure code [GA60MC] Generator Motor Failure
  • Failure code [GA60N1] Generator Motor Overrun
  • Failure code [GA61KZ] Gen. Motor Temp. Sens. Opn/Short Cir
  • Failure code [GA61NS] Generator Motor Temp. Sensor Overheat
  • Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir
  • Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir
  • Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction
  • Failure code [GA62MC] Gen. Mot. Ph-A Cur. Sen. Defect Op
  • Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir
  • Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir
  • Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction
  • Failure code [GA63MC] Gen. Mot. Ph-B Cur. Sen. Defect Op
  • Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir
  • Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir
  • Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction
  • Failure code [GA64MC] Gen. Mot. Ph-C Cur. Sen. Defect Op
  • Failure code [GA70KB] HYB Swing Motor Short Circuit
  • Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion
  • Failure code [GA70NS] HYB Swing Motor Overheat
  • Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir
  • Failure code [GA72MA] HYB Swing Motor Resolver Malfunction
  • Failure code [GA72MC] HYB Swing Motor Resolver Defect Op
  • Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ
  • Failure code [GAA0KB] HYB Con. Battery Relay Drive Short Cir
  • Failure code [GAA2KB] Swing Brake Sol. Supply Line Short Cir
  • Failure code [GAA6KP] Low HYB Control. Sen. Power 2 Sup
  • Failure code [GAA6KY] HYB Control. Sen. Power 2 Short Cir
  • Failure code [GACLKA] Operating Lamp Open Circuit (HYB Con)
  • Failure code [GACLKB] Operating Lamp Short Circuit (HYB Con)
Troubleshooting of electrical system (E-mode)15 topics
  • Engine does not start (Engine does not crank)
  • Manual preheating system does not work
  • Automatic preheating system does not work
  • While preheating is working, preheating monitor does not light up
  • When starting switch is turned to ON position, machine monitor displays nothing
  • Engine coolant temperature monitor lights up in white while engine is running
  • Hydraulic oil temperature monitor lights up in white while engine is running
  • Charge level monitor lights up in red while engine is running
  • Fuel level monitor lights up in red while engine is running
  • Air cleaner clogging monitor lights up in yellow while engine is running
  • Water separator monitor lights up in red while engine is running
  • Engine coolant temperature monitor lights up in red while engine is running
  • Hydraulic oil temperature monitor lights up in red while engine is running
  • Hybrid temperature monitor lights up in red while engine is running
  • Engine oil pressure monitor lights up in red while engine is running
Fuel gauge display does not move from minimum or maximum
Fuel gauge indicates incorrect amount (indicates neither full nor empty)2 topics
  • maximum
    • nor empty)
Hydraulic oil temperature gauge does not move from minimum or maximum1 topic
  • empty)
Hybrid temperature gauge does not move from minimum or maximum2 topics
  • empty)
    • condition
Some areas of machine monitor screen are not displayed
Function switch does not work
Automatic warm-up system does not operate (in cold season)3 topics
  • switch is operated
    • operated
    • changed
Travel speed monitor does not change when travel speed switch is operated
Travel speed does not change while travel speed selection is changed
Alarm buzzer does not stop sounding
Service meter is not displayed, while starting switch is in OFF position
Service mode cannot be selected
None of work equipment, swing or travel works
Any of work equipment, swing and travel cannot be locked3 topics
  • CANCEL position
    • position
    • monitor
One-touch power maximizing function cannot be canceled
Alarm does not sound during travel
Alarm does not stop sounding while machine is stopped
Horn does not sound
Horn does not stop sounding1 topic
  • operated
Wiper does not operate while wiper switch is operated
Window washer does not operate while window washer switch is operated
Boom LOWER is not displayed correctly with monitoring function
Arm OUT is not displayed correctly with monitoring function
Arm IN is not displayed correctly with monitoring function
Boom RAISE is not displayed correctly with monitoring function
Bucket CURL is not displayed correctly with monitoring function
Bucket DUMP is not displayed correctly with monitoring function
Swing is not displayed correctly with monitoring function
Travel is not displayed correctly with monitoring function
Service is not displayed correctly with monitoring function
Attachment hydraulic circuit cannot be changed
KOMTRAX system does not operate normally
Troubleshooting of hydraulic and mechanical system (H-mode)32 topics
  • Information described in troubleshooting table (H-mode)
  • System chart of hydraulic and mechanical systems
  • Failure mode and cause table
  • All of work equipments and travel operations lack speed or power
  • Engine speed drops significantly or engine stalls
  • None of work equipment or travel works
  • Unusual sound is heard from around hydraulic pump
  • Fine control performance or response is poor
  • Boom speed or power is low
  • Arm speed or power is low
  • Bucket speed or power is low
  • Work equipment does not move in single operation
  • Hydraulic drift of boom is large
  • Hydraulic drift of arm is large
  • Hydraulic drift of bucket is large
  • Time lag of work equipment is large
  • One-touch power maximizing function does not operate
  • Machine does not travel straight
  • Travel speed is slow
  • Machine is hard to steer or travel power is low
  • Travel speed does not change, or travel speed is too slow or fast
  • One of tracks does not run
  • Upper structure does not swing to the right or left
  • Upper structure swings only to the right or left
  • Swing acceleration or swing speed is low in both directions (right and left)
  • Upper structure overruns excessively when it stops swinging (either right or left)
  • Shock is large when upper structure stops swinging
  • Large unusual noise is heard when upper structure stops swinging
  • Swing drift on a slope is large while swing parking brake is applied
  • Swing drift on a slope is large while swing parking brake is released
  • Attachment hydraulic circuit cannot be changed while attachment is installed
  • Oil flow in attachment circuit cannot be controlled
Troubleshooting of engine (S-mode)16 topics
  • Information mentioned in troubleshooting table (S mode)
  • Engine does not crank when starting switch is turned to START position
  • Engine cranks but no exhaust smoke comes out
  • Engine startability is poor
  • Engine does not pick up smoothly
  • Engine stops during operation
  • Engine runs rough or is unstable
  • Engine lacks power
  • Exhaust smoke is black
  • Engine oil consumption is excessive
  • Oil becomes contaminated quickly
  • Fuel consumption is excessive
  • Oil is in coolant (or coolant spurts or coolant level goes down)
  • Oil pressure drops
  • Fuel mixes into engine oil
  • Water mixes into engine oil (milky)
Coolant temperature rises too high (overheating)
Unusual noise is heard
Vibration is excessive
Air cannot be bled from fuel circuit
Troubleshooting for hybrid systems (Y mode)
Precautions related to hybrid equipment
Hybrid monitor does not go out
Machine does not swing
Swing acceleration or swing speed is low
Upper structure overruns excessively when it stops swinging
Shock is large when upper structure stops swinging
Large unusual noise is heard when upper structure stops swinging
Swing drift on a slope is large
Electric swing motor temperature increases abnormally
Motor-generator temperature increases abnormally
Inverter temperature increases abnormally
Capacitor temperature increases abnormally
Disassembly and assembly
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Removal and installation of supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of engine, motor-generator, and main pump assembly
Removal and installation of fan belt
Removal and installation of starting motor
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of fuel cooler assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Removal and installation of KDOC assembly
Removal and installation of KCCV assembly
Removal and installation of air cleaner assembly
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
Draining coolant, refilling with coolant, and bleeding air for hybrid system
Removal and installation of hybrid radiator assembly
Removal and installation of hybrid water pump assembly
Removal and installation of inverter assembly
Removal and installation of inverter and capacitor assembly
Procedure for draining and refilling generator lubricating oil
Removal and installation of tandem pump assembly
Removal and installation of motor-generator and housing assembly
Removal and installation of electric swing motor assembly
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of final drive
Removal and installation of swing motor and swing machinery assembly37 topics
  • Disassembly and assembly of swing machinery assembly
  • Removal and installation of swing circle assembly
  • Separation and connection of track shoe assembly
  • Removal and installation of sprocket
  • Removal and installation of idler and idler cushion assembly
  • Disassembly and assembly of idler assembly
  • Disassembly and assembly of idler cushion assembly
  • Disassembly and assembly of track roller assembly
  • Disassembly and assembly of carrier roller assembly
  • Removal and installation of revolving frame assembly
  • Removal and installation of counterweight assembly
  • Removal and installation of center swivel joint assembly
  • Disassembly and assembly of center swivel joint assembly
  • Removal and installation of hydraulic tank assembly
  • Removal and installation of main pump assembly
  • Removal and installation of control valve assembly
  • Disassembly and assembly of control valve assembly
  • Disassembly and assembly of work equipment PPC valve
  • Disassembly and assembly of travel PPC valve assembly
  • Removal and installation of work equipment assembly
  • Disassembly and assembly of work equipment cylinder assembly
  • Removal and installation of operator's cab assembly
  • Removal and installation of operator cab glass (adhered glass)
  • Removal and installation of front window assembly
  • Removal and installation of floor frame assembly
  • Removal and installation of air conditioner unit assembly
  • Removal and installation of operator's seat
  • Removal and installation of seat belt
  • Removal and installation of front wiper assembly
  • Removal and installation of air conditioner compressor assembly
  • Removal and installation of air conditioner condenser assembly
  • Removal and installation of engine controller assembly
  • Removal and installation of pump controller assembly
  • Removal and installation of machine monitor assembly
  • Removal and installation of pump swash plate sensor
  • Removal and installation of mass air flow and temperature sensor
  • Removal and installation of KOMTRAX terminal assembly
Maintenance standard11 topics
  • Engine mount
  • Cooling system
  • Swing circle
  • Swing machinery with swing brake
  • Final drive
  • Sprocket
  • Track frame and idler cushion
  • Idler
  • Track roller
  • Carrier roller
  • Track shoe
Hydraulic tank
Main pump
Control valve
Travel motor
PPC valve
Solenoid valve
Attachment circuit selector valve (for high-pressure circuit)
Attachment circuit selector valve (for low-pressure circuit)
Center swivel joint
Work equipment cylinder
Appendix
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Air conditioner condenser
Sunlight sensor
Outer temperature sensor (outside air temperature sensor)
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Failure code list related to air conditioner
Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting for compressor and refrigerant system (Air is not cooled)1 topic
  • abnormal)
Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping2 topics
  • Handling of compressor oil
  • Desiccant replacement
Diagrams and drawings
Hydraulic circuit diagram2 topics
  • Symbols in hydraulic circuit diagram
  • Hydraulic circuit diagram
Electric circuit diagram3 topics
  • Symbols in electric circuit diagram
  • Electrical circuit diagram
  • Electrical circuit diagram of air conditioner unit

Inside this manual

Real pages from this service manual (1,838 pages). Open the sample pages (PDF, 845 KB)

Sample pages from the Komatsu HB215LC-2 Hybrid Hydraulic Excavator Service Manual: Specifications, Troubleshooting, Diagram, Foldout diagram
  • Specifications, page 76: SHOP MANUAL
  • Troubleshooting, page 888: Failure code [DA26KP] 5V Sensor 2 Power Abnormality
  • Diagram, page 1,056: Note 4: Marks on the engine motor-generator are as follows:
  • Foldout diagram, page 1,818: Electrical circuit diagram (1/8) (EU specification)

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,838 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Komatsu HB215LC-2Operation & Maintenance Manual · TEN00651-01 · $69.57

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).