PDF Shop Manual Komatsu HB215LC-2 Hydraulic Excavator - 7 MB
The official shop manual for the Komatsu HB215LC-2 Hybrid Hydraulic Excavator provides comprehensive service information.
This guide contains detailed, step-by-step procedures for repair and maintenance of all systems, including the unique hybrid powertrain.
It is an essential tool for technicians to correctly diagnose and repair this advanced machine, ensuring optimal performance and efficiency.
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--- Page 1 ---
SHOP MANUAL
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
HB215LC-2 K60001 and up
00 Index and foreword
HB215LC-2 00-1
--- Page 3 ---
00 Index and foreword
Foreword, safety and general information
Some machines are equipped with KDPF
(Komatsu Diesel Particulate Filter).
KDPF is a system for purifying soot in exhaust
gas.Its exhaust gas discharged during
purification process (regeneration) can be at
higher temperature than that from existing
models. Do not bring any flammable material
close to the outlet of the exhaust pipe.
q When there are thatched houses, dry leaves
or pieces of paper near the work site, set the
system to disable the regeneration before
starting work to prevent fire hazards due to
highly heated exhaust gas.
See the operation and maintenance manual
for the setting procedure.
q Explosion caused by lighting equipment
q When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
q When taking the electrical power for the
lighting equipment from the machine itself,
follow the instructions in the operation and
maintenance manual.
00-22 HB215LC-2
--- Page 4 ---
00 Index and foreword
Foreword, safety and general information
When performing arc welding on the machine
body, disconnect all the wiring harness
connectors connected to the controller. Put the
arc welding ground to the place close to the
welding point.
Precautions for troubleshooting electrical
circuits
q Be sure to turn the starting switch to "OFF"
position before disconnecting or connecting the
connectors.
q Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
Handling controller performance by disconnecting and
q The electronic circuits for control including the connecting them several times.
microcomputers are assembled in the controller. q Be sure to connect all the disconnected
These electronic circuits in the controller must connectors before proceeding to the next step.
be handled with care as they control the a If the starting switch is turned to "ON"
machine. position with the connectors disconnected,
q Do not place objects on top of the controller.
the failure which is not related to the part
which is actually failed.
q When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wiring
harnesses and connectors several times and
check that the multimeter reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.
q Cover the control connectors with tape or a vinyl
bag. Never touch the connector contacts.
q During rainy weather, do not leave the controller
in a place where it is exposed to rain.
q 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 period of time.
(Place it on a suitable dry stand.)
q Precautions when performing arc welding
HB215LC-2 00-43
--- Page 5 ---
00 Index and foreword
Foreword, safety and general information
Standard tightening torque table (ALL-M140-03BP01A)
:
Standard tightening torque table
(Rev. 2012/10)
Table of tightening torque for bolts and nuts
Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
Thread diameter Width across flats
Tightening torque (Nm {kgm})
(mm) (mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6.0 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10.0 to 12.5}
(*1, *2) 17
14 22 157 to 196 {16 to 20}
24
16 245 to 309 {25 to 31.5}
(*1) 22
18 27 343 to 427 {35 to 43.5}
20 30 490 to 608 {50 to 62}
22 32 662 to 829 {67.5 to 84.5}
24 36 824 to 1,030 {84 to 105}
27 41 1,180 to 1,470 {120 to 150}
30 46 1,520 to 1,910 {155 to 195}
33 50 1,960 to 2,450 {200 to 250}
36 55 2,450 to 3,040 {250 to 310}
39 60 2,890 to 3,630 {295 to 370}
*1: Split flange bolt.
*2: Flanged bolt.
00-64 HB215LC-2
--- Page 6 ---
00 Index and foreword
Foreword, safety and general information
1°C = 33.8°F
°C °F °C °F °C °F °C °F
-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
HB215LC-2 00-85
--- Page 7 ---
10 Structure and function
Engine and cooling system
1. VFT motor
2. Flange bolt
3. Bracket
4. Thrust sleeve
5. Bracket
10-6 HB215LC-2
--- Page 8 ---
10 Structure and function
Hybrid system
One-touch connector
1. Core conductor
2. Waterproof seal
3. Electromagnetic shield
4. Insulator
q The electrodes of the one-touch connector are protected with waterproof seal (2) and insulator (4), and
you cannot touch them easily.
HB215LC-2 10-27
--- Page 9 ---
10 Structure and function
Hydraulic system
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. R.H. PPC valve for work equipment
5. Hydraulic tank
6. Main pump
7. Control valve
8. Accumulator (for PPC circuit)
9. Oil cooler
10. L.H. travel motor
11. Solenoid valve
12. R.H. travel motor
13. L.H. PPC valve for work equipment
14. 2nd-line attachment PPC valve (*1)
15. Travel PPC valve
16. 1st-line attachment PPC valve (*1)
17. Centre swivel joint
*1: Machines ready for installation of attachment
10-48 HB215LC-2
--- Page 10 ---
10 Structure and function
Hydraulic system
When servo piston is balanced
q The symbols (A1), (A0) and (PEN) represent the area receiving the pressure at the large diameter end of
the piston, the area receiving the pressure at the small diameter end and the pressure transmitted to the
large diameter end of the piston, respectively.
q When the force exerted by main pump pressure (PP) of the LS valve is balanced with the combined force
exerted by LS pressure (PLS) and spring (4), and the relationship becomes (A0) x (PP) = (A1) x (PEN),
servo piston (12) stops in that position.
q The swash plate of the pump is held at the intermediate position. [The swash plate stops at a position
where the openings from port (D) to port (E) and from port (C) to port (D) of spool (6) are approximately
equal]
q The relationship between the area receiving the pressure at both ends of servo piston (12) is (A0) : (A1)
= 3 : 5, and the pressures transmitted to both ends of the piston when the piston is balanced is (PP) : (PEN)
C 5 : 3.
q The force of spring (4) is adjusted so that spool (6) can be balanced at the specified centre when (PP) -
(PLS) = 1.7 MPa {17.75 kg/cm2}.
2
q When (PSIG) [LS-EPC valve output pressure, 0 to 2.9 MPa {0 to 30 kg/cm }] is transmitted to port (G), the
balanced position changes in proportion to the (PSIG) pressure within a range of (PP) - (PLS) = 1.7 MPa
{17.75 kg/cm2} to 0.27 MPa {2.78 kg/cm2}.
HB215LC-2 10-69
--- Page 11 ---
10 Structure and function
Hydraulic system
A1: To bucket cylinder head
A2: To L.H. travel motor
A3: To boom cylinder bottom
A4: Plug
A5: To R.H. travel motor
A6: To arm cylinder head
A-1: To attachment 1
ATT: From attachment
B1: To bucket cylinder bottom
B2: To L.H. travel motor
B3: To boom cylinder head
B4: Plug
B5: To R.H. travel motor
B6: To arm cylinder bottom
B-1: To attachment 1
BP5: From attachment selector solenoid valve
C: To oil cooler
P1: From bucket PPC, EPC valve (bucket DUMP)
P2: From bucket PPC, EPC valve (bucket CURL)
P3: From L.H. travel PPC valve (left travel REVERSE)
P4: From L.H. travel PPC valve (left travel FORWARD)
P5: From boom PPC, EPC valve (boom RAISE)
P6: From boom PPC, EPC valve (boom LOWER)
P9: From R.H. travel PPC valve (right travel REVERSE)
P10: From R.H. travel PPC valve (right travel FORWARD)
P11: From arm PPC, EPC valve (arm OUT)
P12: From arm PPC, EPC valve (arm IN)
P-1: From service 1, PPC valve
P-2: From service 1, PPC valve
PLS1: To rear pump LS valve
PLS2: To front pump LS valve
PLSC: LS pressure pickup port
PP1. From front pump
PP2: From rear pump
PP2S: Pressure sensor mounting port
PPC: Pilot source pressure pickup port
PPS1: Pressure sensor mounting port
PPS2: To front pump control
PR: To solenoid valve, PPC valve and EPC valve
PST: From travel junction solenoid valve
PX1: From 2-stage relief solenoid valve
PX2: From 2-stage relief solenoid valve
T: To tank
T1: To tank
TS: To tank
TSW: Plug
CN: From controller
IS1: From controller
IS2: From controller
1. Boom hydraulic drift prevention valve
2. 6-spool valve
3. Service valve 1
4. Cover A
5. Arm quick return valve
6. Cover B
7. Arm hydraulic drift prevention valve
8. Merge-divider valve
10-90 HB215LC-2
--- Page 12 ---
10 Structure and function
Hydraulic system
When travelling
Structure
q Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve
without shuttle valve (5) is adopted.
HB215LC-2 10-111
--- Page 13 ---
10 Structure and function
Hydraulic system
10-132 HB215LC-2
--- Page 14 ---
10 Structure and function
Hydraulic system
Brake valve (ALL-C4Q0-041K00A)
: Brake valve is comprised of suction safety
Brake valve
q
valves (18A) and (18B), and counterbalance
valve (18).
Counterbalance valve (PC220-C4N0-042K00A)
:
Counterbalance valve
Function
q When the machine travels down a slope, its travel speed tends to get faster than the motor (engine) speed
because of the downward force generated from its own weight.
q Travelling the machine with the engine running at a low speed may induce idle run of the motor that allows
the machine to run out of control, posing a danger.
q These valves serve to prevent the above problem by enabling the machine to travel at a speed that
matches the engine speed (pump discharged volume).
Operation (PC-C4N0-044K00A)
:
Operation
HB215LC-2 10-153
--- Page 15 ---
10 Structure and function
Hydraulic system
P: From self-pressure reducing valve
P1: To control valve (service valve 1 port)
P2: To control valve (service valve 1 port)
T: To hydraulic tank
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. EPC valve
EPC valve (PC200_10-PL2B-041K00A)
:
EPC valve
(Machines ready for installation of attachment)
a EPC: Abbreviation for Electromagnetic Proportional Control
10-174 HB215LC-2
--- Page 16 ---
10 Structure and function
Hydraulic system
Quick coupler control valve
Quick coupler control valve
1a
2
1b
2a
1
4
3
5
5a
5b
1. Pressure regulating valve (Unlock)
1a Lock nut
1b Adjustment screw
2. Solenoid
2a Nut
3. Directional control valve
4. Block
5. Pressure regulating valve (Lock)
5a Lock nut
5b Adjustment screw
Specification
Min. set pressure: 1 MPa (10.2 kg/cm2)
Max. set pressure: 30 ± 5 MPa (306 ± 51 kg/cm2)
Flow: 120 l/min.
Operation
1. When solenoid is switched OFF
q Since the signal from the operation switches is off, solenoid (2) is de-energized.
For this reason, directional control valve (3) is in the default position and oil will flow from port P to port B.
q Oil returning from the quick coupler will flow from port A to port T.
1a. The setting of the pressure regulating valve (5) will determine the maximum pressure at port B.
Note: if the settings of valve (1) is lower than valve (5), the maximum pressure at port B will then be
determined by valve (1).
q When the stroke end of the quick coupler cylinder is reached, the pressure at the cylinder will be the set
pressure of the regulating valve (1).
q The pressure regulating valve can be adjusted according to the specification of the coupler. The minimum
setting is 1 MPa and the maximum setting is 30 MPa ± 5 MPa.
2. When solenoid is switched ON
HB215LC-2 10-195
--- Page 17 ---
10 Structure and function
Electrical system
Pump and valve control function (HB205-C3W1-042K00A)
:
Pump and valve control function
1. Battery disconnect switch
2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resister for PC–EPC valve
7. Pump controller
8. Engine controller
9. Machine monitor
10. Emergency pump drive switch
11. Fuel control dial
12. Fuel supply pump
13. Various sensors
14. Front pump swash plate sensor
15. Rear pump swash plate sensor
16. Front pump
16a. Servo
16b. LS valve
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
10-216 HB215LC-2
--- Page 18 ---
10 Structure and function
Electrical system
PPC lock function (PC-PX16-042K00A)
:
PPC lock function
a PPC: Abbreviation for Proportional Pressure Control
1. Battery disconnect switch
2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Lock lever
8. PPC lock switch
9. Main pump
10. Control valve
10a. Self-pressure reducing valve
10b. Merge-divider valve
10c. Travel junction valve
11. PPC lock solenoid valve
Function
q Interlocked with the lock lever, PPC lock switch is turned off when the lock lever is moved to “LOCK”
position.
q When the PPC lock switch is turned off, current to the PPC lock solenoid valve is shut off. Even if each
control lever or pedal is operated, the work equipment and machine do not move.
HB215LC-2 10-237
--- Page 19 ---
10 Structure and function
Electrical system
Inverter (HB205-PQGK-041K00A)
:
Inverter
Input and output signals of hybrid controller (HB205-PQGK-03CK00A)
:
Input and output signals of hybrid controller
DRC26-24P [CN-HC01]
Pin No. Signal name Input/output
1 Battery relay terminal M power supply (24 V) Input
2 NC (*1) -
3 Capacitor contactor (+) Output
4 NC (*1) -
5 Continuous power supply (24 V) Input
6 Starting switch (ACC) Input
7 Battery relay terminal M power supply (24 V) Input
8 Swing parking brake solenoid Output
10-258 HB215LC-2
--- Page 20 ---
10 Structure and function
Electrical system
Hybrid temperature gauge (detailed)
The temperatures of the hybrid devices shown below are converted into percentages and their maximum
values are indicated on the gauges.
Booster Booster Booster
Hybrid device tempera- Capacitor
% IGBT base tem- IGBT JCT tem- inductor temper-
ture Cell temperature
perature perature ature
E1 102 65 80 130 125
E2 100 63 78 125 120
E3 95 60 75 110 110
E4 50 40 55 90 90
E5 20 0 0 0 0
E6 0 -30 -30 -30 -30
HB215LC-2 10-279
--- Page 21 ---
10 Structure and function
Electrical system
VFT motor (with built-in position sensor) (ENG95-AA56-041K00A)
:
VFT motor (with built-in position sensor)
a VFT: Abbreviation for Variable Flow Turbocharger
a The shape is subject to machine models.
1. VFT motor (brushless motor with built-in position sensor)
2. Turbine part
3. Connector
Function (ENG95-AA56-042K00A)
:
Function
q Controls the flow control valve with a DC motor.
q The VFT motor has a position sensor in it to sense the valve position.
10-300 HB215LC-2
--- Page 22 ---
10 Structure and function
Electrical system
3. Distribution blocks
4. Metering units
5. Secondary grease lines
6. Grease pressure switch
7. Primary grease line A
8. Primary grease line B
1 5
4
6
3
8 7
2
8 7
Figure 1 Overview of the automatic greasing system
Components
(a) The Grease Pump
The relief valve
A relief valve is mounted in the grease line between the plunger-pump and the diverter-valves. When the
grease pressure exceeds 250 bar during the pumping phase, the relief valve will redirect the grease to the
reservoir.
The maximum grease pressure will be exceeded when:
q A malfunction of the grease pressure switch, which is mounted in the system occurs.
q A malfunction in the cable of the grease pressure switch occurs.
The grease pressure switch is intended to end the pumping phase, as soon as the minimum required grease
pressure is reached.
The minimum-level switch
A level switch maintains the grease level in the reservoir. When the grease reaches the minimum level, the
level switch will notify the control unit. At the beginning of every following grease cycle a signal lamp in the
cabin will flash as a warning that the reservoir has to be filled.
The test push-button
The grease system can be tested by starting one or more test cycles by means of the test push-button on the
pump unit. This button also can be used to reset the control unit.
HB215LC-2 10-321
--- Page 23 ---
20 Standard value tables
Standard service value table
Machine model HB215LC-2
Standard value
Item Measurement condition Unit Repair limit
for new machine
Front pump
36.1 to 38.8 36.1 to 38.8
discharged
{368 to 395} {368 to 395}
q Hydraulic oil pressure
temperature: 45 to
PC valve outlet 55°C Servo piston Above value x Above value x
pressure q Engine: High idle
inlet pressure MPa approx. 0.6 approx. 0.6
(servo piston inlet q Working mode: P mode
Rear pump {kg/cm2}
pressure) q Swing lock switch: ON 36.1 to 38.8 36.1 to 38.8
discharged
q Work equipment {368 to 395} {368 to 395}
pressure
control: Arm IN relief
Servo piston Above value x Above value x
inlet pressure approx. 0.6 approx. 0.6
q Hydraulic oil Approx. 2.9 Approx. 2.9
temperature: 45 to {Approx. 30} {Approx. 30}
Low idle
PC mode selector 55°C (Reference (Reference
pressure q Working mode: P mode MPa value) value)
(PC-EPC valve q Swing lock switch: ON {kg/cm2}
output pressure) q Work equipment
control lever: High idle 0 {0} 0 {0}
NEUTRAL
q Hydraulic oil Control lever 2.9 to 4.9 2.9 to 4.9
temperature: 45 to and pedal: {30 to 50} {30 to 50}
55°C NEUTRAL (*2) (*2)
LS valve output
q Engine: High idle
pressure MPa
q Working mode: B mode
(servo piston inlet 2
q Front pump circuit:
{kg/cm }
pressure) Right or left Pump pressure x Pump pressure
Right track track: Idle turn Approx. 0.6 x Approx. 0.6
q Rear pump circuit: Left
track
Hydraulic oil
q Approx. 2.9 Approx. 2.9
temperature: 45 to Travel speed: {Approx. 30} {Approx. 30}
LS set selector 55°C Lo (Reference (Reference
pressure q Engine: High idle MPa value) value)
(LS-EPC valve out- q Working mode: P mode {kg/cm2}
put pressure) q Swing lock switch: OFF
Travel speed:
q Travel control lever: 0 {0} 0 {0}
Hi
Fine control
20-8 HB215LC-2
--- Page 24 ---
20 Standard value tables
Standard service value table
Equipment name Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector P20, and connect T-adapter to male side.
Fuel control dial (throttle Between P20 (male) (1) and (3) 4.0 to 6.0 kz
sensor)
Voltage Between P20 (male) (2) and (3) 0.25 to 5.0 kz
Between P20 (male) (1) and (2) 0.25 to 5.0 kz
HB215LC-2 20-29
--- Page 25 ---
30 Testing and adjusting
Engine and cooling system
6) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
7) After finishing the test, remove the testing
tools, and restore the machine.
30-16 HB215LC-2
--- Page 26 ---
30 Testing and adjusting
Engine and cooling system
Handling cylinder cutout mode operation (PC400-AD00-34FK00A)
:
Handling cylinder cutout mode operation
a The cylinder cut-out test mode operation means to run the engine with the fuel injectors of one or more
cylinders disabled electrically to reduce the number of active cylinders. The purposes and effects of this
operation are as follows.
1. This mode is used to find out a cylinder which does not output power properly (or, combustion in it is
abnormal).
2. When a cylinder is selected for Cylinder Cut-out Mode operation, if the engine speed and output do not
change from the normal operation (all-cylinder operation), that cylinder has one or more defects.
The following problems can be considered:
q Compression leak from cylinder head gasket
q Defective injection from injector
q Defective piston, piston ring or cylinder liner
q Defective valve mechanism (valve operating system)
q Defective electrical system
3. The injector of each cylinder is separately controlled electronically in the common rail fuel injection system,
so the cylinder cut-out test can be performed easily by the simple operations of the switches compared
with the mechanical fuel injection system. This allows to find out a defective cylinder easily.
HB215LC-2 30-37
--- Page 27 ---
30 Testing and adjusting
Hydraulic system
Testing and adjusting oil pressure in work equipment and travel circuits
(HB380-C000-360K00A)
:
Testing and adjusting oil pressure in work equipment and travel circuits
a Testing tools
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
M
2 799-101-5220 Nipple (M10x1.25 mm)
3 07002-11023 O-ring
k Place the machine on a level ground and lower the work equipment to the ground. Then, release
the remaining pressure from the hydraulic system. For details, see "Releasing remaining pressure
from hydraulic system".
a Check this item under the following conditions.
q Hydraulic oil temperature: 45 to 55°
Testing (HB205-C000-362K01A)
:
Testing
a The oil pressures in the work equipment, swing,