HB215LC 2

SEN06488-09
HYDRAULIC HB215LC -2
EXCAVATOR SERIAL NUMBERS 50001 and up
SHOP MANUAL
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
HB215LC-2 50001 and up
00 Index and foreword

1 00 Index and foreword
HB215LC-2 00-1
Index
Index
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-16
Important safety notice (Hybrid)........................................................................................... 00-16
How to read the shop manual.............................................................................................. 00-23
Explanation of terms for maintenance standard .................................................................... 00-25
Handling equipment of fuel system devices .......................................................................... 00-27
Handling of intake system parts........................................................................................... 00-28
Handling of hydraulic equipment.......................................................................................... 00-29
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-31
Handling of electrical equipment.......................................................................................... 00-34
How to read electric wire code (Hybrid) ................................................................................ 00-42
Precautions when performing operation ............................................................................... 00-47
Practical use of KOMTRAX ................................................................................................. 00-52
Handling hybrid components and high voltage wiring harness................................................ 00-53
Standard tightening torque table.......................................................................................... 00-56
List of abbreviation ............................................................................................................. 00-62
Conversion table ................................................................................................................ 00-67
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-9
Table of fuel, coolant, and lubricants .................................................................................... 01-11
10 Structure and function ................................................................................................................... 10-1
Engine and cooling system .......................................................................................................... 10-3
Engine related parts ............................................................................................................. 10-3
VFT .................................................................................................................................... 10-5
EGR system piping drawing .................................................................................................. 10-9
EGR system circuit diagram ................................................................................................ 10-11
EGR valve......................................................................................................................... 10-12
EGR cooler........................................................................................................................ 10-14
KCCV layout drawing ......................................................................................................... 10-16
KCCV ventilator ................................................................................................................. 10-18
KDOC muffler .................................................................................................................... 10-20
Cooling system .................................................................................................................. 10-22
Hybrid system .......................................................................................................................... 10-24
Outline of hybrid system ..................................................................................................... 10-24
Configuration of hybrid system ............................................................................................ 10-25
Protective function of hybrid component ............................................................................... 10-26
Protection function for workers when disassembling hybrid component................................... 10-28
Cooling system of hybrid component ................................................................................... 10-30
Interlock function................................................................................................................ 10-31
Motor-generator ................................................................................................................. 10-32
Electric swing motor ........................................................................................................... 10-34
Electric control unit ............................................................................................................. 10-36
High voltage wiring harness (power cable) ........................................................................... 10-37
Water pump....................................................................................................................... 10-38
Power train............................................................................................................................... 10-39
Power train system............................................................................................................. 10-39
Swing circle ....................................................................................................................... 10-41
Swing machinery with swing brake ...................................................................................... 10-42
Final drive ......................................................................................................................... 10-44
Undercarriage and frame........................................................................................................... 10-46
Track frame and idler cushion ............................................................................................. 10-46
00-2 HB215LC-2
Index
Hydraulic system ...................................................................................................................... 10-48

Hydraulic component layout ................................................................................................ 10-48
Valve control...................................................................................................................... 10-50
Hydraulic tank.................................................................................................................... 10-52
CLSS ................................................................................................................................ 10-54
Main pump ........................................................................................................................ 10-59
Control valve ..................................................................................................................... 10-89
Travel motor .................................................................................................................... 10-144
PPC valve ....................................................................................................................... 10-157
Solenoid valve ................................................................................................................. 10-180
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-183
Attachment circuit selector valve (for low pressure circuit).................................................... 10-185
Center swivel joint ............................................................................................................ 10-188
Accumulator .................................................................................................................... 10-190
Work equipment ..................................................................................................................... 10-191
Work equipment............................................................................................................... 10-191
Work equipment shim....................................................................................................... 10-192
Bucket play adjustment shim............................................................................................. 10-193
Cab and its attachments .......................................................................................................... 10-194
Cab mount and cab tipping stopper ................................................................................... 10-194
ROPS cab ....................................................................................................................... 10-195
Electrical system .................................................................................................................... 10-196
Electrical control system ................................................................................................... 10-196
Machine monitor system ................................................................................................... 10-253
KOMTRAX system ........................................................................................................... 10-277
Sensor ............................................................................................................................ 10-280
20 Standard value tables.................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
Standard value table for electrical system............................................................................. 20-20
30 Testing and adjusting .................................................................................................................... 30-1
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
Testing engine speed ........................................................................................................... 30-8
Testing boost pressure ....................................................................................................... 30-10
Testing exhaust gas color ................................................................................................... 30-13
Testing and adjusting valve clearance .................................................................................. 30-14
Testing compression pressure............................................................................................. 30-17
Testing blowby pressure ..................................................................................................... 30-21
Testing engine oil pressure ................................................................................................. 30-22
Testing fuel pressure .......................................................................................................... 30-23
Testing fuel discharge, return and leakage............................................................................ 30-28
Bleeding air from fuel system .............................................................................................. 30-30
Testing fuel circuit for leakage ............................................................................................. 30-32
Handling cylinder cutout mode operation.............................................................................. 30-33
Handling no-injection cranking operation.............................................................................. 30-34
Testing and adjusting air conditioner compressor belt tension ................................................ 30-35
Replacing fan belt .............................................................................................................. 30-36
Hybrid system .......................................................................................................................... 30-37
Precautions related to hybrid equipment .............................................................................. 30-37
Bleeding air from hybrid cooling system ............................................................................... 30-38
Testing water pressure of hybrid coolant............................................................................... 30-40
Testing swing parking brake ................................................................................................ 30-42
Cleaning and replacing oil filter of electric swing motor .......................................................... 30-43
HB215LC-2 00-3
Index
Power train............................................................................................................................... 30-44

Testing swing circle bearing clearance ................................................................................. 30-44
Testing and adjusting track tension ...................................................................................... 30-45
Releasing remaining pressure from hydraulic circuit .............................................................. 30-46
Testing oil pressure of control circuit .................................................................................... 30-50
Testing and adjusting oil pressure in work equipment and travel circuits .................................. 30-51
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-54
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-58
Testing outlet pressure of solenoid valve .............................................................................. 30-66
Testing PPC valve outlet pressure ....................................................................................... 30-70
Adjusting play of work equipment and swing PPC valves....................................................... 30-72
Testing pump swash plate sensor ........................................................................................ 30-73
Isolating the parts causing hydraulic drift in work equipment................................................... 30-74
Testing oil leakage ............................................................................................................. 30-76
Bleeding air from hydraulic circuit ........................................................................................ 30-78
Cab and its attachments ............................................................................................................ 30-80
Testing cab tipping stopper ................................................................................................. 30-80
Adjusting mirrors ................................................................................................................ 30-81
Electrical system ...................................................................................................................... 30-84
Special functions of machine monitor ................................................................................... 30-84
KOMTRAX terminal start-up procedure .............................................................................. 30-156
Adjusting rearview camera angle ....................................................................................... 30-159
Handling voltage circuit of engine controller........................................................................ 30-161
Handling battery disconnect switch .................................................................................... 30-162
Testing diodes ................................................................................................................. 30-163
Pm clinic ................................................................................................................................ 30-164
Pm Clinic service ............................................................................................................. 30-164
40 Troubleshooting............................................................................................................................ 40-1
Related information on troubleshooting....................................................................................... 40-10
Troubleshooting points ....................................................................................................... 40-10
Sequence of events in troubleshooting................................................................................. 40-12
Checks before troubleshooting ............................................................................................ 40-14
Inspection procedure before troubleshooting ........................................................................ 40-16
Preparation for troubleshooting of electrical system............................................................... 40-37
Classification and procedures for troubleshooting ................................................................. 40-43
Symptom and troubleshooting numbers ............................................................................... 40-46
Information in troubleshooting table ..................................................................................... 40-49
Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................... 40-51
Connector list and layout .................................................................................................... 40-53
Connector contact identification........................................................................................... 40-64
T-branch box and T-branch adapter table ........................................................................... 40-102
Fuse location table ........................................................................................................... 40-107
Failure codes table........................................................................................................... 40-109
Troubleshooting by failure code (Display of code) ...................................................................... 40-120
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-120
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-121
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-122
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-123
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-124
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-125
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-126
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-127
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-128
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-129
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-130
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-131
00-4 HB215LC-2
Index
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-132

Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3............................................ 40-133
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 ............................................ 40-134
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2............................................ 40-135
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-136
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-138
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-140
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-141
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-142
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-143
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-145
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-146
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-147
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-149
Failure code [CA131] Throttle Sensor High Error................................................................. 40-151
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-153
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-155
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-157
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-159
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-161
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-163
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-165
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-167
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-169
Failure code [CA234] Eng Overspeed ................................................................................ 40-170
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-171
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-172
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-173
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-175
Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-177
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-178
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-186
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-187
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-190
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-192
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-195
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-197
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-199
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-200
Failure code [CA442] Battery Voltage High Error................................................................. 40-202
Failure code [CA449] Rail Press Very High Error................................................................. 40-203
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-204
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-206
Failure code [CA466] KVGT Motor Driver Position Error ...................................................... 40-208
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-210
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-211
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-213
Failure code [CA553] Rail Press High Error ........................................................................ 40-215
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-216
Failure code [CA559] Rail Press Low Error......................................................................... 40-218
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-220
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-222
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-224
HB215LC-2 00-5
Index
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-226
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-227
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-228
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-229
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-232
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-233
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-234
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-235
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-237
Failure code [CA1896] EGR Valve Stuck Error.................................................................... 40-239
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-240
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error............................................. 40-241
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-242
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-244
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-246
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-247
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-249
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-250
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-252
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-254
Failure code [CA2373] Exhaust Manifold Press Sens High Error .......................................... 40-255
Failure code [CA2374] Exhaust Manifold Press Sens Low Error ........................................... 40-257
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-259
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-261
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-263
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-264
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-265
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-267
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-269
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-270
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-271
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-273
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error........................................ 40-275
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-277
Failure code [CA3918] KVGT Stuck Error........................................................................... 40-278
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ............................................ 40-279
Failure code [CA3921] KVGT Servo Error 2........................................................................ 40-280
Failure code [CA3922] KVGT Motor Driver Open Error ........................................................ 40-281
Failure code [CA3923] KVGT Motor Driver Short Error ........................................................ 40-283
Failure code [D110KB] Battery Relay Drive Short Circuit...................................................... 40-285
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-287
Failure code [D811MC] KOMTRAX Error............................................................................ 40-290
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-291
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-292
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-294
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-295
Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-296
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-297
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...................................................... 40-299
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-303
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ....................................... 40-305
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ....................................... 40-307
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-308
Failure code [DA2RKR] CAN1 Discon (Pump Con) ............................................................. 40-311
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-312
Failure code [DAF0MC] Monitor Error ................................................................................ 40-313
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-314
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-316
00-6 HB215LC-2
Index
Failure code [DAFGMC] GPS Module Error........................................................................ 40-317

Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-318
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-320
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-321
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-322
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-323
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-327
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-332
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-338
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-340
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................. 40-341
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-344
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality........................................ 40-347
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ................................... 40-349
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality................................... 40-351
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality .................................. 40-353
Failure code [DHSAKZ] Swing RH PPC Press Sensor Abnormality ...................................... 40-355
Failure code [DHSBKZ] Swing LH PPC Press Sensor Abnormality....................................... 40-357
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .................................... 40-359
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-361
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ............................... 40-363
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .............................. 40-365
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ............................... 40-367
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ............................... 40-369
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt. ..................................... 40-371
Failure code [DHVAL8] HYB Swing-R PPC Pr. Sen. Signal Mismatch ................................... 40-374
Failure code [DHVAMA] HYB Swing-R PPC Sensor Malfunction .......................................... 40-375
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen. Opn/Short Cir........................................ 40-377
Failure code [DHVBL8] HYB Swing-L PPC Pr. Sen. Signal Mismatch ................................... 40-379
Failure code [DHVBMA] HYB Swing-L PPC Sensor Malfunction .......................................... 40-380
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality....................................... 40-382
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality ...................................... 40-385
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-388
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-392
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-394
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-396
Failure code [DW45KA] Swing Brake Sol Open Circuit ........................................................ 40-398
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-401
Failure code [DW45KK] Swing Brake Sol. Valve Low Sup. Voltage ....................................... 40-404
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. ............................................. 40-406
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-408
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-410
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-412
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-414
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..................................................... 40-416
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit...................................................... 40-418
Failure code [DWK2KA] Variable Back Press Sol Open Circuit............................................. 40-420
Failure code [DWK2KB] Variable Back Press Sol Short Circuit ............................................. 40-422
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-424
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-426
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-428
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-430
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-432
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-434
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................ 40-436
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................. 40-438
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ................................................ 40-440
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ................................................ 40-442
HB215LC-2 00-7
Index
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ................................................... 40-444

Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ................................................... 40-446
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-448
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-450
Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-452
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...................................................... 40-454
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ....................................................... 40-456
Failure code [GA****] Precautions related to hybrid components and troubleshooting of high
voltage parts ...................................................................................................... 40-458
Failure code [GA——] Table and check sheet of monitoring items on hybrid
components ....................................................................................................... 40-487
Failure code [GA00NS] HYB Equipment Overheat .............................................................. 40-492
Failure code [GA01KA] Power Cable Interlock Open Circuit................................................. 40-493
Failure code [GA01KB] Power Cable Interlock Short Circuit ................................................. 40-495
Failure code [GA02KZ] DC Line Open & Short Circuit ......................................................... 40-497
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster ........................................... 40-498
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster............................................ 40-499
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster ............................................. 40-500
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster .......................................... 40-501
Failure code [GA08KG] Abnorm. DC HW Volt. After Booster ................................................ 40-502
Failure code [GA09KG] Abnorm. DC SW Volt. After Booster ................................................ 40-503
Failure code [GA09KP] Low DC SW Output Volt. After Booster ............................................ 40-504
Failure code [GA0AKZ] DC Vlt. Sen. Op./Shrt Cir. Aft. Booster ............................................. 40-505
Failure code [GA0BKZ] AC Line Open & Short Circuit ......................................................... 40-506
Failure code [GA10MA] HYB Controller Malfunction ............................................................ 40-507
Failure code [GA10MC] HYB Controller Error ..................................................................... 40-508
Failure code [GA12NK] High-Voltage Line Start-up Failure .................................................. 40-509
Failure code [GA13KP] Low HYB Control. Sen. Power Sup. ................................................ 40-510
Failure code [GA13KY] HYB Control. Sen. Power Short Cir ................................................. 40-511
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir........................................ 40-512
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure ............................................ 40-513
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded.................................................. 40-514
Failure code [GA18MC] Gen. Mo.Dr. Excite. Pow. Sup. Failure ............................................ 40-515
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure..................................... 40-516
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. ...................................... 40-517
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction ......................................... 40-518
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure .......................................... 40-519
Failure code [GA1FMA] Abnormal Swing Motor Driver ........................................................ 40-520
Failure code [GA1GKR] Swg Mot. Driver Sub-CPU Comm. Failure....................................... 40-521
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal ...................................... 40-522
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded.................................... 40-523
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir ..................................... 40-524
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir ...................................... 40-525
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir..................................... 40-526
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens. Opn/Shrt Cir ........................................ 40-527
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen. Opn/Shrt Cir. .......................................... 40-528
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat ................................................ 40-529
Failure code [GA1SFS] Contactor Locked .......................................................................... 40-530
Failure code [GA1SMC] Contactor Failure.......................................................................... 40-531
Failure code [GA1TKP] Capacitor Low Output Voltage ........................................................ 40-532
Failure code [GA1TNS] Capacitor Overheat ....................................................................... 40-533
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/short Cir. ........................................... 40-535
Failure code [GA1VFS] Capacitor Contactor Locked ........................................................... 40-537
Failure code [GA1VMC] Capacitor Contactor Failure........................................................... 40-539
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ.......................................... 40-540
Failure code [GA1YNS] Booster Inductor Overheat ............................................................. 40-541
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. ...................................... 40-542
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat .............................................. 40-543
Failure code [GA22NS] Booster IGBT Junction Overheat .................................................... 40-544
00-8 HB215LC-2
Index
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sen.0 Opn/Short Cir......................................... 40-545
Failure code [GA25MA] Gen. Motor Driver IGBT 0 Abnormality ............................................ 40-547
Failure code [GA25NS] Gen. Motor Driver IGBT 0 Overheat ................................................ 40-548
Failure code [GA27KZ] DC Cur. Sens. Bef. Booster Opn/Short Cir ....................................... 40-551
Failure code [GA2QKR] CAN2 Discon (Hyb Con) ............................................................... 40-552
Failure code [GA2RKR] CAN1 Discon (Hyb Con)................................................................ 40-554
Failure code [GA60KZ] Generator Motor Open/Short Circuit ................................................ 40-555
Failure code [GA60MC] Generator Motor Failure ................................................................ 40-556
Failure code [GA60N1] Generator Motor Overrun ............................................................... 40-558
Failure code [GA61KZ] Gen. Motor Temp. Sens. Opn/Short Cir. ........................................... 40-559
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat ........................................ 40-561
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir ....................................... 40-562
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir ........................................ 40-563
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction........................................ 40-564
Failure code [GA62MC] Gen. Mot. Ph-A Cur. Sen. Defect Op............................................... 40-565
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir ....................................... 40-566
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir ........................................ 40-567
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction........................................ 40-568
Failure code [GA63MC] Gen. Mot. Ph-B Cur. Sen. Defect Op............................................... 40-569
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir....................................... 40-570
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir ........................................ 40-571
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction........................................ 40-572
Failure code [GA64MC] Gen. Mot. Ph-C Cur. Sen. Defect Op. ............................................. 40-573
Failure code [GA70KB] HYB Swing Motor Short Circuit ....................................................... 40-574
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion ........................................ 40-575
Failure code [GA70NS] HYB Swing Motor Overheat ........................................................... 40-576
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. ..................................... 40-577
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction .......................................... 40-579
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op. ........................................... 40-581
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ.......................................... 40-582
Failure code [GAA0KB] HYB Con. Battery Relay Drive Short Cir. ......................................... 40-583
Failure code [GAA2KB] Swing Brake Sol. Supply Line Short Cir. .......................................... 40-585
Failure code [GAA6KP] Low HYB Control. Sen. Power 2 Sup. ............................................. 40-587
Failure code [GAA6KY] HYB Control. Sen. Power 2 Short Cir .............................................. 40-588
Failure code [GACLKA] Operating Lamp Open Circuit (HYB Con) ........................................ 40-589
Failure code [GACLKB] Operating Lamp Short Circuit (HYB Con) ........................................ 40-591
Troubleshooting of electrical system (E-mode) .......................................................................... 40-592
E-1 Engine does not start (Engine does not crank) .............................................................. 40-592
E-2 Manual preheating system does not work..................................................................... 40-598
E-3 Automatic preheating system does not work................................................................. 40-601
E-4 While preheating is working, preheating monitor does not light up .................................. 40-603
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-605
E-6 When starting switch is turned to ON position (before starting engine), engine oil level
monitor lights up in yellow.................................................................................... 40-609
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant
level monitor lights up in yellow ............................................................................ 40-610
E-8 Engine coolant temperature monitor lights up in white while engine is running ................. 40-611
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-612
E-10 Charge level monitor lights up in red while engine is running ........................................ 40-613
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-614
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-615
E-13 Water separator monitor lights up in red while engine is running ................................... 40-616
E-14 Engine coolant temperature monitor lights up in red while engine is running .................. 40-617
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-618
E-16 Hybrid temperature monitor lights up in red while engine is running .............................. 40-619
E-17 Engine oil pressure monitor lights up in red while engine is running .............................. 40-621
HB215LC-2 00-9
Index
E-18 Fuel gauge display does not move from minimum or maximum .................................... 40-622
E-19 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-623
E-20 Engine coolant temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-624
E-21 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full
nor empty).......................................................................................................... 40-625
E-22 Hydraulic oil temperature gauge does not move from minimum or maximum ................. 40-626
E-23 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor
empty) ............................................................................................................... 40-628
E-24 Hybrid temperature gauge does not move from minimum or maximum.......................... 40-629
E-25 Hybrid temperature gauge indicates incorrect temperature (indicates neither full nor
empty) ............................................................................................................... 40-630
E-26 Contents of display on machine monitor is different from actual machine
condition ............................................................................................................ 40-632
E-27 Some areas of machine monitor screen are not displayed............................................ 40-633
E-28 Function switch does not work................................................................................... 40-634
E-29 Automatic warm-up system does not operate (in cold season)...................................... 40-635
E-30 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration
switch is operated ............................................................................................... 40-636
E-31 Auto-deceleration function does not operate or is not canceled while lever is
operated ............................................................................................................ 40-637
E-32 Working mode selection screen is not displayed while working mode selector switch is
operated ............................................................................................................ 40-639
E-33 Setting of engine and hydraulic pump is not changed while working mode is
changed............................................................................................................. 40-640
E-34 Travel speed monitor does not change when travel speed switch is operated ................ 40-641
E-35 Travel speed does not change while travel speed selection is changed......................... 40-642
E-36 Alarm buzzer does not stop sounding......................................................................... 40-643
E-37 Service meter is not displayed, while starting switch is in OFF position.......................... 40-644
E-38 Service mode cannot be selected .............................................................................. 40-645
E-39 None of work equipment, swing or travel works........................................................... 40-646
E-40 Any of work equipment, swing and travel cannot be locked .......................................... 40-648
E-41 Upper structure does not swing while swing parking brake cancel switch is set to
CANCEL position................................................................................................ 40-650
E-42 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
position .............................................................................................................. 40-653
E-43 One-touch power maximizing function does not operate, or indicator is not displayed on
monitor .............................................................................................................. 40-655
E-44 One-touch power maximizing function cannot be canceled .......................................... 40-657
E-45 Alarm does not sound during travel ............................................................................ 40-658
E-46 Alarm does not stop sounding while machine is stopped.............................................. 40-659
E-47 Horn does not sound ................................................................................................ 40-660
E-48 Horn does not stop sounding..................................................................................... 40-662
E-49 Wiper monitor does not light up, or does not go out, while wiper switch is
operated ............................................................................................................ 40-663
E-50 Wiper does not operate while wiper switch is operated ................................................ 40-664
E-51 Window washer does not operate while window washer switch is operated ................... 40-666
E-52 Boom LOWER is not displayed correctly with monitoring function ................................. 40-667
E-53 Arm OUT is not displayed correctly with monitoring function......................................... 40-668
E-54 Arm IN is not displayed correctly with monitoring function ............................................ 40-669
E-55 Boom RAISE is not displayed correctly with monitoring function ................................... 40-670
E-56 Bucket CURL is not displayed correctly with monitoring function................................... 40-671
E-57 Bucket DUMP is not displayed correctly with monitoring function.................................. 40-672
E-58 Swing is not displayed correctly with monitoring function.............................................. 40-673
E-59 Travel is not displayed correctly with monitoring function ............................................. 40-674
E-60 Service is not displayed correctly with monitoring function ........................................... 40-675
E-61 Attachment hydraulic circuit cannot be changed.......................................................... 40-678
E-62 KOMTRAX system does not operate normally ............................................................ 40-679
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-680
00-10 HB215LC-2
Index
Information described in troubleshooting table (H-mode) ..................................................... 40-680

System chart of hydraulic and mechanical systems............................................................. 40-681
Failure mode and cause table ........................................................................................... 40-683
H-1 All of work equipments and travel operations lack speed or power.................................. 40-689
H-2 Engine speed drops significantly or engine stalls .......................................................... 40-692
H-3 None of work equipment or travel works....................................................................... 40-695
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-696
H-5 Fine control performance or response is poor ............................................................... 40-697
H-6 Boom speed or power is low ....................................................................................... 40-699
H-7 Arm speed or power is low .......................................................................................... 40-703
H-8 Bucket speed or power is low...................................................................................... 40-708
H-9 Work equipment does not move in single operation....................................................... 40-711
H-10 Hydraulic drift of boom is large .................................................................................. 40-712
H-11 Hydraulic drift of arm is large ..................................................................................... 40-713
H-12 Hydraulic drift of bucket is large ................................................................................. 40-714
H-13 Time lag of work equipment is large ........................................................................... 40-715
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-717
H-15 One-touch power maximizing function does not operate .............................................. 40-718
H-16 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-719
H-17 Machine does not travel straight ................................................................................ 40-720
H-18 Travel speed is slow ................................................................................................. 40-723
H-19 Machine is hard to steer or travel power is low ............................................................ 40-726
H-20 Travel speed does not change, or travel speed is too slow or fast ................................. 40-730
H-21 One of tracks does not run ........................................................................................ 40-731
H-22 Upper structure does not swing to the right or left ........................................................ 40-733
H-23 Upper structure swings only to the right or left............................................................. 40-734
H-24 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-735
H-25 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-736
H-26 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-737
H-27 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-738
H-28 Shock is large when upper structure stops swinging.................................................... 40-739
H-29 Large unusual noise is heard when upper structure stops swinging .............................. 40-740
H-30 Swing drift on a slope is large while swing parking brake is applied............................... 40-741
H-31 Swing drift on a slope is large while swing parking brake is released............................. 40-742
H-32 Attachment hydraulic circuit cannot be changed while attachment is installed................ 40-743
H-33 Oil flow in attachment circuit cannot be controlled ....................................................... 40-744
Troubleshooting of engine (S-mode)......................................................................................... 40-745
Information mentioned in troubleshooting table (S mode)..................................................... 40-745
S-1 Engine does not crank when starting switch is turned to START position......................... 40-746
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-747
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-748
S-4 Engine startability is poor ............................................................................................ 40-749
S-5 Engine does not pick up smoothly ............................................................................... 40-751
S-6 Engine stops during operation ..................................................................................... 40-753
S-7 Engine runs rough or is unstable ................................................................................. 40-755
S-8 Engine lacks power .................................................................................................... 40-756
S-9 Exhaust smoke is black .............................................................................................. 40-758
S-10 Engine oil consumption is excessive .......................................................................... 40-760
S-11 Oil becomes contaminated quickly ............................................................................. 40-761
S-12 Fuel consumption is excessive .................................................................................. 40-762
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-763
S-14 Oil pressure drops .................................................................................................... 40-764
S-15 Fuel mixes into engine oil.......................................................................................... 40-765
S-16 Water mixes into engine oil (milky) ............................................................................. 40-766
HB215LC-2 00-11
Index
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-767

S-18 Unusual noise is heard ............................................................................................. 40-768
S-19 Vibration is excessive ............................................................................................... 40-769
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-770
Troubleshooting for hybrid systems (Y mode)............................................................................ 40-771
Precautions related to hybrid equipment ............................................................................ 40-771
Y-1 Hybrid monitor does not go out .................................................................................... 40-772
Y-2 Machine does not swing.............................................................................................. 40-773
Y-3 Swing acceleration or swing speed is low ..................................................................... 40-776
Y-4 Upper structure overruns excessively when it stops swinging ......................................... 40-777
Y-5 Shock is large when upper structure stops swinging ...................................................... 40-778
Y-6 Large unusual noise is heard when upper structure stops swinging ................................ 40-779
Y-7 Swing drift on a slope is large ...................................................................................... 40-780
Y-8 Electric swing motor temperature increases abnormally................................................. 40-781
Y-9 Motor-generator temperature increases abnormally....................................................... 40-782
Y-10 Inverter temperature increases abnormally ................................................................. 40-783
Y-11 Capacitor temperature increases abnormally .............................................................. 40-784
50 Disassembly and assembly ........................................................................................................... 50-1
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Precautions related to hybrid equipment ................................................................................ 50-6
Coating materials list ............................................................................................................ 50-7
Special tools list ................................................................................................................. 50-11
Sketches of special tools .............................................................................................................. 50-16
Engine and cooling system ................................................................................................................... 50-23
Removal and installation of supply pump assembly...................................................................... 50-23
Removal and installation of injector assembly.............................................................................. 50-27
Removal and installation of cylinder head assembly.................................................................... 50-33
Removal and installation of radiator assembly ............................................................................. 50-51
Removal and installation of hydraulic oil cooler assembly ........................................................... 50-54
Removal and installation of aftercooler assembly ......................................................................... 50-57
Removal and installation of engine, motor-generator, and main pump assembly ........................ 50-59
Removal and installation of fan belt............................................................................................... 50-71
Removal and installation of starting motor .................................................................................... 50-74
Removal and installation of engine front oil seal ........................................................................... 50-76
Removal and installation of engine rear oil seal............................................................................ 50-79
Removal and installation of fuel cooler assembly ......................................................................... 50-82
Removal and installation of fuel tank assembly ............................................................................ 50-84
Removal and installation of engine hood assembly ..................................................................... 50-86
Removal and installation of KDOC assembly ............................................................................... 50-89
Removal and installation of KCCV assembly ............................................................................... 50-90
Removal and installation of air cleaner assembly ......................................................................... 50-96
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly .......................... 50-97
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly......................... 50-99
Hybrid system ..................................................................................................................................... 50-102
Draining coolant, refilling with coolant, and bleeding air for hybrid system ................................ 50-102
Removal and installation of hybrid radiator assembly ................................................................ 50-106
Removal and installation of hybrid water pump assembly ......................................................... 50-109
Removal and installation of inverter assembly ............................................................................50-111
Removal and installation of inverter and capacitor assembly ..................................................... 50-114
Procedure for draining and refilling generator lubricating oil ...................................................... 50-119
Removal and installation of tandem pump assembly ................................................................. 50-121
Removal and installation of motor-generator and housing assembly ......................................... 50-124
Removal and installation of electric swing motor assembly ....................................................... 50-131
Power train system ............................................................................................................................. 50-136
Removal and installation of travel motor and final drive assembly ............................................. 50-136
Disassembly and assembly of final drive .................................................................................... 50-137
Removal and installation of swing motor and swing machinery assembly ................................. 50-146
00-12 HB215LC-2
Index
Disassembly and assembly of swing machinery assembly........................................................ 50-150

Removal and installation of swing circle assembly .................................................................... 50-164
Undercarriage and frame.................................................................................................................... 50-165
Separation and connection of track shoe assembly ................................................................... 50-165
Removal and installation of sprocket.......................................................................................... 50-168
Removal and installation of idler and idler cushion assembly ................................................... 50-169
Disassembly and assembly of idler assembly ............................................................................ 50-170
Disassembly and assembly of idler cushion assembly............................................................... 50-172
Disassembly and assembly of track roller assembly .................................................................. 50-174
Disassembly and assembly of carrier roller assembly ................................................................ 50-176
Removal and installation of revolving frame assembly ............................................................... 50-179
Removal and installation of counterweight assembly ................................................................. 50-181
Hydraulic system ................................................................................................................................ 50-184
Removal and installation of center swivel joint assembly .......................................................... 50-184
Disassembly and assembly of center swivel joint assembly ...................................................... 50-187
Removal and installation of hydraulic tank assembly ................................................................. 50-189
Removal and installation of main pump assembly ..................................................................... 50-192
Removal and installation of control valve assembly ................................................................... 50-196
Disassembly and assembly of control valve assembly............................................................... 50-200
Disassembly and assembly of work equipment PPC valve........................................................ 50-206
Disassembly and assembly of travel PPC valve assembly ........................................................ 50-208
Work equipment ................................................................................................................................. 50-210
Removal and installation of work equipment assembly ............................................................. 50-210
Disassembly and assembly of work equipment cylinder assembly............................................ 50-213
Cab and its attachments ..................................................................................................................... 50-220
Removal and installation of operator's cab assembly................................................................. 50-220
Removal and installation of operator cab glass (adhered glass) ............................................... 50-225
Removal and installation of front window assembly ................................................................... 50-235
Removal and installation of floor frame assembly...................................................................... 50-241
Removal and installation of air conditioner unit assembly.......................................................... 50-247
Removal and installation of operator's seat................................................................................ 50-251
Removal and installation of seat belt .......................................................................................... 50-253
Removal and installation of work equipment control lever assembly...................................... 50-254-1
Removal and installation of front wiper assembly ...................................................................... 50-255
Electrical system ................................................................................................................................ 50-262
Removal and installation of air conditioner compressor assembly............................................. 50-262
Removal and installation of air conditioner condenser assembly .............................................. 50-264
Removal and installation of engine controller assembly ............................................................ 50-266
Removal and installation of pump controller assembly............................................................... 50-268
Removal and installation of machine monitor assembly ............................................................. 50-271
Removal and installation of pump swash plate sensor ............................................................... 50-273
Removal and installation of mass air flow and temperature sensor ........................................... 50-274
Removal and installation of KOMTRAX terminal assembly ....................................................... 50-275
60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Power train system ..................................................................................................................... 60-5
Swing circle ......................................................................................................................... 60-5
Swing machinery with swing brake ........................................................................................ 60-6
Final drive ........................................................................................................................... 60-8
Sprocket............................................................................................................................ 60-10
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-16
Carrier roller ...................................................................................................................... 60-17
Track shoe ........................................................................................................................ 60-18
HB215LC-2 00-13
Index

Hydraulic tank.................................................................................................................... 60-24
Main pump ........................................................................................................................ 60-25
Control valve ..................................................................................................................... 60-26
Travel motor ...................................................................................................................... 60-36
PPC valve ......................................................................................................................... 60-39
Solenoid valve ................................................................................................................... 60-49
Attachment circuit selector valve (for high-pressure circuit) .................................................... 60-50
Attachment circuit selector valve (for low-pressure circuit) ..................................................... 60-51
Center swivel joint .............................................................................................................. 60-52
Work equipment ....................................................................................................................... 60-53
Work equipment................................................................................................................. 60-53
Work equipment cylinder .................................................................................................... 60-62
80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-17
Air conditioner controller ..................................................................................................... 80-18
Compressor....................................................................................................................... 80-19
Air conditioner condenser ................................................................................................... 80-20
Sunlight sensor .................................................................................................................. 80-22
Outer temperature sensor (outside air temperature sensor) ................................................... 80-23
Procedure for testing and troubleshooting ............................................................................ 80-24
Circuit diagram and arrangement of connector pins............................................................... 80-26
System diagram................................................................................................................. 80-28
Parts and connectors layout................................................................................................ 80-31
Testing air leakage (duct) .................................................................................................... 80-35
Testing with self-diagnosis function ...................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-41
Testing FRESH/RECIRC air changeover.............................................................................. 80-43
Testing sunlight sensor ....................................................................................................... 80-44
Testing (dual) pressure switch for refrigerant......................................................................... 80-45
Testing relays .................................................................................................................... 80-46
Troubleshooting chart 1 ...................................................................................................... 80-47
Failure code list related to air conditioner.............................................................................. 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-54
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-55
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-57
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-59
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-60
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-61
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-63
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-64
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-65
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-66
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-68
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-71
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-73
Troubleshooting with gauge pressure................................................................................... 80-75
Connection of service tool................................................................................................... 80-78
00-14 HB215LC-2
Index
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-80
Handling of compressor oil.................................................................................................. 80-82
Desiccant replacement ....................................................................................................... 80-84
90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram .............................................................................................................. 90-13
Symbols in electric circuit diagram ....................................................................................... 90-13
Electrical circuit diagram ..................................................................................................... 90-17
Electrical circuit diagram of air conditioner unit...................................................................... 90-47
Index.................................................................................................................................................................... 1
HB215LC-2 00-15
Foreword, safety and general information
Foreword, safety and general information (ALL-0370-001-A-00-A)
Important safety notice (Hybrid) (HB380-1120-012-A-00-A)

Important safety precautions
(Rev. 2013/04)
• 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 indicated
with this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Precautions peculiar to hybrid machine k When handling the hybrid devices or high-
voltage wirings, you are required to look into
k This machine is equipped with the hybrid the charge level inspection window on the
system consisting of an electric motor and a contactor box at the top of the capacitor and
diesel engine. The above Hybrid mark is check that the LED display indicates that the
attached to each explanation peculiar to the capacitor is discharged. Before discharging
hybrid system (contents different from those the capacitor, check the indicating function
for the common diesel engine machine). Be of this LED according to the following
sure to read the Operation and Maintenance procedure.
Manual, "Introduction", "Safety", "Handling
hybrid components and high voltage wiring 1. Both LEDs light up 1 minute after the
harness" in this manual, and Structure and engine is started.
operation, "Hybrid system" (Chapter 10) to 2. Only 1 LED lights up after the starting
understand the hybrid system. switch is turned to OFF position. (When
the starting switch is turned to OFF
k The persons who engage in the installing or position, 1 LED goes off.)
removing work of the hybrid devices (motor- If the above cannot be confirmed while no
generator, capacitor, inverter, electric swing failure is occurring in the hybrid system, the
motor) must follow the local Industrial Safety LED display function of showing the charge
and Health Law concerning electricity. level of the capacitor may be defective. In
this case, replace the capacitor according to
k Never disassemble the hybrid devices for "Precautions for normal testing and
quality assurance. The hybrid devices and adjusting".
high-voltage wiring (orange color) must be
Safety points
replaced in a unit.
• Good arrangement
k Before handling a hybrid device, be sure to • Correct work clothes
discharge the capacitor. For details see • Observance of work standard
Testing and adjusting, "Capacitor discharge • Practice of making and checking signals
procedure" (Chapter 30). • Prohibition of operation and handling by
unlicensed workers
k When handling the hybrid devices or high- • Safety check before starting work
voltage wirings, be sure to follow "Handling • Wearing protective goggles (for cleaning or
hybrid components and high voltage wiring grinding work)
harness". • Wearing shielding goggles and protectors (for
welding work)
• Good physical condition and preparation
• Precautions against work which you are not
used to or you are used to too much
00-16 HB215LC-2
General precautions • Before starting work, lower the work equipment

(blade, ripper, bucket, etc.) to the ground. If this
k Inappropriate handling creates an extreme is not possible, insert the lock pin or use blocks
danger. Read and understand what is to prevent the work equipment from falling. In
described in the Operation and Maintenance addition, be sure to lock all the control levers
Manual before operating the machine. In and hang warning tag on them.
addition read this manual carefully and • When performing the disassembling or
understand its contents before starting work. assembling work, support the machine securely
with blocks, jacks, or stands before starting the
• Before performing any greasing or repairs, read
work.
all the safety labels stuck to the machine. For
• Remove all mud and oil from the steps or other
the locations of the safety labels and detailed
places used to get on and off the machine.
explanation of precautions, see the Operation
Always use the handrails, ladders or steps when
and Maintenance Manual.
getting on or off the machine. Never jump on or
• Locate a place in the repair workshop to keep
off the machine. If it is impossible to use the
tools and removed parts. Always keep the tools
handrails, ladders or steps, use a stand to
and parts in their correct places. Always keep
provide safe footing.
the work area clean and make sure that there is
no dirt, water, or oil on the floor. Smoke only in Precautions during work
the areas provided for smoking. Never smoke • For the machine equipped with a battery
while working. disconnect switch, before starting the work,
• When performing any operation, always wear check that the system operating lamp is turned
safety shoes and helmet. Do not wear loose OFF, and then turn the battery disconnect switch
work clothes, or clothes with buttons missing. to the OFF(Q) position and pull the switch key
• Always wear the protective eyeglasses when out. For machines without a battery disconnect
hitting parts with a hammer. switch, before starting the work, remove the
• Always wear the protective eyeglasses when cables from the battery. Always remove the
grinding parts with a grinder, etc. cable from the negative (-) terminal first.
• When performing any operation with two or more • Before disconnecting or removing components
workers, always agree on the operating of the oil or fuel or water or air circuits, first
procedure before starting. Always inform your release the remaining pressure completely from
fellow workers before starting any step of the the circuit. When removing the oil filter cap, a
operation. Before starting work, hang UNDER drain plug, or an oil pressure pickup plug, loosen
REPAIR warning tag in the operator's it slowly to prevent the oil from spurting out.
compartment. • When removing or installing the checking plug or
• Only qualified workers must perform the work the piping in the fuel circuit, wait 30 seconds or
and operation which require license or longer after the engine is shut down and start
qualification. the work after the remaining pressure is
• Keep all tools in good condition, learn the correct released from the fuel circuit.
way to use them, and use the proper ones. • The coolant and oil in the circuits are hot when
Before starting work, thoroughly check the tools, the engine is shut down, so be careful not to get
machine, forklift truck, service car, etc. scalded. Wait for the oil and coolant to cool
• If welding repairs are needed, always have a before performing any work on the oil or coolant
trained and experienced welder perform the circuits.
work. When performing welding work, always • Before starting work, shut down the engine.
wear welding gloves, apron, shielding goggles, When working on or around a rotating part, in
cap and other clothes suited for welding work. particular, shut down the engine. When checking
• Before starting work, warm up your body the machine without shutting down the engine
thoroughly to start work under good condition. (measuring oil pressure, revolving speed,
• Avoid continuing work for long hours and take temperature, etc.), take extreme care not to get
rests at proper intervals to keep your body in caught in rotating parts or moving parts.
good condition and at the provided place. • When raising a heavy component (heavier than
25 kg), use a hoist or crane. Before starting work,
Precautions for preparatory work
check that the slings (wire ropes, chains, and
• Before adding oil or making any repairs, place
hooks) are free from damage. Always use slings
the machine on a firm and level ground, and
which have ample capacity and install them to
apply the parking brake and chock the wheels or
proper places. Operate the hoist or crane slowly
tracks to prevent the machine from moving.
to prevent the component from hitting any other
HB215LC-2 00-17
part. Do not work with any part still raised by the The signaler must always stand in front of the
hoist or crane. load and guide the operator safely.
• When removing a part which is under internal • Never stand under the load.
pressure or under reaction force of a spring, • Do not move a load over a person.
always leave 2 bolts in diagonal positions. • Never stand on the load.
Loosen those 2 bolts gradually and alternately to • Do not prevent the load from swinging or
release the pressure, and then remove the part. falling down by holding it simply with the
• When removing components, be careful not to hands.
break or damage the electrical wiring. Damaged • The sling workers and assistant workers
wiring may cause a fire. other than the guide must move to a place
• When removing piping, stop the fuel or oil from where they are not caught between the load
spilling out. If any fuel or oil drips onto the floor, and materials or equipment on the ground or
wipe it off immediately. Fuel or oil on the floor hit by the load even if the crane starts
can cause you to slip and can even cause fires. abruptly.
• As a general rule, do not use gasoline to wash • Check the slings before starting sling work.
parts. Do not use it to clean electrical parts, in • Keep putting on gloves during sling work. (Put
particular. on leather gloves, if available.)
• Be sure to assemble all parts again in their • Measure the weight of the load by the eye and
original places. Replace any damaged parts and check its center of gravity.
parts which must not be reused with new parts. • Use proper sling corresponding to the weight of
When installing hoses and wiring harnesses, be the load and method of slinging. If too thick wire
sure that they will not be damaged by contact ropes are used to sling a light load, the load may
with other parts when the machine is operated. slip and fall.
• When installing high pressure hoses and tubes, • Do not sling a load with one wire rope alone. If it
make sure that they are not twisted. Damaged is slung so, It may rotate and may slip out of the
hoses and tubes are dangerous, so be rope. Install two or more wire ropes
extremely careful when installing hoses and symmetrically.
tubes for high pressure circuits. In addition,
check that connections of them are correct. k Slinging with one rope may cause turning
• When assembling or installing parts, always of the load during hoisting, untwisting of
tighten them to the specified torques. When the rope, or slipping of the rope from its
installing protective parts such as guards, or original slinging position on the load,
parts which vibrate violently or rotate at high which can result in a dangerous accident.
speed, be particularly careful to check that they
are installed correctly. • Hanging angle must be 60° or smaller as a rule.
• When aligning 2 holes, never insert your fingers • When hanging a heavy load (25 kg or heavier),
or hand. Be careful not to get your fingers the hanging angle of the rope must be narrower
caught in a hole. than that of the hook.
• When measuring hydraulic pressure, check that a When hoisting a load with 2 or more ropes,
the measuring tools are correctly installed. the force subjected to each rope increases
• Take care when removing or installing the tracks with the hanging angle. The figure below
of track-type machines. Since the track shoe shows the variation of allowable load in kg
may separate suddenly when you remove it, when hoisting is made with 2 ropes, each of
never let anyone stand at either end of the track which is allowed to sling up to 9.8 kN {1,000
shoe. kg} vertically, at various hanging angles.
• If the engine is operated for a long time in a When the 2 ropes sling a load vertically, they
closed place which is not ventilated well, you can sling up to 2,000 kg of total weight. This
may suffer from gas poisoning. Accordingly, weight is reduced to 1,000 kg when the 2
open the windows and doors to ventilate the ropes make a hanging angle of 120°. If the 2
place well. ropes sling a 2,000 kg load at a lifting angle
Precautions for slinging work and making of 150° each rope is subjected to a force as
signals large as 39.2kN {4,000 kg}.
• Only one appointed worker must make signals
and co-workers must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at a place where
he is well seen from the operator's seat and
where he can see the working condition easily.
00-18 HB215LC-2
• When lifting down a load, stop it temporarily at

30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove
the sling.
• Remove kinks and dirt from the wire ropes and
chains used for the sling work, and put them in
the specified place.
Precautions for using mobile crane

a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
• When installing wire ropes to an angular load, Precautions for using overhead traveling crane
apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the k When lifting a heavy load (25 kg or more),
wire rope from slipping. use a hoist crane or similar device. The
• Use the specified eye bolts and fix wire ropes, weight of a part that is 25 kg or more is
chains, etc. to them with shackles, etc. indicated with the symbol 4 in
• Apply wire ropes to the middle part of the hook. Disassembly and assembly.
a Slinging near the tip of the hook may cause
the rope to slip off the hook during hoisting. • Before starting work, check the wire ropes,
The hook has the maximum strength at the brake, clutch, controller, rails, over winding
middle part. prevention device, ground fault circuit interrupter
for electric shock prevention, crane collision
prevention device, and energizing warning lamp,
and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction
indication plate (north, south, east and west) and
the operating button.
• Do not sling a load at an angle. Do not move the
crane while the slung load is swinging.
• Do not raise or lower a load while the crane is
moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it leaves
• Do not use twisted or kinked wire ropes. the ground and check safety, and then lift it up.
Precautions for slinging up • Consider the travel route in advance and lift up a
• Wind in the crane slowly until wire ropes are load to a safe height.
stretched. When settling the wire ropes with the • Place the control switch in a position where it is
hand, do not grasp them but press them from not an obstacle to work and passage.
above. If you grasp them, your fingers may be • After operating the hoist, do not swing the
caught. control switch.
• Wind in the crane slowly until wire ropes are • Remember the position of the main switch so
stretched. When settling the wire ropes with the that you can turn off the power immediately in an
hand, do not grasp them but press them from emergency.
above. If you grasp them, your fingers may be • If the hoist stops because of a power failure, turn
caught. the main switch OFF. When turning on a switch
• After the wire ropes are stretched, stop the after it is turned OFF by the ground fault circuit
crane and check the condition of the slung load, interrupter, check that the devices related to that
wire ropes, and pads. switch are not in operating condition.
• If the load is unstable or the wire rope or chains • If you find an obstacle around the hoist, stop the
are twisted, lower the load and lift it up again. operation.
• Do not lift up the load at an angle. • After finishing the work, stop the hoist at the
specified position and raise the hook to at least 2
Precautions for slinging down
m above the floor. Do not leave the sling
installed to the hook.
HB215LC-2 00-19
Selecting wire ropes • Check that the O-rings are fitted to the joints
• Select adequate ropes for the weight of the parts when connecting the air conditioner piping.
to be hoisted, referring to the table below • Once an O-ring is used, it is deformed and
Wire rope (JIS G3525, 6 x 37 - Type A) deteriorated. Accordingly, do not reuse it.
(Standard Z twist wire ropes without galvanizing) • When removing the O-rings, use a soft tool so
that the piping is not damaged.
Nominal • Check that each O-ring is not damaged or
diameter of rope Allowable load
deteriorated.
mm kN ton • Apply compressor oil for refrigerant (R134a) to
10 8.8 0.9 the O-ring.
12 12.7 1.3
a However, do not apply oil to the threaded
14 17.3 1.7
portions of bolts, nuts or unions.
16 22.6 2.3
18 28.6 2.9 Manufacturer Part name
20 35.3 3.6 DENSO ND-OIL8
25 55.3 5.6 VALEO THERMAL ZXL100PG (equivalent to
30 79.6 8.1 SYSTEMS PAG46)
40 141.6 14.4 SANDEN SP-10
50 221.6 22.6 • When tightening nuts of the air conditioner
60 318.3 32.4 piping, be sure to use 2 wrenches. Use one
wrench to fix one nut and tighten the other nut
a The allowable load is calculated as one 6th of with the other wrench to the specified torque
the breaking load of the rope to be used (safety (Use a torque wrench for tightening).
factor: 6).
a Example of fitting of O-ring
Precautions for disconnecting air conditioner • An O-ring is fitted to every joint of the air
piping conditioner piping.
k When replacing the air conditioner unit, air
conditioner compressor, condenser or
receiver drier, etc., collect the refrigerant (air
conditioner gas: R134a) from the air
conditioner circuit before disconnecting the
air conditioner hoses.
a Ask a qualified person for collecting, adding and

filling operations of the refrigerant (air
conditioner gas: R134a).
a Never release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
k If refrigerant gas (air conditioner gas: R134a)
gets in your eyes, you may lose your sight. If
it touches your skin, you may suffer from
frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.
• When loosening the nuts of the air conditioner

piping, be sure to use 2 wrenches; Use one
wrench to fix one nut and use the other one to
loosen the other nut.
Precautions for air conditioner piping
For tightening torques, see Others,
• When installing the air conditioner hoses, be
"Precautions for disconnection and connection
careful to prevent dirt, dusts and water from
of air conditioner piping" (Chapter 80).
entering into them.
00-20 HB215LC-2
Precautions to prevent fire (ALL-0000-17B-K-03-A)
• Fire caused by fuel, oil, coolant or window • Remove any dry leaves, chips, pieces of
washer fluid paper, coal dust, or any other flammable
Do not bring any flame or fire close to flammable materials accumulated or attached to or
substances such as fuel, oil, coolant or window around the engine exhaust manifold, muffler,
washer fluid.There is danger that they may catch or battery, or on the undercovers.
fire. Always observe the following. • To prevent fires from being caught, remove
• Do not smoke or use any flame near fuel or any flammable materials such as dry leaves,
other flammable substances. chips, pieces of paper, coal dust, or any
• Shut down the engine before adding fuel. other flammable materials accumulated
• Do not leave the machine when adding fuel around the cooling system (radiator, oil
or oil. cooler) or on the undercover.
• Tighten all the fuel and oil caps securely. • Fire coming from electric wiring
• Be careful not to spill fuel on overheated Short circuits in the electrical system can cause
surfaces or on parts of the electrical system. fire. Always observe the following.
• After adding fuel or oil, wipe up any spilled • Keep all the electric wiring connections clean
fuel or oil. and securely tightened.
• Put greasy rags and other flammable • Check the wiring every day for looseness or
materials into a safe container to maintain damage. Reconnect any loose connectors or
safety at the workplace. refasten wiring clamps. Repair or replace any
• When washing parts with oil, use a non- damaged wiring.
flammable oil. Do not use diesel oil or • Fire caused by piping
gasoline.There is danger that they may catch Check that all the clamps for the hoses and
fire. tubes, guards, and cushions are securely fixed
• Do not weld or use a cutting torch to cut any in position.
pipes or tubes that contain flammable liquids. If they are loose, they may vibrate during
• Determine well-ventilated areas for storing oil operation and rub against other parts. There is
and fuel. Keep the oil and fuel in the danger that this may lead to damage to the
specified place and do not allow hoses and cause high-pressure oil to spurt out,
unauthorized persons to enter. leading to fire and serious personal injury or
• When performing grinding or welding work death.
on the machine, move any flammable • Fire around the machine due to highly heated
materials to a safe place before starting. exhaust gas
Some machines are equipped with KDPF
(Komatsu Diesel Particulate Filter).
KDPF is a system for purifying soot in exhaust
gas. Its exhaust 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.
• When there are thatched houses, dry leaves
or pieces of paper near the work site, set the
9 J D 0 1 7 2 0
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.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
• When taking the electrical power for the
lighting equipment from the machine itself,
9 J D 0 1 7 2 1
follow the instructions in the operation and
• Fire caused by accumulation or attachment maintenance manual.
of flammable material
HB215LC-2 00-21
Action if fire occurs (ALL-0000-17A-K-01-A)
• Turn the starting switch to OFF position to stop

the engine.
• Use the handrails and steps to get off the
machine.
• Do not jump off the machine. You may fall or
suffer serious injury.
• The fume generated by a fire contains harmful
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
• After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is
recommended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature
environment).
When wearing cotton-work-gloves, wear rubber
gloves under them.
Dispose of waste materials (ALL-0000-99A-K-02-A)
To prevent pollution, pay full attention to the way to

dispose of waste materials.
• Always put the oil and coolant drained from the
machine in containers. Never drain the oil and
coolant directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
• Observe the related laws and regulations when
disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.
Some kinds of rubber and plastics may produce

poisonous gas harmful to human body when they
are burned.
• As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain those
materials, ask the industrial waste treatment
firms for their disposals in accordance with the
local regulations.
00-22 HB215LC-2
How to read the shop manual (ALL-0320-010-A-01-A)
(Rev. 2012/10)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual

• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
HB215LC-2 00-23
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described.
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
indicated.
Tightening The tightening torques that require special attention during assembly
3 torque work are indicated.
The places to be coated with adhesives, grease, etc. during assembling
2 Coat
are indicated.
Oil, coolant The places where oil, coolant, etc. must be added and the quantity to be
5 added are indicated.
Places where oil, coolant, etc. must be drained and the quantity to be
6 Drain
drained are indicated.
Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.
00-24 HB215LC-2
Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)
(Rev. 2012/10)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance • When some parts are repaired, the value of
• To be accurate, the finished dimension of a part performance/function is set to the standard
is slightly different from one to another. value.
• The finished dimension of a part specifies the
allowable difference from the standard
dimension which is set first.
• The dimension set as the standard is called the
standard dimension and the range of difference
from this standard dimension is called the
"tolerance".
• An indication example of a standard dimension
and tolerance is shown in the following table.
(The standard dimension is entered on the left
side and the tolerance is entered with a positive
or negative symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• 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)
• Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
• An indication example of a shaft and hole is
shown in the following table.
Standard interference
(The standard dimension is entered on the left
• When the diameter of a hole of a part shown in
side and the tolerance of the shaft is entered
with a positive or negative symbol at the center the given standard dimension and tolerance
table is smaller than that of the shaft to be
and that of the hole on the right side)
inserted, the difference between those
Standard Tolerance diameters is called the "interference".
dimension Shaft Hole • Subtract the maximum dimension of the hole
-0.030 +0.046 from the minimum dimension of the shaft and
60
-0.076 0 call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
Standard clearance and standard value shaft and call it (B). The range between (A) and
• The clearance made when new parts are (B) is the "standard interference".
assembled is called the standard clearance, • After repairing or replacing some parts, measure
which is indicated by the range from the the dimension of their hole and shaft and check
minimum clearance to the maximum clearance. that the interference is in the standard range.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance. Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimensions of parts change because of the
"standard value", which is indicated by a range wear or deformation while they are used. When
or a target value. the dimension changes exceeding certain value,
HB215LC-2 00-25
the parts can not be used any longer. This value

is called "repair limit".
• If a part is worn to the repair limit, it must be
replaced or repaired.
• The performance and function of the products
lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.
Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.
00-26 HB215LC-2
Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)
(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.
Use care for working environment

• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.
How to clean parts when dirt is stuck

• If any dirt or dust sticks the parts of the fuel
system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge

• Be sure to use the Komatsu genuine fuel filter
cartridge.
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. In order to prevent foreign material from
entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.
HB215LC-2 00-27
Handling of intake system parts (PC220-A900-2A4-K-00-A)
(Rev.2013/10)
• The Komatsu Variable Geometry Turbocharger
consists of more precise parts (variable
mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.
Be careful of working environment

• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
components which are removed, with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.
00-28 HB215LC-2
Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)
(Rev. 2012/10)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.
Be careful of working 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.
Disassembly and maintenance work in the field

• When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the Preventing intrusion of foreign materials during
performance test of the components must be refilling operations.
performed with the special testing equipment. • Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.
Plugging of opening (prevention of flowing out

of oil)
components which are removed (when plugs
are not prepared, seal with caps, tapes, vinyl
bags, etc.) to prevent entry of foreign material Replacing hydraulic oil while its temperature is
and flowing out of oil. Never leave the openings high
• When the hydraulic oil is warm, it flows easily. In
of the pipes and hoses without being covered or
addition, sludge can also be drained from the
plugged with cloth as foreign material may enter
them or environment may be polluted by the oil circuit together with the oil. So, it is better to
leaked. Do not discard the waste oil somewhere change the hydraulic oil while it is warm. When
or other. Hand it over to your customer for changing the hydraulic oil, the old oil must be
disposal, or dispose it by yourself. drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.
HB215LC-2 00-29
Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.
Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.
00-30 HB215LC-2
Method of disconnecting and connecting of push-pull type coupler (ALL-

C930-001-P-00-A)
(Rev. 2012/01)
k Loosen the oil filler cap of the hydraulic tank slowly 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 (ALL-C930-925-P-01-A)
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3) aligning them with each other.
(Fig. 4)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3),
the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until
connecting condition. (Fig. 4)
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the
(Fig. 3) rubber cap will move approximately 3.5mm
toward the hose, however, it is not a problem.
a Since some hydraulic oil flows out, prepare
an oil container.
HB215LC-2 00-31
Type 2 (ALL-C930-925-P-02-A)
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)
00-32 HB215LC-2
Type 3 (ALL-C930-925-P-03-A)
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)
HB215LC-2 00-33
Handling of electrical equipment (ALL-E000-2A4-P-01-A)
(Rev. 2012/11)
• To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors

• Wiring harnesses consist of wires connecting
one component to another component,
connectors 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 Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely • The pins of the male and female connectors are
careful when handling the wiring harnesses. attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.
Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female connectors) Disconnections in wiring
• Problems with defective contact are likely to • If the wiring harness is pulled to disconnect the
occur because the male connector is not connector, or the components are lifted with a
properly inserted into the female connector,or crane while the wiring harness is still connected,
because one or both of connectors are or a heavy object hits the wiring harness, the
deformed or the position is not correctly aligned, crimping of the connector may separate, or the
or because there is corrosion or oxidization of soldering may be damaged, or the wiring
the contact surfaces. The corroded or oxidized harness may be broken.
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connectors approximately 10
times.
00-34 HB215LC-2
blow it with compressed air and spray it with

electrical contact restorer.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier. So,
remove the oil and water from the
compressed air completely before cleaning
the connector with the compressed air.
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 once water does enter, it is difficult
to drain it. 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 Removing, installing, and drying connectors
and wiring harnesses
or take other appropriate action before passing
Disconnecting connectors
electricity through it.
1. Hold the connectors when disconnecting.
• Disconnect connectors by holding the
connector bodies. For the connectors held by
a screw, loosen the screw fully, then hold the
male and female connectors with each hand
respectively and pull them apart horizontally.
For the connectors with lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull the connector with one hand.
Entry of water, mud or dirt when disconnecting a

connector
• If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off any
stuck water or dirt by using a piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt stuck to connector
• If any oil or grease is stuck to the connector and
an oil film is formed on the mating surface of the 2. When removing from clips
male and female pins, the oil prevents electricity • Both of the connector and clip have stoppers,
from passing through, resulting in defective which are engaged with each other when the
contact. If any oil or grease, mud or dirt is stuck connector is connected.
to the connector, wipe it off with a dry cloth or
HB215LC-2 00-35
• Check that there is no oil, dirt or water stick

to the connector pins (joint portion).
• Check that the 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 any oil, water or dirt is stuck to the
connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring
• When removing a connector from a clip, pull harness with a dryer. But be careful not to
the connector in a parallel direction to the clip make it too hot as it causes short circuit.
for removing stoppers. a If there is any damage or breakage, replace
a If the connector is pried up and down or the connector.
to the right and left, the housing may 2. Fix the connector securely.
break. • Align the connectors correctly, and fit them
securely. For the connectors with the lock
stopper, push in the connectors until "click" is
heard.
3. Action to take after removing connectors

• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion. 3. Correct the protrusion of the boot and
misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness or the clamp is out of the
cover the connector. position, put it in its original position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
Connecting connectors
1. Check the connector visually.
00-36 HB215LC-2
• If the connector clamp is removed, be sure to Drying wiring harness

return it to its original position. And check • If there is any oil or dirt on the wiring harness,
that it is securely installed. wipe it off with a dry cloth. Avoid washing by
using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to 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 a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.
Handling of Deutsch connector (DT8-pin, DT12-
pin)
Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).
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 to use hot air in order to
prevent the connector or related parts from
Connection becoming too hot, as it causes deformation
1. Push in female connector (2) horizontally until or damage to the connector.
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.
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 the connector is completely dried, blow
the contact restorer and reassemble them.
HB215LC-2 00-37
2. While pressing lock (L2), pull out connector (1).

Handling of connectors used on engine
Slide, lock type

(FRAMATOME-3, FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).
Connection
1. Insert the connector securely until a click is Connection
heard.
1. Insert the connector securely until a click is
(FRAMATOME-24)
heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type
(PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.
00-38 HB215LC-2
Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
(AMP-3)
Push lock type
(BOSCH-3) Disconnection
Disconnection 1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
1. While pressing lock (C), pull out connector (3) in
• 114 series
Connection
heard.
• 107 series (SUMITOMO-2)
Disconnection
1. While pressing lock (E), pull out connector (5) in
a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
While pushing up lock (C) of the connector Connection
with flat-head screwdriver [1], pull out 1. Insert the connector securely until a click is
connector (3) in the direction of the arrow. heard.
HB215LC-2 00-39
(SUMITOMO-3)
Disconnection
1. While pressing lock (E), pull out connector (5) in
a Pull the connector straight up.
Connection
1. Insert the connector to the end while aligning its
grove to the other.
2. Turn housing (H1) in the direction of the arrow
until it "clicks".
Connection
heard.
(SUMITOMO-4)
Disconnection
1. While pressing lock (D), pull out connector (4) in
Handling controller
• The electronic circuits for control including the
microcomputers are assembled in the controller.
These electronic circuits in the controller must
be handled with care as they control the
machine.
• Do not place objects on top of the controller.
Connection
heard.
Turn-housing type (Round green connector)
(CANNON-4)
Disconnection
1. Turn housing (H1) in the direction of the arrow.
a Unlock the connector by turning housing (H1).
When the lock is release the housing is felt
tight to turn.
2. Pull out housing (H1) in the direction of the • Cover the control connectors with tape or a vinyl
arrow. bag. Never touch the connector contacts.
a Housing (H1) is left on the wiring harness • During rainy weather, do not leave the controller
side. in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high
00-40 HB215LC-2
temperature even for a short period of time.

(Place it on a suitable dry stand.)
• Precautions when performing arc welding

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
• Be sure to turn the starting switch to "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
performance by disconnecting and
connecting them several times.
• Be sure to connect all the disconnected
connectors before proceeding to the next step.
a If the starting switch is turned to "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• 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.
HB215LC-2 00-41
How to read electric wire code (Hybrid) (HB380-E500-030-P-00-A)
(Rev. 2013/10)
• This section describes the wire code unique to the hybrid models.
• 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) AEX0.85L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV, AVS, AVSS, and CAVS wires depends on size (nominal No.), their
symbols are not indicated on the electrical circuit diagram.)
Indicates size of wire by nominal No.
0.85
Sizes (Nominal Nos.) are shown in Table 3.
Indicates color of wire by color code.
L
Color codes are shown in Table 7.
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 but different from AV, AVS, and AVSS in material of the cover.
CAVS has a circular compressed conductor and different appearance from AV and AVS.
(Table 1)
Temperature
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Low-voltage For large current wiring
wire for AV
(nominal No. 5 and above)
automobile
Thin-cover
AVS: General wiring
low-voltage
AVS (Nominal No. 3 to 5)
wire for
automobile AVSS AVSS: General wiring
Soft polyvinyl chloride -30 to +60 (Nominal No. 2)
(Type 1) Annealed
Thin-cover copper for
low-voltage electric For mid- to small-size
wire for CAVS appliance excavators
automobile (nominal No. 1.25 and lower)
(Type 2)
Heat- General wiring for extremely
resistant low- Heat-resistant cross- cold weather specification
voltage wire AEX linked polyethylene -50 to +110
for Wiring at high-temperature
automobile place
00-42 HB215LC-2
(Table 2)
Temperature
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Annealed copper for
Conductor electric appliance
Foil shielded Insulator Soft polyvinyl chloride For general signal wiring
AVSS- Drain Sn plated annealed
cable for -30 to +60 (nominal size: 0.5, double
CS copper wire strand
automobiles wire core)
Shield Aluminum foil
Sheath Soft polyvinyl chloride
Annealed copper for
Heat- Thin low-capacitance
resistant low- Insulator crosslinked For signal wiring in high-
PEXB- polyethylene temperature place
voltage wire -50 to +120
S
for Sn plated, annealed, (nominal size: 0.5, 3 cores)
automobile Shield braided copper wire
Heat-resistant cross-
Sheath linked polyethylene
Annealed copper for
Shielded
braided cable CAVS- Insulator Soft polyvinyl chloride For general signal wiring
-30 to +60
for BS Sn plated, annealed, (nominal size: 0.5, 3 cores)
automobiles Shield braided copper wire
Sheath Soft polyvinyl chloride
HB215LC-2 00-43
Dimensions
(Table 3)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (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 -
Coating 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/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor Cross-
sectional 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Coating 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 - - - - - - - - -
(Table 4)
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25
Number of
strands/ 7/round 11/round 16/round
- - -
Diameter of compression compression compression
strand
Conductor Cross-
sectional - 0.56 - 0.88 - 1.29
area (mm2)
d (approx.) - 0.9 - 1.1 - 1.4
Coating D
CAVS Standard - 1.6 - 1.8 - 2.1
00-44 HB215LC-2
AVSSCS
(Table 5)
Nominal No. 0.5f
Number of cores 2
Construction (No./mm) 19/0.19
Core conductor Cross-sectional area (mm2) 0.54
Outside diameter (mm) 1.6
Drain wire
Cross-sectional area (mm2) 0.51
Aluminum foil thickness (mm) 0.03
Sheath thickness (mm) 0.5
Finished outside diameter (mm) 4.3
PEXBS
(Table 6)
Nominal No. 0.5f
Number of cores 3
Core conductor Cross-sectional area (mm2) 0.51
Outside diameter (mm) 2.0
Strand diameter (mm) 0.12
Braided shield No. of wires/strands 5/16
Density (%) Min. 70
Sheath thickness (mm) 0.5
Finished outside diameter (mm) 5.9
a "f" of nominal No. denotes "flexible".
HB215LC-2 00-45
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
a 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".
Types of circuits and color codes

(Table 8)
Type of wire AVS, AV, CAVS 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 - - - - - - -
00-46 HB215LC-2
Precautions when performing operation (ALL-1160-927-A-00-A)
(Rev. 2012/11)
• When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and
assembly" of the components, observe the following general cautions.
Precautions for removal and disassembly work

• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
a The O-rings in the table are emergency parts used for disassembly or transportation of the machine.
When assembling, confirm the part numbers in the parts book and use the parts conforming to the
using condition.
Disconnection of face seal type hoses and tubes
Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
HB215LC-2 00-47
Disconnection of taper seal type hoses and tubes
Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422
Disconnection of split flange type hoses and tubes
No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
04 38.1 17.5 07371-30400 07378-10400 07000-12021 01643-50823
00400 80825
07379- 01010-
05 42.9 19.8 07371-30500 07378-10500 07000-13022 01643-50823
00500 80830
07379- 07372-
06 47.6 22.2 07371-30640 07378-10600 07000-13025 01643-51032
00640 51035
07379- 07372-
10 52.4 26.2 07371-31049 07378-11000 07000-13032 01643-51032
01044 51035
07379- 07372-
58.7 30.2 07371-31255 07378-11200 07000-13038 01643-51032
01250 51035
12
07379- 01010-
66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232
01260 81245
07379- 07372-
14 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232
01460 51240
00-48 HB215LC-2
No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
79.4 36.5 07371-51470 07378-11410 07000-13048 01643-31445
01470 81455
07379- 07372-
77.8 42.8 07371-32076 07378-12000 07000-12060 01643-51232
02071 51240
20
07379- 01010-
96.8 44.5 07371-52080 07378-12010 07000-12060 01643-31845
02080 81865
07379- 07372-
24 88.9 50.8 07371-12484 07378-12400 07000-12070 01643-51232
02484 51240
07379- 07372-
30 106.4 62 07371-13010 07378-13000 07000-12085 01643-51645
03010 51650
07372-
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 01643-51645
51650
07379- 07372-
40 130.2 77.8 07371-14012 07378-14000 07000-12110 01643-51645
04012 51650
07372-
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 01643-51645
51655
Removal of pipe joints of O-ring boss type
Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
Removal of pipe joints of taper pipe thread type
HB215LC-2 00-49
Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R 1/ 8 07042-00108 07043-00108
02 R 1/ 4 07042-00211 07043-00211
03 R 3/ 8 07042-00312 07043-00312
04 R 1/ 2 07042-00415 07043-00415
06 R 3/ 4 07042-00617 07043-00617
10 R1 07042-01019 07043-01019
12 R1 1/4 07042-01222 07043-01222
14 R1 1/2 07042-01422 07043-01422
20 R2 07042-02026 07043-02026
Precautions for installation and assembly work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified.
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the threaded
part.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
• Clean all of the parts, and repair any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded part of each taper male
screws which receives pressure.
However, if the threaded part is difficult to degrease, you may use a seal tape.
• When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing
direction of the threads, seeing from the screw end and starting at the third thread.
a If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is
pushed out, and that can cause oil leakage.
00-50 HB215LC-2
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start the engine, and run it at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end 4 to 5 times.
3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke.
a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
Precautions at the time of completing work

Refilling of coolant, oil and grease
• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping,
and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Testing of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Cooling system for water leakage.
Fuel system for fuel leakage.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
HB215LC-2 00-51
Practical use of KOMTRAX (ALL-Q210-13V-K-00-A)

(Rev. 2012/10)
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX
operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the
KOMTRAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)
Merit of using KOMTRAX

• The working place of the machine can be checked in the map on PC.
• Operation information such as service meter reading, operating hours, fuel consumption, occurred caution
and failure code can be checked.
• The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil
filter, hydraulic oil and engine oil can be checked.
• The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.)
can be checked and the machine operating condition can be presumed with these information.
• Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice as well for the user and operator.
How to use KOMTRAX practically

With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.
How to operate KOMTRAX

For the operating method of each screen of KOMTRAX, see "Global KOMTRAX Web Reference Manual (For
Key Person)".
00-52 HB215LC-2
Handling hybrid components and high voltage wiring harness (HB380-PQJE-015-K-

00-A)
(Rev. 2013/08)
k When you remove or work on the hybrid devices (motor-generator, electric swing motor, capacitor,
inverter) or high-voltage wirings, 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 is lost and a serious trouble may occur.
a For the locations of the hybrid devices, see "Outline of hybrid system" (Chapter 10).
k Replace the hybrid devices and high-voltage wirings (wound with orange conduits) by the
assembly.
k When testing, servicing or replacing a hybrid device or a high-voltage wiring, discharge the
capacitor in advance.
a For details, see "Precautions for normal testing and adjusting(PAGE 00-54)".
k The machine has the function of discharging the capacitor. If it breaks down, discharge the
capacitor with an external capacitor discharger.
k Handling of inverter and capacitor

1. Handling of inverter and capacitor
Handle the inverter and capacitor with extreme care since they have microcomputers and
electronic control circuits in them.
2. Precautions for arc welding
When performing arc welding on the machine body for repair, etc., disconnect all the wiring
harness connectors and ground cables connected to the inverter and capacitor. Connect the
arc welding ground cable close to the weld portion.
Precautions for maintenance on hybrid system (HB380-PQG9-012-K-05-A)
Gear for handling hybrid devices and high-voltage wirings

• Insulating gloves (rubber gloves, etc.)
• Safety shoes (insulating type)
• Protective eyeglasses
• ABC fire extinguisher
• Sealing tape (for insulation)
• Cloth (factory rag)
Precautions for high voltage and high temperature (HB380-PQJE-012-K-00-A)
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).
HB215LC-2 00-53
Precautions for normal testing and adjusting (HB380-PQG9-012-K-01-A)
Never disassemble the hybrid devices (motor-generator, electric swing motor, capacitor, inverter) and high-
voltage wirings (orange).
When the hybrid devices need to be tested, removed and restored, work according to the following procedure.
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 Testing and adjusting, “Capacitor discharge procedure” (Chapter
30).
3. Perform testing and service with the key switch OFF.
4. Put on insulating gloves, protective eyeglasses and safety shoes (insulating type).
5. Look into the charge level inspection window at the top of the capacitor and check that the LED display
indicates that the capacitor is discharged, and then disconnect the one-touch connector of the capacitor.
If the capacitor is not discharged, leave it until it is discharged (Number of days for leaving: maximum of 14
days). Stick a sealing tape, etc. to the capacitor unit and write "Cannot be discharged" on it with a marker
pen, etc.
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 multimeter. If the hybrid
device case is not grounded, fix the ground cable securely when performing restoration procedure step (1).
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 50 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 50 V, wait for a while until it decreases below 50 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 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.
Restoration
1. Install the hybrid device.
2. Thoroughly wipe the connector mounting face of the hybrid device and insert the connector terminal to the
end.
3. Fix the connector terminal with genuine M6 bolts to the specified of 11.8 to 14.7 Nm (1.2 to 1.5 kgm).
4. Connector the capacitor one-touch connector.
Precautions when machine tips over and hybrid component damages (HB380-PQG9-
012-K-02-A)
When the machine tips over or any hybrid device or high-voltage wiring (orange) is broken in an accident, if
you touch them carelessly, you may be injured seriously.
In such a case, observe the following items and work with extreme care for the safety.
1. When servicing, be sure to stop the engine so that a high voltage will not be applied to the hybrid devices.
2. If a fire breaks out on the machine, put it out with an “ABC fire extinguisher” (for both oil and electric fires).
00-54 HB215LC-2
It is rather dangerous to try to extinguish a fire with a small amount of water. When extinguishing with
water, splash a large quantity of water from a hydrant, etc.
3. Put on insulating gloves (rubber gloves etc.), protective eyeglasses and safety shoes (insulating type).
4. Raise the machine with another machine and move it to a safe place.
5. Do not touch an bare wire which is unknown if it is a high-voltage wiring. If it is obliged or possible for you
to touch such a wire, put on insulating gloves, ensure that the voltage between the wire and the machine
body is below 50 V (safety voltage) by using a multimeter, and then insulate the wire with a sealing tape.
6. Disconnect the one-touch connector of the capacitor.
7. Discharge the capacitor with the capacitor discharger.
8. Look into the charge level inspection window on the contactor box at the top of the capacitor and check
that the LED display indicates that the capacitor is discharged.
days). Stick a sealing tape, etc. to the capacitor unit and write “Discharge is not available” on it with a
marker pen, etc.
9. Perform testing, maintenance, removal, etc. of the hybrid devices according to "Precautions for normal
testing and adjusting(PAGE 00-54)", step 6 and after.
If the capacitor case is broken, take extreme care not to touch the cells directly.
Precautions for submersion (HB380-PQG9-012-K-03-A)
If the hybrid devices are submerged, they may malfunction and can cause a trouble and the operator may not
able to operate the machine safely. If you touch the machine carelessly, you may get an electric shock and
may be injured seriously.
Observe the following items and test and service the machine with extreme care for safety.
1. Put on insulating gloves (rubber gloves etc.), protective eyeglasses, and safety shoes (insulating type).
2. Be sure to stop the engine so that a high voltage will not be applied to the hybrid devices.
3. Lift up the machine above the water with another machine.
4. Disconnect the one-touch connector of the capacitor.
5. Discharge the capacitor with the capacitor discharger.
6. Look into the charge level inspection window at the top of the capacitor and check that the LED display
indicates that the capacitor is discharged.
days). Stick a sealing tape, etc. to the capacitor unit and write “Discharge is not available” on it with a
marker pen, etc.
7. Perform testing, maintenance, removal, etc. of the hybrid devices according to "Precautions for normal
testing and adjusting(PAGE 00-54)", step 6 and after.
Precautions for cold season (HB380-PQG9-012-K-04-A)
• In a cold weather the upper structure swings at the normal speed but the work equipment speed and travel
speed become slower than at the normal temperature, thus the machine does not move as the operator
expects. Warm up the machine sufficiently since it may collide with an obstacle.
• If it is obliged to move the machine before warming it up, fully recognize the difference of the movement of
the machine and work equipment during the work equipment operation, travel, and swinging, then operate
the machine carefully.
HB215LC-2 00-55
Standard tightening torque table (ALL-M140-03B-P-01-A)
(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.
00-56 HB215LC-2
a Tighten the following flanged bolt on which "7" is stamped on its top to the tightening torque shown in the
following table.
Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}
Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the table
below.
Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-20UNC 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
5/16-18UNC 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
3/8-16UNC 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
1/2-13UNC 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
9/16-12UNC 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
5/8-11UNC 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
3/4-10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
7/8-9UNC 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
1-8UNC 883 to 1,196 {90 to 122} 1,040 {106} 245 to 333 {25 to 34} 284 {29}
1 1/8-7UNC 1,187 to 1,608 {121 to 164} 1,393 {142} 333 to 451 {34 to 46} 392 {40}
1 1/4-7UNC 1,598 to 2,157 {163 to 220} 1,873 {191} 451 to 608 {46 to 62} 530 {54}
1 1/2-6UNC 2,354 to 3,177 {240 to 324} 2,765 {282} 657 to 892 {67 to 91} 775 {79}
HB215LC-2 00-57
Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table
below.
Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-28UNF 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
5/16-24UNF 34.3 to 39.2 {3.5 to 4} 37.3 {3.8} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
3/8-24UNF 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
1/2-20UNF 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
9/16-18UNF 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.6 {6}
5/8-18UNF 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
3/4-16UNF 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
7/8-14UNF 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
1-14UNF 1,020 to 1,373 {104 to 140} 1,196 {122} 284 to 382 {29 to 39} 333 {34}
1 1/8-12UNF 1,353 to 1,844 {138 to 188} 1,598 {163} 382 to 520 {39 to 53} 451 {46}
1 1/4-12UNF 1,804 to 2,432 {184 to 248} 2,118 {216} 510 to 686 {52 to 70} 598 {61}
1 1/2-12UNF 2,707 to 3,658 {276 to 373} 3,177 {324} 765 to 1,030 {78 to 105} 892 {91}
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})

Nominal No. diameter across flats
(mm) (mm) Range Target
02 14 Varies 35 to 63 {3.5 to 6.5} 44 {4.5}
— 18 depending 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 on type of 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 connector. 128 to 186 {13.0 to 19.0} 157 {16.0}
00-58 HB215LC-2

10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.

08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
Table of tightening torque for hose (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 table below.
a The table is applied to the threads coated with engine oil (wet threads)
HB215LC-2 00-59
Tightening torque (Nm {kgm}) Taper seal Face seal

Width
Nominal across Nominal No. - Thread root
No. of flats Thread size threads per diameter
Range Target
hose (mm) (mm) inch, type of (mm)
thread (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16-18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16-16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13 /16-16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1 3/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —
Table of tightening torque for face seal joints

a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Tightening torque (Nm {kgm}) Face seal

Outside Width
diameter of across flats Nominal No. - Thread root
pipe (mm) (mm) Range Target threads per inch, diameter (mm)
type of thread (reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16-16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1 3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the table below.
Thread diameter (mm) Tightening torque (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 —
00-60 HB215LC-2
Tightening torque table for 102, 107, and 114 series engines (joint bolts)
a Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to
the torque shown in the table below.
Thread diameter (mm) Tightening torque (Nm {kgm})

6 8 ± 2 {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}
Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe
thread (NPT))
a Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107,
and 114 series engines to the torques shown in the table below.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
1/16 15 ± 2 {1.53 ± 0.20} 5 ± 1 {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}
HB215LC-2 00-61
List of abbreviation (ALL-0360-005-A-00-A)

(Rev. 2013/03)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text (marked with a).
• This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the shop manual

Purpose of use (major
Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
With this function, when the tires skid (wheels
Anti-skid Brake Travel and brake stop rotating), the brakes are released, and
ABS System when the wheels start to rotate, the brakes are
(HD, HM)
applied again.
Automatic Idling This function automatically sets the idle
AISS Engine
Setting System speed.
A lever is used to perform the steering
Advanced Joystick Steering operations instead of a steering wheel.
AJSS Steering System Moreover, it shifts gear and changes direction
(WA)
(FORWARD or REVERSE).
When the accelerator pedal is released while
Automatic Retarder Travel and brake the machine is traveling downhill, this function
ARAC automatically applies the retarder with a
Accelerator Control (HD, HM)
constant braking force.
When the accelerator pedal is released while
Travel and brake the machine is traveling downhill, this function
Automatic Retarder
ARSC automatically applies the retarder to ensure
Speed Control (HD, HM) that the machine speed does not accelerate
above the speed set by the operator.
Travel and brake When the tires spin on soft ground surfaces,
Automatic Spin
ASR this function automatically uses the optimum
Regulator (HD, HM) braking force to drive both wheels.
A device that can be fixed onto a machine in
ATT Attachment Work equipment
order to enable it to do different jobs.
Brake When the retarder is not being used, this
Brake cooling oil valve bypasses part of the brake cooling oil to
BCV
control valve (HD) reduce the load on the hydraulic pump.
Controller Area Communication and One of communication standards that is used
CAN
Network electronic control in the network on the machine.
A regulator valve which is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and it is
Regulator
not used independently.
This system can simultaneously actuate
Closed-center Load multiple actuators regardless of the load
CLSS Hydraulic system
Sensing System (provides better combined operation than O.L.
S.S.).
Engine controller electronically controls
supply pump, common rail, and injector. This
CRI Common Rail Injection Engine
function maintains optimum fuel injection
amount and fuel injection timing.
Electronic control device uses the signals
Electronic Control from the sensors on the machine. This signal
ECM Electronic control system
Module indicates the optimum actuation to the
actuators. (Same as E.C.U.)
00-62 HB215LC-2

Transmission Proportional electromagnetic valve that
Electronic Control
ECMV gradually increases oil pressure to engage
Modulation Valve (D, HD, WA, etc.)
clutch and reduces transmission shock.
Electronically This system ensures smooth high-speed
Travel travel by absorbing vibration of machine
ECSS Controlled Suspension
System (WA) during travel with hydraulic spring effect of
accumulator.
Electronic control device uses the signals
from the sensors on the machine. This signal
ECU Electronic Control Unit Electronic control system indicates the optimum actuation to the
actuators. (Same as E.C.M.)
This function recirculates part of exhaust gas
Exhaust Gas Engine to combustion chamber in order to reduce
EGR
Recirculation combustion temperature, controls emission of
NOx.
Equipment This system allows data (filter, oil replacement
Management interval, malfunctions on machine, failure
EMMS Machine monitor
Monitoring System code, and failure history) from each sensor on
the machine to be checked on the monitor.
Electromagnetic This mechanism allows actuators to be
EPC Hydraulic system
Proportional Control operated in proportion to the current supplied.
This structure protects the operator's head
from falling objects. (Falling Object Protective
Falling Object Cab and canopy Structure)
FOPS
Protective Structure
This performance is standardized as ISO
3449.
Forward-Neutral- Operation
F-N-R Forward-Neutral-Reverse
Reverse
Global Navigation A general term for positioning system using
GNSS Satellite System Communication satellites such as GPS, GALILEO, etc.
Communication
Global Positioning This system uses satellites to determine the
GPS System (KOMTRAX, KOMTRAX current location on the earth.
Plus)
This function uses a combination of hydraulic
Steering motor and bevel shaft to control difference in
Hydrostatic Steering
HSS travel speed of right and left tracks.
System (D) Accordingly machine can turn without using
steering clutch.
Transmission This function uses a combination of hydraulic
Hydro Static pump and hydraulic motor to shift the speed
HST
Transmission (D, WA) range steplessly without using gears.
Information and A general term for the engineering and its
Communication Intelligent Machine socially applied technology of information
ICT
Technology Control processing and communication.
This valve is installed at inlet port of pump,
Inlet Metering Actuator Engine and it adjusts fuel intake amount in order to
IMA
control fuel discharge of supply pump. Same
as I.M.V.
This is a device to detect the angular velocity
Inertial Measurement Intelligent Machine
IMU and acceleration of the 3 axes that control
Unit Control
motions.
This valve is installed at inlet port of pump,
and it adjusts fuel intake amount in order to
IMV Inlet Metering Valve Engine
control fuel discharge of supply pump. Same
as I.M.V. (I.M.A.)
This mechanism separates oil in blowby gas
Komatsu Closed Engine and returns it to the intake side to afterburn it
KCCV
Crankcase Ventilation there. It primarily consists of filters.
HB215LC-2 00-63

Komatsu Catalyzed This filter captures soot in exhaust gas.
KCSF Engine
Soot Filter It is built in to KDPF.
The catalyst used for purifying exhaust gas.
Komatsu Diesel
KDOC Engine This is built in KDPF or assembled with the
Oxidation Catalyst
muffler.
This component is used to purify the exhaust
gas. KDOC (catalyst) and KCSF (filter to
Komatsu Diesel Engine capture soot) are built-in it.
KDPF
Particulate Filter
It is installed in place of the conventional
muffler.
This function recovers the drive force of the
wheels by braking automatically with the
Komatsu Traction Travel and brake optimum force and at the same time activates
KTCS Control System the inter-axle differential lock when the wheels
(HM system)
idle while the machine travels on the soft
ground road.
Komatsu Variable
The turbocharger on which the cross-section
KVGT Geometry Engine
area of the exhaust passage is made variable.
Turbocharger
Image display equipment such as a monitor
LCD Liquid Crystal Display Machine monitor which assembles in the liquid crystal element.
It refers to semiconductor element that emits
LED Light Emitting Diode Electronic parts light when the voltage is applied in forward
direction.
Local Interconnect Communication and One of communication standards that is used
LIN
Network electronic control in the network on the machine
Function that detects differential pressure of
LS Load Sensing Hydraulic system pump and controls discharge amount
corresponding to load.
Low Voltage Communication and One of communication standards that is used
LVDS Differential Signaling electronic control in the network on the machine
This indicates engine intake air flow.It is not
Engine used independently but it is used as combined
MAF Mass Air Flow
with sensor.Mass air flow sensor can be called
as MAF sensor.
Service that allows transmission and
Multimedia Messaging reception of short messages consisting of
MMS Communication characters or voice or images between cell
Service
phones.
Electric and hydraulic Device actuated to open electric or hydraulic
NC Normally Closed circuits that are normally closed if not
systems
actuated.
Electric and hydraulic Device actuated to close electric or hydraulic
NO Normally Open
systems circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Hydraulic system actuators at the same time, regardless of the
Sensing System
load.
Pressure
PC Hydraulic system A function used to correct oil pressure.
Compensation
System in which a controller instantly
Palm command control Steering analyses data from each lever, pedal, and
PCCS system dial, and performs optimum electronic control
(D)
of the engine and transmission.
This valve is installed at inlet port of pump and
Pre-stroke Control Engine it adjusts fuel intake amount in order to control
PCV
Valve fuel discharge amount of supply pump.
00-64 HB215LC-2

Used for controlling proportional pressure.
Proportional Pressure Hydraulic system This system moves actuators in proportion to
PPC
Control the oil pressure.
Piston Pump and Hydraulic system
PPM Piston pump and motor.
Motor (D, PC, etc.)
PTO Power Take Off Power transmission Power take-off mechanism
Power Tilt and power Work equipment This function performs hydraulic control of the
PTP tilt and pitch of the bulldozer blade.
Pitch dozer (D)
If a machine tips over, this structure protects
the operator with the seat belt fastened from
Roll-Over Protective being crushed. (Operator Protective Structure
ROPS Cab and canopy When Tipping)
Structure
This performance is standardized as ISO
3471.
Le Systeme Abbreviation for the "International System of
International d’ Unites Units". It is the universal unit system and "a
SI (International unit Unit single unit for a single quantity" is the basic
system) principle applied.
It refers to an actuator consisting of a solenoid
and an iron core that is moved by the
SOL Solenoid Electric system
magnetic force when the solenoid is
energized.
Hydraulic and electric Solenoid valve that switches over direction of
TWV 2-Way Valve
systems flow.
Variable Flow Turbocharger variable in route of exhaust
VFT Engine
Turbocharger passage.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
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
HB215LC-2 00-65
Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
00-66 HB215LC-2
Conversion table (ALL-2150-931-A-00-A)

(Rev. 2012/10)
Method of using the conversion table

• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 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 vertical line down from (B).
3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit from
millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 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 get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
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 get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
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 2.017 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
HB215LC-2 00-67
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
Kilograms to pounds
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 51.91 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
l 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
00-68 HB215LC-2
l 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 1,005
140 1,013 1,020 1,027 1,034 1,042 1,049 1,056 1,063 1,071 1,078
150 1,085 1,092 1,099 1,107 1,114 1,121 1,128 1,136 1,143 1,150
160 1,157 1,165 1,172 1,179 1,186 1,193 1,201 1,208 1,215 1,222
170 1,130 1,237 1,244 1,251 1,259 1,266 1,273 1,280 1,288 1,295
180 1,302 1,309 1,316 1,324 1,331 1,338 1,345 1,353 1,360 1,367
190 1,374 1,382 1,389 1,396 1,403 1,410 1,418 1,425 1,432 1,439
HB215LC-2 00-69
kg/cm2 to lb/in22
1 kg/cm2 = 14.2233 lb/in22
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
00-70 HB215LC-2
Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°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
HB215LC-2 00-71
00-72 HB215LC-2
SHOP MANUAL
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
01 Specification
2 01 Specification
HB215LC-2 01-1
01 Specification
Table of contents
Table of contents (ALL-0310-002-A-00-A)

01 Specification................................................................................................................................. 01-1
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-9
Table of fuel, coolant, and lubricants .................................................................................... 01-11
01-2 HB215LC-2
01 Specification
Specification drawing
Specifications (ALL-2111-001-A-00-A)
Specification drawing (ALL-2110-001-A-00-A)
HB215LC-2 (HB205-2110-931-A-07-A)
Item Unit HB215LC–2

Machine weight kg 22,400
Bucket capacity m3 0.8
Engine model - Komatsu SAA4D107E–2 diesel engine
Engine rated horsepower
• SAE J1995 (gross) 110 {148} / 2,000 {2,000}
kW {HP}/min-1
• ISO 14396 110 {148} / 2,000 {2,000}
{rpm}
• ISO 9249/SAE J1349 (net) 104 {139} / 2,000 {2,000}
A Overall length mm 9,625
Overall height (work equipment)
B mm 2,970
(*2)
C Overall width mm 3,080
D Shoe width mm 700
E Cab height (*1) mm 3,045
F Tail swing radius mm 2,940
G Overall length of the track mm 4,450
Distance between tumbler mm 3,655
H
centers
I Overall height of handrail (*1) mm 3,135
J Min. ground clearance (*2) mm 440
Travel speed (Lo/Mi/Hi) km/h 3.0/4.1/5.5
Continuous swing speed min-1 {rpm} 12.4 {12.4}
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated
horsepower measured on the basic engine unit. While, net denotes the value measured of an engine
under the condition essentially the same as that when it is installed on a machine.
*1: Including grouser height (26 mm)
*2: Excluding grouser height (26 mm)
HB215LC-2 01-3
01 Specification
Working range drawings
Working range drawings (ALL-2110-001-A-02-A)
HB215LC-2 (HB205-2110-931-A-08-A)
Item Unit HB215LC–2

A Max. digging reach mm 9,875
B Max. digging depth mm 6,620
C Max. digging height mm 10,000
D Max. vertical wall digging depth mm 5,980
E Max. dumping height mm 7,110
F Min. dumping height mm 2,645
Max. digging reach at ground mm 9,700
G
level
01-4 HB215LC-2
01 Specification
Specifications
Specifications (ALL-2111-001-A-01-A)
HB215LC-2 (HB205-2111-931-A-03-A)
Machine model HB215LC–2

Unit
Serial No. 50001 and up
Bucket capacity m3 0.8
Machine weight kg 22,400
Performance
Working ranges
Max. digging depth mm 6,620
Max. vertical wall digging depth mm 5,980
Max. digging reach mm 9,875
Max. digging reach at ground level mm 9,700
Max. digging height mm 10,000
Max. dumping height mm 7,110
Max. digging force
138.3 {14,100}
(When one-touch power maximizing kN {kg}
149.1 {15,200}
function operates.)
Continuous swing speed min-1 {rpm} 12.4 {12.4}
Swing operation max. slope angle deg. 25
Travel speed (Lo/Mi/Hi) km/h 3.0/4.1/5.5
Gradeability deg. 35
Ground pressure (standard shoe) kPa {kg/cm2} 39.6 {0.40}
Dimensions
Overall length mm 9,625
Overall width mm 3,080
Overall height (for transport) (*1) mm 3,135
Cab height (*1) mm 3,045
Ground clearance of upper structure
mm 1,085
bottom (*2)
Min. ground clearance (*2) mm 440
Tail swing radius mm 2,940
Min. swing radius of work equipment mm 3,040
Max. height of work equipment in min.
mm 8,005
swing radius posture
Overall width of track mm 2,980
Overall length of track mm 4,450
Track gauge mm 2,380
Distance between tumbler centers mm 3,655
Machine cab height (*2) (*3) mm 2,250
Width of standard shoe mm 700
*1: Including grouser height (26 mm)
*2: Excluding grouser height (26 mm)
*3 Excluding engine hood
HB215LC-2 01-5
01 Specification
Specifications

Unit
Engine
Model - SAA4D107E–2
4-cycle, water-cooled, in-line, vertical, direct
Type - injection, with turbocharger and air-cooled
aftercooler
No. of cylinders - bore x stroke mm 4 - 107 x 124
Total piston displacement l {cc} 4.46 {4,460}
Performance
Rated horsepower
• SAE J1995 (gross) 110 {148} / 2,000 {2,000}
kW {HP}/min-1
• ISO 14396 110 {148} / 2,000 {2,000}
{rpm}
• ISO 9249/SAE J1349 (net) 104 {139} / 2,000 {2,000}
Max. torque Nm {kgm}/min-1 {rpm} 621 {63.3}/1,600 {1,600}
Max. speed with no load
• When mounted on machine (*4) min-1 {rpm} 1,850 ± 50 {1,850 ± 50}
• At basic engine min-1 {rpm} 2,060 ± 50 {2,060 ± 50}
Min. speed with no load min-1 {rpm} 700 ± 25 {700 ± 25}
Fuel consumption ratio at rated
g/kWh {g/HPh} 211 {157}
horsepower
Starting motor 24 V, 5.5 kW
Alternator 24 V, 60 A
Battery (*5) 12 V, 140 Ah x 2 pieces
Radiator model CF90-5
*4: It shows when operated in B-mode and the travel control lever is controlled finely.
*5: The battery capacity (Ah) is indicated in the 5-hour rate.
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated
horsepower measured on the basic engine unit. While, net denotes the value measured of an engine
under the condition essentially the same as that when it is installed on a machine.
Undercarriage
Carrier roller 2 (each side)
Track roller 9 (each side)
Assembly type triple grouser shoe
Track shoe
49 (each side)
01-6 HB215LC-2
01 Specification
Specifications

Unit
Hydraulic system
Hydraulic pump
Variable displacement piston type (HPV125 +
Type x quantity -
125) x 2 pcs.
Discharged volume l/min 245 x 2
Set pressure MPa {kg/cm2} 37.2 {380}
Control valve
Type x quantity - 6-spool type x 1 piece
Operating method - Hydraulic
Travel motor
Variable displacement piston type (HMV120-
Type x quantity - 2) x 2 pcs.
(with brake valve and parking brake)
Boom cylinder (*6)
Type - Double-acting piston type
Cylinder bore mm 130
Piston rod diameter mm 90
Stroke mm 1,335
Max. distance between pins mm 3,205
Min. distance between pins mm 1,870
Arm cylinder (*7)
Stroke mm 1,490
Bucket cylinder
Stroke mm 1,120
Hydraulic tank - Box-shaped sealed type
Hydraulic oil filter - Tank return side
Hydraulic oil cooler - Air-cooled type (CF91)
*6: With cushion on head side.
*7: With cushions on head side and bottom side.
HB215LC-2 01-7
01 Specification
Specifications

Unit
Electrical system
Motor-generator
Type x quantity - 3-phase motor x 1 pc.
Operating voltage V(DC) 550
Drive method - Direct coupling with engine
Swing motor
Type x quantity - 3-phase motor x 1 pc.
Operating voltage V(AC) 550
Control unit
Type x quantity - Inverter x 1 pc.
Power storage device
Type x quantity - Capacitor x 1 pc.
01-8 HB215LC-2
01 Specification
Weight table
Weight table (ALL-2120-001-A-01-A)
HB215LC-2 (HB205-2120-931-A-03-A)
k This weight table is prepared for your reference when handling or transporting the components.
k This weight table shows the dry weight.

Unit: kg
Serial No. 50001
Engine assembly 815
• Engine (*1) 438
• Motor-generator (*1) 187
• Main pump 190
Radiator and oil cooler assembly 206
Inverter (*1) 33
Capacitor (*1) 80
Hydraulic tank and filter assembly 140
Fuel tank assembly 165
Revolving frame 2,197
Operator cab (including head guard and front half guard) 430
Operator's seat 35
Counterweight 3,880
Swing machinery 229
Control valve 235
Electric swing motor (*1) 65
Travel motor 93 x 2
Center swivel joint 36
Track frame assembly (excluding piping) 4,957
• Track frame 2,662
• Swing circle 273
• Idler 101 x 2
• Idler cushion 127 x 2
• Carrier roller 13 x 4
• Track roller 36 x 18
• Final drive (including travel motor and sprocket) 355 x 2
Track shoe assembly
Triple grouser shoe (700 mm) 1,530 x 2
Boom assembly 1,516
Arm assembly 795
Bucket assembly 759
Boom cylinder assembly 204 x 2
Arm cylinder assembly 224
Bucket cylinder assembly 133
Bucket link (large) assembly 83
Bucket link (small) assembly 22 x 2
Boom foot pin 42
Boom cylinder bottom pin 8x2
Boom cylinder head pin 28
Arm cylinder bottom pin 10
Arm cylinder head pin 12
Boom and arm connecting pin 26
Bucket cylinder bottom pin 8
Bucket pin 20 x 2
Bucket link pin 13 x 2
HB215LC-2 01-9
01 Specification
Weight table
*1:
01-10 HB215LC-2
01 Specification
Table of fuel, coolant, and lubricants
Table of fuel, coolant, and lubricants (HB205-RA19-05A-K-03-A)
a For details of notes (Note 1, Note 2...) in the table, see the Operation and Maintenance Manual.
HB215LC-2 01-11
01 Specification
Table of fuel, coolant, and lubricants
Unit: l
HB215LC-2
Applicable part
Specified capacity Refill capacity
Engine oil pan (*1) 20 18
Motor-generator case (*1) 6.5 6.0
Electric swing motor case (*1) 2.3 1.6
Swing machinery case (*1) 7.1 6.5
Final drive case (each of right and
left) 5.4 5.0
Hydraulic oil system 234 132
Fuel tank 400 ‐
Engine cooling system (*1) 23 ‐
Hybrid equipment cooling system
(*1) 7.5 6.0
*1:
01-12 HB215LC-2
SHOP MANUAL
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
10 Structure and function

3 10 Structure and function
HB215LC-2 10-1
Table of contents

10 Structure and function ................................................................................................................... 10-1
Engine related parts ............................................................................................................. 10-3
VFT .................................................................................................................................... 10-5
EGR system piping drawing .................................................................................................. 10-9
EGR system circuit diagram ................................................................................................ 10-11
EGR valve......................................................................................................................... 10-12
EGR cooler........................................................................................................................ 10-14
KCCV layout drawing ......................................................................................................... 10-16
KCCV ventilator ................................................................................................................. 10-18
KDOC muffler .................................................................................................................... 10-20
Cooling system .................................................................................................................. 10-22
Hybrid system .......................................................................................................................... 10-24
Outline of hybrid system ..................................................................................................... 10-24
Configuration of hybrid system ............................................................................................ 10-25
Protective function of hybrid component ............................................................................... 10-26
Protection function for workers when disassembling hybrid component................................... 10-28
Cooling system of hybrid component ................................................................................... 10-30
Interlock function................................................................................................................ 10-31
Motor-generator ................................................................................................................. 10-32
Electric swing motor ........................................................................................................... 10-34
Electric control unit ............................................................................................................. 10-36
High voltage wiring harness (power cable) ........................................................................... 10-37
Water pump....................................................................................................................... 10-38
Power train............................................................................................................................... 10-39
Power train system............................................................................................................. 10-39
Swing circle ....................................................................................................................... 10-41
Swing machinery with swing brake ...................................................................................... 10-42
Final drive ......................................................................................................................... 10-44
Hydraulic component layout ................................................................................................ 10-48
Valve control...................................................................................................................... 10-50
Hydraulic tank.................................................................................................................... 10-52
CLSS ................................................................................................................................ 10-54
Main pump ........................................................................................................................ 10-59
Control valve ..................................................................................................................... 10-89
Travel motor .................................................................................................................... 10-144
PPC valve ....................................................................................................................... 10-157
Solenoid valve ................................................................................................................. 10-180
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-183
Attachment circuit selector valve (for low pressure circuit).................................................... 10-185
Center swivel joint ............................................................................................................ 10-188
Accumulator .................................................................................................................... 10-190
Work equipment ..................................................................................................................... 10-191
Work equipment............................................................................................................... 10-191
Work equipment shim....................................................................................................... 10-192
Bucket play adjustment shim............................................................................................. 10-193
Cab mount and cab tipping stopper ................................................................................... 10-194
ROPS cab ....................................................................................................................... 10-195
Electrical control system ................................................................................................... 10-196
Machine monitor system ................................................................................................... 10-253
KOMTRAX system ........................................................................................................... 10-277
Sensor ............................................................................................................................ 10-280
10-2 HB215LC-2
Engine related parts
Engine and cooling system (ALL-R401-001-K-00-A)
Engine related parts (HB205-A001-041-K-00-A)
1. EGR cooler (*2)
HB215LC-2 10-3
Engine related parts
2. Engine oil filter

3. KDOC muffler
4. KCCV ventilator (*4)
5. Vibration damper (*1)
6. Auto-tensioner
7. Air cleaner (*1)
8. VFT (*5)
9. Motor-generator
10. Rear engine mount
11. Front engine mount
*1: For details, see Engine Shop Manual.
*2: For EGR cooler, see "EGR cooler".
*3: For KDOC muffler, see "KDOC muffler".
*4: For KCCV ventilator, see "KCCV ventilator".
*5: For VFT, see "VFT".
10-4 HB215LC-2
VFT
VFT (ENG95-AA10-041-K-00-A)
a VFT: Abbreviation for Variable Flow Turbocharger

a The shape is subject to machine models.
A: Air intake inlet

B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
HB215LC-2 10-5
VFT
1. VFT motor
2. Flange bolt
3. Bracket
4. Thrust sleeve
10-6 HB215LC-2
VFT
5. Bracket
6. O-ring
7. Insert
8. Oil deflector
9. Thrust bearing
10. Thrust ring
11. Bearing housing
12. Bearing
13. Piston ring
14. Turbine wheel
15. Turbine insert
16. Turbine housing assembly
17. Pin
18. Seal ring
19. Snap ring
20. O-ring
21. Snap ring
22. Piston ring
23. Compressor cover assembly
24. Compressor wheel
25. Lock nut
26. Flange bolt
27. Flange bolt
28. Connector assembly
29. Snap ring
30. Snap ring
31. Lock plate
32. Flange bolt
E: Oil inlet
F: Oil outlet
Specifications (PC160-AA10-030-K-00-A)
Turbocharger model: TD04M4t-VFT

Rotation direction: Clockwise (seen from intake air inlet)
HB215LC-2 10-7
VFT
Operation (ENG95-AA10-044-K-00-A)
1. Large scroll
2. Small scroll
3. Fixed vane
4. Flow control valve
A: When flow control valve is fully closed (small flow rate)
B: When flow control valve is fully open (large flow rate)
• The turbine housing of the VFT consists of large scroll (1) and small scroll (2).
• Fixed vane (3) is installed between large scroll (1) and small scroll (2) for flow rectification.
• The flow rate into large scroll (1) side is controlled by opening or closing the flow control valve (4).
• The position of the flow control valve (4) is controlled by the actuator which is driven by the command from
the engine controller.
10-8 HB215LC-2
EGR system piping drawing
EGR system piping drawing (PC160-A9J0-04D-K-00-A)
a EGR: Abbreviation for Exhaust Gas Recirculation

1. VFT
2. EGR valve
3. Air intake connector
4. Mixing connector
5. Exhaust manifold
6. EGR cooler
Function (ENG95-A9J0-042-K-00-A)
• EGR valve (driven with electric motor)

Controls the gas flow from exhaust side to intake side. Since the exhaust pressure is higher than the boost
pressure, the exhaust gas flows into the intake side.
• EGR cooler
Cools the exhaust gas.
The engine coolant is used for cooling.
• Intake air connector
Returns the air from the air-cooled aftercooler and the exhaust gas from the EGR valve to the intake side.
• Sensors
Control the EGR according to the operating condition.
Troubleshoot the system.
HB215LC-2 10-9
EGR system piping drawing
• Control each part of the EGR circuit and control the EGR rate according to the operating condition to clean
the exhaust gas constantly.
• Monitor the condition of the EGR circuit and perform troubleshooting to prevent a serious failure.
10-10 HB215LC-2
EGR system circuit diagram
EGR system circuit diagram (ENG107-A9J0-052-K-01-A)
1. Air cleaner
2. KDOC muffler
3. Mass air flow and temperature sensor (MAF)
4. Electric actuator (VFT)
5. EGR cooler
6. EGR valve
7. Electric actuator (EGR valve)
8. Ambient pressure sensor
9. Aftercooler
10. Exhaust manifold
11. Air intake manifold
12. Charge (boost) pressure and temperature sensor
13. Engine controller
14. EGR orifice temperature sensor
15. Exhaust manifold pressure sensor
C: Blower impeller
T: Turbine impeller
Operation (ENG95-A9J0-044-K-00-A)
• The engine controller outputs signals so that EGR valve (6) opens properly according to the engine load to
realize both clean exhaust gas and low fuel consumption.
• If EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10) into EGR
cooler (5) through the EGR piping.
• The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6), merges with the intake air in the
air intake connector, and flows into intake manifold (11).
HB215LC-2 10-11
EGR valve
EGR valve (ENG95-A9K1-041-K-00-A)

1. DC motor assembly (brushless motor with built-in position sensor)

2. DC motor shaft
3. Rod
4. Filter
5. Housing
6. Valve seat
7. Valve
8. Seal
9. Spring
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
Structure
• Small-sized EGR valve driven with a DC motor.
• The DC motor has a position sensor in it to sense the valve position.
• Since 2 valves are combined to cancel the EGR gas pressure, the operating effort is small.
10-12 HB215LC-2
EGR valve
Operation (ENG95-A9K1-044-K-00-A)
A: EGR gas inlet (from EGR cooler)

B: EGR gas outlet (to air intake manifold)
• DC motor shaft (2) of the DC motor converts rotary motion into linear motion. Accordingly, valve (7) is
opened or closed by turning the motor.
Open valve: The DC motor is turned and DC motor shaft (2) is pushed out to push rod (3) and open valve (7).
When valve (7) opens, the EGR gas flows into the air intake manifold.
Close valve: The DC motor is turned in reverse and DC motor shaft (2) is pulled in, then rod (3) is pushed
back by spring (9) and valve (7) closes.
HB215LC-2 10-13
EGR cooler
EGR cooler (PC160-A9L0-041-K-00-A)
1: Tube
A: EGR gas inlet
B: Air vent
C: Coolant outlet
D: EGR gas outlet (to EGR valve)
E: Coolant inlet
1. Flat tube
10-14 HB215LC-2
EGR cooler
2. Inner fin
Operation (ENG95-A9L0-044-K-00-A)
• The EGR gas enters from (A) and flows through 9 flat tubes (1).
• Coolant enters from (E) and flows around flat tube (1) in the shell and then goes out from (C).
• The EGR gas is effectively cooled by flat tubes (1) with inner fins (2) and flows out from EGR gas outlet
(D).
HB215LC-2 10-15
KCCV layout drawing
KCCV layout drawing (HB205-A180-04D-K-00-A)
a KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation

A: Blowby gas (from rear flange)

B: Blowby gas from which engine oil is removed (to VFT)
C: Engine oil (to oil pan)
1. KCCV ventilator
2. VFT
3. Blowby duct
4. Rear flange
5. Check valve
6. Crankcase pressure sensor
7. CDR valve
• Blowby gas (A) has been emitted to the atmosphere up until now. Since the emission regulation has
become strict, the regulation is applied to the blowby gas. As a consequence of the blowby gas regulation,
the blowby gas intake recirculation system is employed.
• Blowby gas (A) contains ingredients of the engine oil. If it is recirculated to VFT (2) as it is, it causes the
following problems. To prevent this, a filter is installed to KCCV ventilator (1) to remove the engine oil.
1. Deterioration of turbocharger and aftercooler performance caused by sticking engine oil
2. Abnormal combustion in engine
3. Malfunction of each sensor caused by sticking engine oil
10-16 HB215LC-2
KCCV layout drawing
Operation (PC160-A180-044-K-00-A)
a The figure on the left shows the traditional flow of blowby gas that has been discharged to the atmosphere.
The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV
ventilator.
1. Air cleaner
2. VFT
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
• Engine oil is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and
then the cleaned gas (B) is recirculated to the intake side of the VFT.
• Removed engine oil (C) flows through a check valve and falls to the oil pan.
HB215LC-2 10-17
KCCV ventilator
KCCV ventilator (HB205-A18H-041-K-00-A)
A: Blowby gas inlet (from rear flange)

B: Blowby gas outlet (to VFT intake side)
C: Oil drain port (to oil pan)
D: Coolant inlet
E: Coolant outlet
1. Case
2. CDR valve
3. Crankcase pressure sensor
4. Relief valve
5. Impactor
6. Filter
7. Heater tube
Function (PC160-A18H-042-K-00-A)
• If the blowby gas is returned to the intake side of VFT, inside of crank case becomes negative pressure
and the dust may be sucked in through crank seal. To prevent this, the blowby pressure is controlled by
CDR valve (regulator valve ) (2) and crank case pressure sensor.
• If the filter of the KCCV ventilator is clogged, the crankcase pressure may increases to cause oil leakage.
To prevent this, crankcase pressure sensor (3) senses clogging of filter (6).
• There are 2 types of the filter; one is the top load type (taken out upward) and the other is the bottom load
type (taken out downward).
• Keep the KCCV ventilator warm with warmed-up engine coolant, and prevent clogging of blowby gas
passage due to freeze.
10-18 HB215LC-2
KCCV ventilator
Operation (ENG107-A18H-044-K-00-A)
• Blowby gas enters (A) and large oil particles in the engine oil mist are separated when it flows through the
hole of impactor (5) in filter (6).
• Small oil particles are separated by filter (6).
• The separated oil flows along the case wall to oil drain port (C), and then flows into the oil pan.
• When the crankcase pressure becomes negative, CDR valve (2) operates to prevent the crankcase
pressure from becoming excessively negative.
• The crankcase pressure sensor (3) senses the blowby gas pressure (crankcase pressure).
• If the engine controller judges from the value sensed by the crankcase pressure sensor (3) that the filter is
clogged, it displays failure code CA555 and then displays CA556 if the pressure increases further.
• Relief valve (4) is installed inside case (1) and operates to protect the KCCV ventilator and engine when
filter (6) is blocked.
CDR valve (PC160-A18A-041-K-00-A)
CDR: Abbreviation for Crankcase Depression Regulator
1. Diaphragm
2. Spring
A: Crankcase side
B: VFT side (intake side)
• The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to VFT
side (intake side) (B).
• When intake air flow at VFT side (intake side) (B) increases and crankcase pressure (P1) decreases, the
reaction force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and
temporarily blocks the flow.
• After that, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.
HB215LC-2 10-19
KDOC muffler
KDOC muffler (PC160-A9H2-041-K-00-A)
a KDOC: Abbreviation for Komatsu Diesel Oxidation Catalyst

1. DOC unit
2. Silencer unit
3. To exhaust gas outlet piping
4. From exhaust gas inlet piping
5. Drain pipe
Structure
• The KDOC muffler consists of inlet piping (4) to lead in the exhaust gas from the engine, DOC unit (1) to
store the oxidation catalyst, silencer unit (2) having silencing function and containing a "dam" to prevent
rain water from flowing into the DOC unit from exhaust gas outlet piping, outlet piping (3) to discharge the
exhaust gas, and drain piping (5) to drain water from the silencer unit. Those components are welded
together into one unit.
• DOC unit (1) consists of ceramic honeycomb with oxidation catalyst.
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramic
under the vibrations from the engine and chassis.
10-20 HB215LC-2
KDOC muffler
Function (PC160-A9H2-042-K-00-A)
A: Flow of exhaust gas

1. DOC unit
2. Silencer unit
• The KDOC muffler is installed to meet the latest very severe emission regulations. It oxidizes SOF
(soluble organic fraction in minute particle in exhaust gas), HC (hydrocarbon not combusted), and CO
(carbon monoxide) contained in the engine exhaust gas to clean the exhaust gas. The silencer is also
equipped to reduce the exhaust noise.
• Function of DOC unit
(1) Oxidization of SOF (soluble organic fraction in minute particle in exhaust gas)
(2) Oxidization of HC (hydrocarbon not combusted)
(3) Oxidization of CO (carbon monoxide)
• Function of silencer unit
Reduction of exhaust noise
HB215LC-2 10-21
Cooling system
Cooling system (HB205-B000-041-K-00-A)
10-22 HB215LC-2
Cooling system
1. Radiator outlet hose

2.Radiator cap for hybrid model (*1)
3. Oil cooler outlet tube
4. Radiator
5. Air conditioner condenser
6. Radiator for hybrid model (*1)
7. Fuel cooler outlet
8. Fuel cooler
9. Fuel cooler inlet
10. Reservoir tank
11. Oil cooler inlet tube
12. Aftercooler inlet tube
13. Shroud
14. Fan
15. Fan guard
16. Aftercooler outlet hose
17. Aftercooler
18. Oil cooler
19. Radiator cap
20. Radiator inlet hose
21. Radiator drain valve
*1:
Specifications (HB205-B000-030-K-00-A)
Radiator Oil cooler Aftercooler Fuel cooler Radiator for

hybrid
(*1)
Core type Corrugated Corrugated
CF90-5 CF91 Drawn cup
aluminum, 4 rows aluminum
Fin pitch (mm) 3.5 / 2 3.5 / 2 3.5 / 2 4.0 / 2 4.0 / 2
Total heat
dissipation area 59.19 7.94 x 2 16.27 0.45 15.17
(m2)
Cracking pressure
of pressure valve 0.05 {0.5} - - - 0.05 {0.5}
(MPa {kg/cm2})
Cracking pressure
of vacuum valve -0.005 {-0.05} - - - -0.005 {-0.05}
(MPa {kg/cm2})
*1:
HB215LC-2 10-23
Outline of hybrid system
Hybrid system (HB380-PQG9-001-K-00-A)
Outline of hybrid system (HB205-PQG9-04A-K-00-A)
This machine is equipped with the hybrid system consisting of an electric motor and a diesel engine to reduce
fuel consumption.
In the hybrid system of this machine, the high-voltage wirings connecting the hybrid devices of approximately
550V (motor generator, electric swing motor, capacitor, inverter) and other devices and the cooling system
become high temperature in the machine operation.
1. Motor-generator (*1)
2. High-voltage wiring (orange) (*1)
3. Capacitor (storage battery) (*1)
4. Inverter (control unit) (*1)
5. Cooling unit
6. Electric swing motor (*1)
*1: High-voltage (550 V) section
Low fuel consumption by hybrid system

• The upper structure is swung with the electric swing 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 electric swing motor when the upper structure is swung next
time.
• When the control lever is in neutral, the engine speed is decreased to the minimum to reduce fuel
consumption.
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.
10-24 HB215LC-2
Configuration of hybrid system
Configuration of hybrid system (HB380-PQG9-041-K-00-A)
1. Motor-generator case
2. Engine
3. High-voltage section of motor-generator
4. Connector
5. High-voltage wiring
6. Capacitor case
7. Inverter case
8. Electric swing motor case
9. High-voltage section of inverter
10. High-voltage section of electric swing motor
11. High-voltage section of capacitor
12. Swing machinery
13. Machine frame
14. Flexible wiring
a: Insulation
b: Braided shield
a The high-voltage system of the hybrid system is not grounded but insulated from the machine frame inside
the each hybrid component case and braided high-voltage wiring shield.
a There is no danger of getting an electric shock, as long as you do not break the insulation of the high-
voltage system and touch both positive and negative wires.
a The case and braided shield of each hybrid component case are grounded to the machine frame through
flexible wires or other components.
HB215LC-2 10-25
Protective function of hybrid component
Protective function of hybrid component (HB380-PQJL-042-K-01-A)
1. Key switch
2. Hybrid system stop switch
3. Electric leakage sensor (built in inverter)
a. High temperature
b. Overcurrent (electric swing motor, motor-generator, and capacitor)
c. Overcurrent (high-voltage wiring)
d. Connector trouble
e. Blowing of fuse when capacitor cable has short circuit
Function
• The inverter contains an electric leakage sensor, which detects deterioration of insulation of the high-
voltage components and a short circuit to the machine body and stops the devices in the inverter (inverter,
booster, driver) to minimize breakage of the hybrid components when an electric leakage occurs.
10-26 HB215LC-2
Protective function of hybrid component
Conditions for stopping whole hybrid system

1. When the temperature of the electric swing motor, motor-generator, inverter, or capacitor exceeds the
system stop temperature shown in the following table
Example of corresponding error code:
(GA00NS) HYV Equipment Overheat
System stop
Equipment name Part name Monitoring item name
temperature (°C)
Electric swing Stator coil Electric swing motor coil
temperature 160
motor
Motor-generator Generator coil Motor-generator temperature 190
Booster transformer Booster inductor temperature 130
Booster IGBT junction (*1) - 135
Booster IGBT base Booster IGBT temperature 100
Inverter
IGBT junction for PM (*1) Swing inverter JCT temperature 135
Generator driver IGBT base
IGBT junction for SR (*1) 100
temperature
Capacitor - - -
The values of items marked with *1 are not measured but estimated by calculation.
2. When an overcurrent is detected in the electric swing motor or motor-generator (including blowing of fuse)
When abnormality is detected in the current sensor of the high-voltage wiring
(GA62KY) Gen. Mot. Ph-A Cur. Sen. Power Short Cir
(GA62MA) Gen. Mot. Ph-A Current Sen. Malfunction
3. When an overcurrent is detected in the high-voltage wiring
When abnormality is detected in the current sensor of the high-voltage wiring
(GA08KG) HW source voltage high error in DC line after boosting
(GA0AKZ) DC Vlt. Sen. Op./Shrt Cir. Aft. Booster
4. When abnormality is detected in the high-voltage wiring connector (open circuit, hot short, ground fault in
the interlock circuit)
(GA01KA) Power Cable Interlock Open Circuit
5. When electric leakage is detected
(GA02KZ) DC Line Open & Short Circuit
(GA0BKZ) AC Line Open & Short Circuit
6. When abnormality is detected in the capacitor or its high-voltage wiring (including wrong connection)
(GA02KZ) DC Line Open & Short Circuit
(GA04KG) Abnormal DC HW Volt. Before Booster
HB215LC-2 10-27
Protection function for workers when disassembling
hybrid component
Protection function for workers when disassembling hybrid

component (HB205-PQJK-042-K-00-A)
A: Consumed by motor-generator
B: Consumed in motor-generator by discharging function of monitor
1. Inverter
2. Capacitor
3. One-touch connector
4. Contactor
5. High-voltage wiring
6. Discharging resistor
7. Electric leakage protection fuse
Function
• When the starting switch is turned to OFF position, each hybrid component is disconnected from the high-
voltage power supply.
• The safety is secured by one-touch connector (3) even when capacitor (2) is still charged.
• Contactors (4) (2 pieces) used to connect capacitor (2) to inverter (1) are opened to stop the power to
capacitor (2).
• The charge in inverter (1) is consumed by the motor-generator when the starting switch is turned to OFF
position.
• If the motor-generator does not function because of an error, etc., the capacitor is discharged through
internal discharging resistor (6) in several minutes.
• When high-voltage wiring (5) is removed, the shut-off operation described above is performed by the
interlock switch even when the starting switch is in ON position.
• Capacitor (2) can be discharged by consuming its charge in the motor-generator with the discharge
function of the monitor.
10-28 HB215LC-2
Protection function for workers when disassembling
hybrid component
One-touch connector
1. Core conductor
2. Waterproof seal
3. Electromagnetic shield
4. Insulator
• The electrodes of the one-touch connector are protected with waterproof seal (2) and insulator (4), and
you cannot touch them easily.
HB215LC-2 10-29
Cooling system of hybrid component
Cooling system of hybrid component (HB380-PQG9-041-K-02-A)
1. Electric swing motor

2. Stator coil temperature
3. Stator coil
4. Radiator
5. Hybrid radiator
6. Engine
7. Motor-generator
8. Coil temperature
9. Pump
10. Rotor
11. Coil
12. Cooling and lubrication pump
13. Inverter
14. Water pump
15. In booster
16. Capacitor
17. Capacitor cell
18. Capacitor cell and bus bar temperature
19. Oil cooler
a. Cooling and lubricating oil route

b. Coolant route
c. Temperature sensor
10-30 HB215LC-2
Interlock function
Interlock function (HB205-PQJM-042-K-00-A)

2. Connector
3. Motor-generator
4. Inverter
5. Capacitor
a. High-voltage wiring harness (power cable)
b. Interlock circuit
c. Interlock output
d. Interlock input
Function
• The hybrid system has interlock circuit (b) among the high-voltage wiring connectors of motor-generator
(3), inverter (4), and electric swing motor (1).
• Inverter (4) monitors connector (2) of high-voltage wiring (power cable) (a) for loosening and
disconnection by using interlock circuit (b). When it detects an abnormality, it displays an error and stops
the hybrid system.
• If the connector (2) is installed inversely or disconnected and the circuit contacts are separated, inverter
(4) judges it abnormal and stops the hybrid system.
• Inverter (4) monitors interlock circuit (b) for abnormality. When it detects an abnormality, it displays an
error and stops the hybrid system.
a Interlock circuit (b) is also connected to the connector of high-voltage wiring (power cable) (a) connected
to inverter (4) and monitors for looseness and disconnection of connector (2) similarly.
HB215LC-2 10-31
Motor-generator
Motor-generator (HB205-PQH3-041-K-00-A)
1. Generator
2. Lubricating pump (For motor-generator and electric swing motor)
3. Coolant pipe
4. Coolant pipe
5. Oil cooler
6. Oil filler pipe
7. Filter
8. Dipstick
Specifications (HB205-PQH3-030-K-00-A)
Model ZG033
Specified capacity
(l) 6.5
Lubricating oil
Refill capacity (l) 6.0
Oil type TO10
Weight (kg) 185
Function (HB380-PQH3-042-K-00-A)
• The motor-generator coverts the rotation and torque of the engine into electric power and supplies it to the
electric swing motor.
10-32 HB215LC-2
Motor-generator
• The motor-generator receives electric power from the capacitor and assists the engine output.
HB215LC-2 10-33
Electric swing motor
Electric swing motor (HB205-PQHH-041-K-00-A)
A: Lubricating oil inlet

B: Coolant inlet
C: Lubricating oil drain
D: Lubricating oil outlet
E: Coolant outlet
2. Dipstick
Specifications (HB205-PQHH-030-K-00-A)
Model ZM104
Specified capacity
(l) 2.3
Lubricating oil
Refill capacity (l) 1.6
Oil type TO10
Weight (kg) 67
Function (HB380-PQHH-042-K-00-A)
• The electric swing motor converts the electric power supplied from the generator and capacitor into
rotation and torque of the motor output shaft and transmits it to the swing machinery.
10-34 HB215LC-2
Electric swing motor
• The electric swing motor coverts the kinetic energy of the upper structure into electric power and supplies
it to the capacitor.
HB215LC-2 10-35
Electric control unit
Electric control unit (HB205-PQGA-041-K-00-A)
1. Inverter
2. Capacitor
3. Mount rubber
Specifications (HB205-PQGA-030-K-00-A)
Inverter model ZD120

Fuse rating (A) 150
Overall weight (kg) 114
Weight of inverter (kg) 33
Function (HB380-PQGA-042-K-00-A)
• The electric control unit controls the motor-generator, the electric swing motor, and charge and discharge
of the capacitor.
10-36 HB215LC-2
High voltage wiring harness (power cable)
High voltage wiring harness (power cable) (HB205-PQJF-041-K-00-A)
1. Motor-generator
2. High-voltage wiring (motor generator)
4. Electric control unit
5. High-voltage wiring (capacitor)
6. High-voltage wiring (electric swing motor)
Structure
• A waterproof and shielded structure is employed.
Function (HB380-PQJF-042-K-00-A)
• The high-voltage wiring supplies high-voltage electric power.

• The cables of the high-voltage wiring are marked with different numbers of black lines to prevent wrong
connection of the connectors.
• Each connector of the high-voltage wiring is equipped with an interlock switch.
If the connector is disconnected, the switch is opened and the hybrid system stops.
HB215LC-2 10-37
Water pump
Water pump (HB205-PQGV-041-K-00-A)
1. Water pump
Specifications (HB205-PQGV-030-K-00-A)
Rated voltage (V) 24

Rated current (A) 2.4
Weight (kg) 2.1
Function (HB380-PQGV-042-K-00-A)
• This pump starts when the starting switch is turned to ON position.

• This pump is driven with the electric power from the battery.
• This pump circulates the coolant for the hybrid component.
• This pump draws in the coolant for the hybrid component from the radiator and discharges it to the
capacitor.
10-38 HB215LC-2
Power train system
Power train (ALL-C100-001-K-00-A)
Power train system (HB205-C100-041-K-00-A)
1. Idler
2. Center swivel joint
3. Control valve
4. Final drive
5. Travel motor
6. Main pump
7. Motor-generator (*1)
8. Engine
9. Travel speed increase solenoid valve
10. Swing parking brake solenoid valve
11. Electric swing motor (*1)
12. Swing machinery
HB215LC-2 10-39
Power train system
13. Swing circle

*1:
10-40 HB215LC-2
Swing circle
Swing circle (HB205-J110-041-K-00-A)
1. Inner race (number of teeth: 96)

2. Ball
3. Outer race
a. Position of inner race soft zone
b. Position of outer race soft zone
Specification (PC200_10-J110-030-K-00-A)
Reduction ratio -96 / 13 = -7.385

Grease G2-LI
Grease quantity (l) 14.6
HB215LC-2 10-41
Swing machinery with swing brake
Swing machinery with swing brake (HB205-J130-041-K-00-A)
10-42 HB215LC-2
1. Swing pinion (number of teeth: 13)

2. Cover
3. Plate
4. No. 3 sun gear (number of teeth: 18)
5. No. 3 planetary gear (number of teeth: 19)
6. No. 3 planetary carrier
7. No. 2 and No. 3 ring gear (number of teeth: 58)
9. No.2 planetary gear (number of teeth: 20)
12. Case
13. Spring
14. No. 1 ring gear (number of teeth: 62)
16. Cover
18. Brake piston
19. Brake gear
20. Brake plate
21. Brake disc
Specifications (HB205-J110-030-K-00-A)
Reduction ratio ((16 + 62) / 16) x ((17 + 58) / 17) x ((18 + 58) / 18) = 90.811
HB215LC-2 10-43
Final drive
Final drive (HB205-DF10-041-K-00-A)
10-44 HB215LC-2
Final drive
1. Oil level plug

3. Drain plug
7. Cover
8. Ring gear (number of teeth: 95)
10. Ring nut
11. Hub
12. Sprocket
13. Floating seal
14. Travel motor
Specifications (HB205-DF10-030-K-00-A)
Reduction ratio -((10 + 95) / 10) x ((21 + 95) / 21) + 1 = -57.000
HB215LC-2 10-45
Track frame and idler cushion
Undercarriage and frame (ALL-DT00-001-K-00-A)
Track frame and idler cushion (HB205-DT20-041-K-01-A)
1. Idler
2. Track frame
3. Carrier roller
4. Final drive
5. Track roller
6. Center guard
7. Idler cushion
8. Front guard
9. Track shoe
10-46 HB215LC-2
Specifications (HB205-DT20-030-K-01-A)
• Number of track rollers

Model Number (each side)
HB215LC–2 9
• Standard shoe
Model HB215LC–2
Shoe width (mm) 700
Link pitch (mm) 190
Number of shoes (each side) 49
HB215LC-2 10-47
Hydraulic component layout
Hydraulic system (ALL-C000-001-K-00-A)
Hydraulic component layout (HB205-C000-04D-K-00-A)
10-48 HB215LC-2
Hydraulic component layout
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. Center swivel joint
*1: Machines ready for installation of attachment
HB215LC-2 10-49
Valve control
Valve control (PC-PK01-041-K-00-A)
1. Attachment 1 control pedal (*1)

2. Travel lever
3. R.H. PPC valve for work equipment
4. R.H. work equipment control lever (for boom and bucket control)
5. Control valve
6. Junction block
7. Accumulator (for PPC circuit)
8. Solenoid valve
9. L.H. work equipment control lever (for arm and swing control)
10. L.H. PPC valve for work equipment
11. Lock lever
12. Attachment 2 control pedal (*1)
13. Attachment 2 PPC valve (*1)
10-50 HB215LC-2
Valve control
14. Travel PPC valve

15. Travel pedal
16. Attachment 1 PPC valve (*1)
17. Lock pin (*1)
*1: Machine ready for installation of attachment
HB215LC-2 10-51
Hydraulic tank
Hydraulic tank (HB205-PM30-041-K-00-A)
1. Main pump
2. Hydraulic tank
3. Oil filler cap
4. Sight gauge
5. Drain plug
6. Bypass valve
7. Strainer
8. Filter element
9. Suction strainer
Specifications (PC220-PM30-030-K-00-A)
Hydraulic tank capacity (l) 190

Amount of oil in hydraulic tank (l) 132
Bypass valve set pressure (MPa {kg/cm2}) 0.15 ± 0.03 {1.5 ± 0.3}
10-52 HB215LC-2
Hydraulic tank
Oil filler cap (PC-AD1C-041-K-00-A)
1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
Prevention of negative pressure in tank

• The hydraulic tank is sealed and pressurized. When the oil level in the hydraulic tank drops, negative
pressure is generated in the tank. To prevent this negative pressure generation, seam valve (4) is opened
to draw the atmosphere to the tank.
(Intake valve set pressure: 0 to 0.49 kPa {0 to 0.005 kg/cm2})
Prevention of pressure rise in tank

• When the hydraulic circuit is working, the pressure in the hydraulic tank increases as the hydraulic
cylinders operate, and the oil level and temperature increase in the tank. If the pressure in the tank rises
above the set value, bottom plate (2) is pushed up to release the pressure in the tank.
(Exhaust valve set pressure: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm2 })
HB215LC-2 10-53
CLSS
CLSS (ALL-PNJ1-001-K-00-A)
a CLSS: Abbreviation for Closed center Load Sensing System

Structure of CLSS (ALL-PNJ1-041-K-00-A)
Features
• Fine control not influenced by load
• Control performance that allows digging even when fine control operation is turned on
• Ease of combined operation enabled by the flow divider function that is determined by the opening areas
of spools during combined operations
• Energy saving by variable pump control
Configuration
• CLSS consists of variable capacity piston pump, control valve, and actuators.
• The main pump consists of pump itself, PC valve and LS valve.
10-54 HB215LC-2
CLSS
Basic principle
Pump swash plate angle control

• The pump swash plate angle (pump discharged volume) is controlled so that LS differential pressure
(dPLS), which is the difference between pump delivery pressure (PP) and LS pressure (PLS)) (load
pressure of actuator) at control valve outlet, is constant.
• [LS differential pressure (dPLS) = Pump delivery pressure (PP) - LS pressure (PLS)]
• 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).
• If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate
angle shifts toward the minimum position.
HB215LC-2 10-55
CLSS
d PLS) and pump swash plate angle

LS differential pressure (d
a See "Main pump" for the explanation of the operation.
Pressure compensation control
10-56 HB215LC-2
CLSS
• A pressure compensation valve is installed to the outlet port side of each control valve to balance the load
pressure.
• When actuators are operated in combination, the pressure 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).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
System diagram
a The illustration shows the state when actuator (7) is relieved at the stroke end in the merge mode.
1. Front pump
2. Rear pump
3. Main relief valve
4. Unload valve
5. Merge-divider valve
6. Control valve
HB215LC-2 10-57
CLSS
7. Actuator
8. Pump circuit
9. LS circuit
10. Tank circuit
11. Valve
12. Spring
13. LS bypass plug
14. LS valve
15. PC valve
10-58 HB215LC-2
Main pump
Main pump (PC220-C200-041-K-00-A)
Model: HPV125 + 125
IMF: Front pump PC mode selector current

IMR: Rear pump PC mode selector current
HB215LC-2 10-59
Main pump
ISIG: LS set pressure selector current

PAF: Front pump delivery port
PAR: Rear pump delivery port
PBF: Front pump pressure input port
PD3R: Air bleeder
PD1R: Case drain port
PD2F: Drain plug
PD2R: Drain plug
PENF: Front pump control pressure pickup port
PENR: Rear pump control pressure pickup port
PEPC: EPC source pressure input port
PEPB: EPC source pressure pickup port
PFC: Front pump delivery pressure pickup port
PLSF: Front pump load pressure input port
PLSFC: Front pump load pressure pickup port
PLSR: Rear pump load pressure input port
PLSRC: Rear pump load pressure pickup port
PMF: Front pump PC mode selector pressure pickup port
PMR: Rear pump PC mode selector pressure pickup port
PRC: Rear pump delivery pressure pickup port
PS: Pump suction port
PSIG: LS set selector pressure pickup port
1. Front pump
2. Rear pump
3. LS - EPC valve
4. Front pump PC - EPC valve
5. Rear pump PC - EPC valve
6. Rear pump PC valve
7. Rear pump swash plate sensor
8: Front pump LS valve
9. Rear pump LS valve
10. Front pump swash plate sensor
11: Front pump PC valve
10-60 HB215LC-2
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. PC valve
13. Servo piston
14. Slider
HB215LC-2 10-61
Main pump
15. Spline
16. Bearing
17. LS valve
Outline
• This pump consists of two variable capacity swash plate piston pumps, PC valve, LS valve, EPC valve,
and swash plate sensor.
Function
• The pump converts the engine speed and torque transmitted to its shaft (1) into oil pressure and delivers
pressurized oil corresponding to the load.
• It is possible to change the discharged volume by changing the swash plate angle.
Structure
• Cylinder block (7) is supported to shaft (1) by spline (15).
• Shaft (1) is supported by each bearing (16) at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and is crimped together with shoe (5).
• Piston (6) and shoe (5) constitute a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) transmits high pressure oil to cylindrical surface (B) with cradle (2), which is secured to the
case, and forms a static pressure bearing when it slides.
• Piston (6) performs reciprocal motion in the axial direction inside each cylinder chamber of cylinder block
(7).
• Cylinder block (7) seals the pressurized oil to valve plate (8) and performs relative rotation.
• The oil pressure balance on the valve plate is maintained properly.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
Operation (PC220-C200-044-K-00-A)
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
• If swash plate angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7),
plane (A) functions as a cam against shoe (5).
• Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7).
• Each piston (6) sucks and discharges oil by (F) - (E).
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• The volume of chamber (F) grows larger and, in this process, the oil is sucked.
10-62 HB215LC-2
Main pump
• As center line (X) of rocker cam (4) matches the axis of cylinder block (7) (swash plate angle = 0), the
difference between volumes (E) and (F) inside cylinder block (7) equals 0.
• Suction and delivery of pressurized oil is not carried out in this state. Namely pumping action is not
performed. (Actually, however, the swash plate angle is not set to 0 deg.)
Control of discharged volume

• If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and pump
discharged volume (Q) increases.
• Swash plate angle (a) is changed by servo piston (13).
• Servo piston (13) moves in a linear reciprocating movement according to the signal pressure from the PC
valve and LS valve.
• This linear reciprocating movement is transmitted to rocker cam (4) through slider (14).
• Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
• Output pressure (PEN) of the LS valve is transmitted to the pressure chamber of the large diameter piston
side.
• The areas receiving the pressure on the right and left sides of servo piston (13) are different from each
other, and discharged volume pressure (self pressure) (PP) of the main pump is constantly transmitted to
the pressure chamber of the small diameter piston side.
• The movement of servo piston (13) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter piston side (PEN) and by the ratio of the areas receiving the pressure
of the small diameter piston and large diameter piston.
HB215LC-2 10-63
Main pump
10-64 HB215LC-2
Main pump
LS valve (PC-C2J0-041-K-00-A)
a LS: Abbreviation for Load Sensing
PA: Pump port

PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port
PSIG: LS mode selector pilot port
1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Lock nut
Function (PC-C2J0-042-K-00-A)
• The LS (load sensing) valve detects the load and controls the pump discharged volume.
• This valve controls main pump discharged volume (Q) according to differential pressure (dPLS) [= PP -
PLS], called the LS differential pressure (the difference between main pump delivery pressure (PP) and
control valve outlet port pressure (PLS)).
• This valve receives main pump delivery pressure (PP), pressure (PLS) (called the LS pressure) coming
from the control valve output, and pressure (PSIG) (called the LS set selector pressure) from the
proportional solenoid valve.
• The relation between the pump discharged volume (Q) and the differential pressure (dPLS) [= (PP) -
(PLS)] between the main pump pressure (PP) and LS pressure (PLS) is changed by the LS set pressure
selector current (ISIG) of the LS-EPC valve as shown in the figure below.
• When the (ISIG) changes from 0 A to 1 A, the spring setting force will change accordingly, to let the center
of the standard value range of the pump discharged volume selector point vary within the range from 0.27
MPa {2.78 kg/cm2} to 1.7 MPa {17.75 kg/cm2}.
HB215LC-2 10-65
Main pump
Operation (PC-C2J0-044-K-00-A)
When control valve is in "NEUTRAL" position
• The LS valve is a 3-way selector valve, and LS pressure (PLS) (actuator load pressure) on the outlet of
control valve is transmitted to spring chamber (B), and pump delivery pressure (PP) is transmitted to port
(H) of sleeve (8).
• Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery
pressure (self pressure) (PP) determine the position of spool (6).
10-66 HB215LC-2
Main pump
• However, magnitude of the output pressure (PSIG) (called the LS set 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)
• Before the engine is started, servo piston (12) is pushed to the left. (See the following figure)
• If the control lever is at the neutral position when the engine is started, LS pressure (PLS) is set to 0 MPa
{0 kg/cm2}. (It is connected to the drain circuit through the control valve spool.)
• Spool (6) is pushed to the right, and port (C) and port (D) are connected.
• Pump delivery pressure (PP) is transmitted to the larger diameter end of the pump from the port (K).
• The same pump delivery pressure (PP) is transmitted to the smaller diameter end at the port (J).
• According to the area difference of servo piston (12), the servo piston is moved to the right, in the direction
which makes the swash plate angle minimum. (See the previous figure.)
HB215LC-2 10-67
Main pump
When pump delivery is increased
• When the difference between pump delivery pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) decreases (for example, when the control valve opening area increases and
pump delivery pressure (PP) decreases), the combined force exerted by LS pressure (PLS) and spring (4)
pushes spool (6) to the left.
• As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve and drain port are connected, the pressure between ports (D) and (K) becomes drain
pressure (PT). (PC valve operation will be explained later.)
• The pressure on the large diameter piston side of servo piston (12) becomes drain pressure (PT), and
pump pressure (PP) is constantly transmitted to port (J) on the small diameter end. Accordingly, servo
piston (12) is pushed to the left and the swash plate is moved to increase the discharged volume.
• At this time, when the output pressure from the EPC valve for the LS valve is transmitted to port (G), a
force is applied on piston (7) to move the piston to the right.
• If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential
pressure (dPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6)
are connected.
10-68 HB215LC-2
Main pump
When pump discharged volume is decreased
• When servo piston (12) moves to the right (the direction that reduces pump delivery) and LS differential
pressure (dPLS) increases (for example, when the control valve opening area decreases and pump
delivery pressure (PP) increases), the force exerted by pump delivery pressure (PP) pushes spool (6) to
the right.
• The movement of spool (6) transmits pump delivery pressure (PP) to the large diameter end of the piston
through port (C), port (D) and port (K).
• Pump delivery pressure (PP) is also transmitted to port (J) of the small diameter end of the piston, but
because of the difference in area between the large diameter end and the small diameter end on servo
piston (12), it is pushed to the right. As the result, the servo piston (12) moves into the direction of reducing
the swash plate angle.
• When the LS set selector pressure (PSIG) is transmitted to port (G), the spring (4) setting force is
weakened.
HB215LC-2 10-69
Main pump
When servo piston is balanced
• 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.
• 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.
• 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]
• 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.
• The force of spring (4) is adjusted so that spool (6) can be balanced at the specified center when (PP) -
(PLS) = 1.7 MPa {17.75 kg/cm2}.
• When (PSIG) [LS-EPC valve output pressure, 0 to 2.9 MPa {0 to 30 kg/cm 2}] 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}.
10-70 HB215LC-2
Main pump
PC valve (PC-C2K0-041-K-00-A)
a PC: Abbreviation for Pressure Compensation
PA: Pump port

PA2: Pump pressure pilot port
PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring
Function (PC-C2K0-042-K-00-A)
• When the pump discharged pressure (PP1) (self-pressure) or (PP2) (other pump pressure) is high, the PC
valve controls the pump so that no more oil than the constant flow (corresponding with the discharged
pressure) flows even if the stroke of the control valve becomes larger. As a result, it controls that the
horsepower absorbed by the pump does not exceed the engine horsepower.
• When the load increases and pump discharged pressure (PP) increases accordingly during operation, this
valve reduces the pump discharged volume.
• When the pump discharged pressure decreases, this valve increases the pump discharged volume.
• The relationship between average discharged pressure of the front and rear pumps [(PP1 + PP2]/2 and
pump discharged volume (Q) in this case is shown below as a parameter of current value (X) given to the
PC-EPC valve solenoid.
• The controller counts the actual engine speed.
• When the load increases and the engine speed decreases, this valve decreases the pump discharged
volume to recover the engine speed.
• When the load increases and the engine speed decreases below the set value, the command current from
the controller to the PC-EPC valve solenoid increases according to the engine speed drop to decrease the
pump swash plate angle.
HB215LC-2 10-71
Main pump
Operation (PC-C2K0-044-K-00-A)
When the pump controller is normal
When load on the actuator is small and pump pressures (PP1) and (PP2) are low
Actuation of PC-EPC valve solenoid (1)

• Command current (X) from the pump controller flows to the PC-EPC valve solenoid (1).
• This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).
10-72 HB215LC-2
Main pump
• Spool (3) stops at a position where the combined force exerted by springs (4) and (6) is equalized to the
combined force exerted by pump pressure (PP1) (self pressure) and pump pressure (PP2) (other pump's
pressure) acting on spool (3).
• Depending on this position, the pressure output from the PC valve [port (C) pressure] varies.
• The amperage of the command current (X) depends on the type of work (lever operation), work mode
selection, engine speed setting, and the actual engine speed.
a Other pump's 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. And for the rear pump
pressure, the other pump's pressure is that of the front pump.
Action of spring
• The spring force of springs (4) and (6) in the PC valve depends on the position of the swash plate.
• When servo piston (9) moves to the right, spring (6) is compressed.
• When the piston moves further to the right, the piston comes in contact with seat (5) and spring (6) is fixed.
• Then, only spring (4) operates.
• When servo piston (9) compresses or decompresses springs (4) and (6), the spring force varies.
• When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
• The spring forces of springs (4) and (6) are also varied by the PC-EPC valve solenoid command current
(X).
• Port (C) on the PC valve is connected to port (E) on the LS valve.
• Self pressure (PP1) is transmitted to the small diameter end of servo piston (9) and port (B), and other
pump's pressure (PP2) is transmitted to port (A).
• When pressures (PP1) and (PP2) are low, spool (3) is on the left.
HB215LC-2 10-73
Main pump
• Port (C) and port (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT).
• When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter end of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
• The pump discharged volume goes to increase.
• Springs (4) and (6) extend according to the movement of servo piston (9), and the reaction force of spring
decreases.
• When the reaction force of spring decreases, spool (3) moves to the right. Ports (C) is disconnected from
port (D), and pump delivery pressure port (B) is connected to port (C).
• Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.
• Accordingly, the stop position (= pump discharged volume) of servo piston (9) is determined by the
position where the force exerted by pressures (PP1) and (PP2), the thrust generated by the PC-EPC valve
solenoid, and the force exerted by springs (4) and (6) acting on the spool (3) are balanced.
When load on the actuator is large and pump pressures (PP1) and (PP2) are high
Outline
• When the load is large and the pump delivery pressures (PP1) and (PP2) are high, the thrust moving
spool (3) to the right increases, and spool (3) comes to a position as shown above.
• The pressure from port (C) to the LS valve becomes approximately half of pump pressure (PP2), because
a part of the pressure from port (B) flows through the LS valve and port (C) to port (D), as shown above.
• When spool (3) moves to the left, the opening of ports (C) and (D) widens.
• The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
10-74 HB215LC-2
Main pump
• Servo piston (9) stops at a position further to the right than the position when pump pressures (PP1) and
(PP2) are low.
Operation
• When ports (E) and (G) of the LS valve are connected, the pressure is transmitted from port (J) to the
large diameter end of servo piston (9), and servo piston (9) stops moving.
• When pump pressure (PP2) increases more and spool (3) moves further to the right, pump pressure (PP1)
flows to port (C) to minimize the pump discharged volume.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed, and spool (3) is pushed
back.
• The relationship between the average pump pressure (PP1 + PP2)/2 and servo piston (9) in terms of their
positions can be represented by the polygonal line in the figure because springs (4) and (6) form the 2-
stage springs.
• The relationship between the average pump pressure (PP1 + PP2)/2 and average pump discharged
volume (Q) becomes as shown below.
• If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between
average pump pressure (PP1 + PP2)/2 and pump discharged volume (Q) is shifted parallel in proportion to
the thrust of PC-EPC valve solenoid.
• Namely, the thrust of PC-EPC valve solenoid (1) is added to the pushing force to the right because of the
pump pressure transmitted to the spool (3), so the relationship between the average pump pressure (PP1
+ PP2)/2 and the pump discharged volume (Q) moves from (A) to (B) as the command current (X) is
increased.
HB215LC-2 10-75
Main pump
When the pump controller malfunctions and the emergency pump drive switch is at "ON" position
When load on the main pump is small
• If the pump controller fails, turn the emergency pump drive switch to "ON" position to select the resistor
side.
• In this case, power is taken directly from the battery, however, the current is too high as is, a resistor is
needed to control the current supplied to PC-EPC valve solenoid (1).
• Since the current is constant, the thrust applied to piston (2) is constant.
• When main pump pressures (PP1) and (PP2) are low, the combined force exerted by PC-EPC valve
solenoid (1) thrust and the pump pressure is smaller than the combined force exerted by the springs.
Spool (3) stays balanced at the left.
• Port (C) is connected to port (D) at drain pressure, and the pressure at the large diameter end of servo
piston (9) comes to drain pressure (PT) through the LS valve.
• Since the pressure at the small diameter end of the piston is large, servo piston (9) moves in the direction
to increase the discharged volume.
10-76 HB215LC-2
Main pump
When load on the main pump is large
• As mentioned before, when the emergency pump drive switch is turned to "ON" position, the command
current (X) sent to PC-EPC valve solenoid (1) is constant.
• Therefore, the thrust applied by piston (2) to spool (3) comes to constant.
• When main pump pressures (PP1) and (PP2) increase, spool (3) moves to a position further to the right
than when the main pump load is small, and stays balanced as shown above.
• Since the pressure from port (B) flows into port (C), servo piston (9) moves to the right (discharged volume
decreases), and stops at a position further to the right than when the pump load is small.
• When the emergency pump drive switch is turned to "ON" position, the curve indicating the relation
between the pump delivery pressure (PP) and discharged volume (Q) is plotted in accordance with the
current supplied through the resistor to the PC-EPC valve solenoid.
• When the emergency pump drive switch is turned to "ON" position, the curve is plotted as (B), which is
shifted toward the left than curve (A) for a normal pump controller.
HB215LC-2 10-77
Main pump
10-78 HB215LC-2
Main pump
LS-EPC valve (HB380-C2M0-041-K-00-A)

a EPC: Abbreviation for Electromagnetic Proportional Control
C: To LS valve
P: From self-pressure reducing valve
T: To hydraulic tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
HB215LC-2 10-79
Main pump
Structure
• The EPC valve consists of the proportional solenoid and the hydraulic valve.
Function (HB380-C2M0-042-K-00-A)
• When EPC valve receives signal current (i) from the controller, it generates an EPC output pressure in
proportion to that current and outputs it to LS valve.
10-80 HB215LC-2
Main pump
Operation (HB205-C2M0-044-K-00-A)
When signal current is zero (coil de-energized)
• When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left side by spring (4).
• Port (P) is closed, and the pressurized oil from the self-pressure reducing valve does not flow to LS valve.
• The pressurized oil from LS valve is drained to the tank through port (C) and port (T).
HB215LC-2 10-81
Main pump
When signal current is minute (coil is energized)
• When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to
the right is generated.
• Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C).
• The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and the
reaction force exerted by spring (4) becomes larger than the thrust of plunger (7).
• Spool (5) is pushed to the left, and ports (P) and (C) are disconnected.
• Port (C) connects to port (T).
• Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the force
exerted by pressure at port (C) and the reaction force exerted by spring (4).
• The circuit pressure between the EPC valve and the LS valve is controlled in proportion to the amperage
of the signal current.
10-82 HB215LC-2
Main pump
When signal current is maximum (coil is energized)
• Coil (2) is energized when signal current is supplied to coil (2).

• As the amperage of signal current is maximum, the thrust of plunger (7) is also maximized.
• Spool (5) is pushed to the right by rod (6).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and LS valve is maximized.
• Port (T) closes, and no pressurized oil flows to the tank.
HB215LC-2 10-83
Main pump
PC-EPC valve (HB380-C2N0-041-K-00-A)

C: To PC valve
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
10-84 HB215LC-2
Main pump
Structure
• The EPC valve consists of the proportional solenoid and the hydraulic valve.
Function (HB380-C2N0-042-K-00-A)
• When EPC valve receives signal current (i) from the controller, it generates an EPC output pressure in
proportion to that current and outputs it to PC valve.
HB215LC-2 10-85
Main pump
Operation (HB205-C2N0-044-K-00-A)
When signal current is zero amp. (coil is de-energized)
• When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left side by spring (4).
• Port (P) is closed, and the pressurized oil from the self-pressure reducing valve does not flow to the PC
valve.
• The pressurized oil from the PC valve is drained to the tank through port (C) and then port (T).
10-86 HB215LC-2
Main pump
• When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to
the right is generated.
• Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C).
• The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and the
reaction force exerted by spring (4) becomes larger than the thrust of plunger (7).
• Spool (5) is pushed to the left, and port (P) is shut off from port (C).
• Port (C) connects to port (T).
• Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the force
exerted by pressure at port (C) and the reaction force exerted by spring (4).
• The circuit pressure between the EPC valve and PC valve is controlled in proportion to the amperage of
signal current.
HB215LC-2 10-87
Main pump
• Coil (2) is energized when signal current is supplied to coil (2).

• As the amperage of signal current is maximum, the thrust of plunger (7) is also maximized.
• Spool (5) is pushed to the right by rod (6).
the EPC valve and PC valve is maximized.
• Port (T) closes, and no pressurized oil flows to the tank.
10-88 HB215LC-2
Control valve
Control valve (HB205-C030-041-K-01-A)

General view
A1: To bucket cylinder head

A2: To L.H. travel motor
HB215LC-2 10-89
Control valve
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 LSvalve
PLS2: To front pump LSvalve
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
10-90 HB215LC-2
Control valve
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
HB215LC-2 10-91
Control valve
Sectional view
(1/5)
1. Pressure compensation valve (arm OUT)

2. Pressure compensation valve (right travel REVERSE)
3. Pressure compensation valve (boom RAISE)
4. Pressure compensation valve (left travel REVERSE)
5. Pressure compensation valve (bucket DUMP)
6. Pressure compensation valve (service 1)
7. Pressure compensation valve (bucket CURL)
10-92 HB215LC-2
Control valve
8. Pressure compensation valve (left travel FORWARD)

9. Pressure compensation valve (boom LOWER)
10. Pressure compensation valve (right travel FORWARD)
11. Pressure compensation valve (arm IN)
13. Unload valve
15. Spool (service 1)
16. Spool (bucket)
17. Spool (left travel)
18. Spool (boom)
19. Spool (right travel)
20. Spool (arm)
HB215LC-2 10-93
Control valve
(2/5)
1. Suction valve (arm OUT)

2. Suction valve (right travel REVERSE)
3. Suction valve (boom RAISE)
4. Suction valve (left travel REVERSE)
5. Suction safety valve (bucket DUMP)
6. Suction safety valve (service 1)
7. 2-stage suction safety valve (service)
8. Suction safety valve (bucket CURL)
10-94 HB215LC-2
Control valve
9. Suction valve (left travel FORWARD)

10. Suction safety valve (boom LOWER)
11. Suction valve (right travel FORWARD)
12. Suction safety valve (arm IN)
13. LS shuttle valve (arm)
14. LS shuttle valve (right travel)
15. LS shuttle valve (boom)
16. LS shuttle valve (left travel)
17. LS shuttle valve (bucket)
18. LS shuttle valve (service 1)
19. LS check valve
20. Pressure relief plug
HB215LC-2 10-95
Control valve
(3/5)
1. Unload valve
2. Safety valve (boom RAISE and arm OUT)
4. Variable back pressure valve
Arm valve
6. LS shuttle valve
8. Pressure compensation valve (CURL)
9. Spool
10. Suction safety valve (CURL)
11. Back pressure valve
12. Check valve for regeneration circuit
10-96 HB215LC-2
Control valve
13. Suction valve (OUT)

14. Pressure compensation valve (DUMP)
R.H. travel valve

15. LS shuttle valve
16. Pressure compensation valve (FORWARD)
17. Spool
18. Suction valve (FORWARD)
19. Suction valve (REVERSE)
20. Pressure compensation valve (REVERSE)
HB215LC-2 10-97
Control valve
(4/5)
1. Return spring
2. Merge-divider valve (for LS)
3. Valve (sequence valve)
4. Spring (sequence valve)
5. Merge-divider valve (main)
6. Return spring
Boom valve
8. LS shuttle valve
9. Pressure compensation valve (LOWER)
10. Spool
11. Suction safety valve (LOWER)
12. Check valve for regeneration circuit
10-98 HB215LC-2
Control valve
13. Suction valve (RAISE)

14. Pressure compensation valve (RAISE)
L.H. travel valve

15. Merge-divider valve (Travel junction valve)
16. Return spring
18. Pressure compensation valve (FORWARD)
19. Spool
20. Suction valve (FORWARD)
21. Suction valve (REVERSE)
22. Pressure compensation valve (REVERSE)
Bucket valve
24. Pressure compensation valve (CURL)
25. Spool
26. Suction safety valve (CURL)
27. Suction safety valve (DUMP)
28. Pressure compensation valve (DUMP)
HB215LC-2 10-99
Control valve
(5/5)
Service valve 1
1. LS shuttle valve
2. Pressure compensation valve
3. Spool
4. 2-stage suction safety valve
5. Suction safety valve
6. Unload valve
8. LS bypass plug
Structure
• The control valve consists of a 6-spool valve (integrated) and service valve, and the merge-divider valve,
variable back pressure valve, and boom hydraulic drift prevention valve are installed to it.
10-100 HB215LC-2
Control valve
• Since all the valves are fixed in one unit with connecting bolts and their passages are connected internally,
the whole unit is compact in size and easy to service.
• Since this control valve has a 1-spool-to-1-work equipment configuration, its structure is simple.
HB215LC-2 10-101
Control valve
Hydraulic circuit diagram and names of valves (HB205-C030-054-K-01-A)
1. Arm valve
2. R.H. travel valve
10-102 HB215LC-2
Control 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
14. Suction valve
15. Check valve (for boom regeneration circuit)
16. Check valve (for arm regeneration circuit)
17. EPC valve (for merge-divider main spool changeover)
18. EPC valve (for Merge-divider LS spool changeover)
23. Self-pressure reducing valve
24. Travel junction valve
26. Cooler check valve
28. Main relief valve (bucket side)
　　 Set pressure: 35.4 MPa {360.5 kg/cm2}
　　 When digging force increased: 38.0 MPa {387kg/cm2}
29. Main relief valve (arm side)
　　 Set pressure: 35.4 MPa {360.5 kg/cm2}
　　 When digging force increased: 38.0 MPa {387kg/cm2}
30. Unload valve (bucket side)
　　 Cracking pressure: 2.5 MPa {26 kg/cm2}
31. Unload valve (arm side)
　　 Cracking pressure: 2.5 MPa {26 kg/cm2}
　　 Set pressure: 24.5 MPa {250 kg/cm2}
35. 2-stage suction safety valve
　　 1st stage set pressure: 24.5 MPa {250 kg/cm2}
　　 2nd stage set pressure: 20.6 MPa {210 kg/cm2}
HB215LC-2 10-103
Control valve
Unload valve (PC220-PQD5-041-K-00-A)
1. LS circuit
2. Valve
3. Pump circuit
4. Tank circuit
5. Spring
Function (PC220-PQD5-042-K-00-A)
• When all control valves are at HOLD, this valve serves to drain as same amount of oil as the pump
discharged volume with swash plate angle at the minimum.
• The pump pressure becomes the pressure corresponding to the set load of spring (5) in the valve (referred
to as P1).
• Since LS pressure is drained from LS bypass valve, LS pressure C tank pressure C 0 MPa {0 kg/cm2}.
Operation (ALL-PQD5-044-K-00-A)
• Pressure of pump circuit (3) is received by the end of valve (2).
• Since the control valve is in NEUTRAL position, pressure of LS circuit (1) is 0 MPa {0 kg/cm 2}.
• Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available.
• If this pressure grows larger than the force of spring (5), valve (2) moves to the left.
• Ports (b) and (c) are interconnected, and the pump pressurized oil flows to tank circuit (4).
• The pressurized oil of LS circuit (1) passes from orifice (a) through port (c) and is drained to tank circuit
(4).
• When this valve is actuated, the LS pressure becomes nearly equal to the tank pressure.
• Since the pump delivery pressure - LS circuit pressure during unloading is larger than pump LS control
pressure, the signal is output to minimize the pump swash plate angle.
• During operation (when a given work is done within the discharged volume available with the minimum
swash plate angle), the delivery pressure corresponding to the minimum pump swash plate angle is set to
LS pressure + P1 pressure.
• The LS differential pressure (dPLS) with the swash plate angle at the minimum becomes P1 pressure.
Operation of relief valve

• When cylinder reaches its stroke end, main relief valve opens.
• Pump discharged volume (Q) is relieved to the tank. (For details, see " System diagram" of "Structure of
CLSS".
• Since the pump delivery pressure (PP) and LS pressure (PLS) do not flow neither to the upstream nor
downstream, they become approximately the same and LS differential pressure (dPLS) becomes 0 MPa
{0 kg/cm2}.
• As LS differential pressure (dPLS) is lower than the LS set pressure of LS valve, LS valve operates to
make the pump swash plate angle maximum.
• Mechanically, operation of PC valve has priority over that of LS valve.
• The pump is maintained at the minimum swash plate angle due to PC valve cut-off function.
10-104 HB215LC-2
Control valve
HB215LC-2 10-105
Control valve
Introduction of LS pressure (PC220-C2A4-041-K-00-A)
1. Main pump
2. Main spool
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function (HB205-C2A4-042-K-00-A)
• Drawing the upstream pressure (spool meter-in downstream pressure) of pressure compensation valve
(3) into LS shuttle valve (7) as LS pressure.
• The LS pressure is connected through valve (4) to port (B) of the actuator ≒ the actuator load pressure.
• Inlet hole (a) in main spool (2) has not only a small diameter but also a throttling function.
Operation (PC220-C2A4-044-K-00-A)
• When main spool (2) is operated, the pump pressure is transmitted to port (c) through leading hole (a) and
is led to LS circuit.
• When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens and the
pressurized oil flows.
10-106 HB215LC-2
Control valve
LS bypass plug (HB205-PNSH-041-K-01-A)
1. Main pump
2. Main spool
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function (ALL-PNSH-042-K-00-A)
• This valve relieves the residual pressure in LS pressure circuit (6) from orifices (a) and (b).
• Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure.
• Depending on the bypass flow from LS bypass plug (5), pressure loss is generated due to the circuit
resistance from orifice (c) of main spool (2) to LS shuttle valve (4).
• Effective LS differential pressure drops to improve a dynamic stability of the actuator.
HB215LC-2 10-107
Control valve
Pressure compensation valve (HB205-L6D0-040-K-00-A)

During independent operation and at Max. high load pressure
(When load pressure is higher than other work equipment during combined operation)
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function
• Pressure compensation valve works as a load check valve.
• When the pump pressure (LS pressure) is lower than port (c), shuttle valve (3) in pressure compensation
piston (4) interconnects spring chamber (E) with port (C).
• Piston (4) and valve (2) moves in the closing direction with the force of spring (5).
Unit type pressure compensation valve

• When high peak pressure is generated in actuator circuit, or continuous peak pressure (when using
breaker etc.) is repeatedly generated, valve (2) hits seat (C) in valve chest and may cause high stress.
• To prevent this, use the pressure compensation valve which consists of valve (2) and piston (4) as a unit.
• This is used for the travel valve, the bucket valve (cylinder bottom) and the service valve in this machine.
• Port (C) and spring chamber (E) are basically not interconnected in the unit type pressure compensation
valve.
• Valve (7) does not hit valve chest even when high peak pressure is generated in port (C).
• For the bucket valve etc., port (C) interconnects with spring chamber (E) just before valve (7) seats.
10-108 HB215LC-2
Control valve
When compensated
(When load pressure is lower than other work equipment during combined operation)
Function
• The pressure compensation valve is closed with the LS pressure of port (D), the spool meter-in
downstream pressure of port (B) becomes the same as maximum pressure of other work equipment.
• Since the spool meter-in upstream pressure of port (A) is the pump pressure, spool meter-in differential
pressure (upstream pressure [port (A) pressure] - downstream pressure [port (B) pressure]) becomes the
same in all spools in operation.
• The pump flow is divided corresponding to the meter-in opening area ratio.
Operation
• Spring chamber (E) is interconnected with port (D).
• Piston (4) and valve (2) moves in the closing direction (right side) with the LS circuit pressure from other
work equipment of port (F).
• The valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled by LS
pressure.
HB215LC-2 10-109
Control valve
Surface area ratio of pressure compensation valve
Function
• The flow division ratio varies with the surface area ratio of portions (A1) and (A2) of the pressure
compensation valve. Surface area ratio = (A2) / (A1)
• When the surface area ratio is 1: The spool meter-in downstream pressure is equal to the maximum load
pressure and oil flows corresponding to the opening area ratio.
• When the surface area ratio is 1 or more: The spool meter-in downstream pressure is higher than the
maximum load pressure and oil flows into the compensated side less than the opening area ratio.
• When the surface area ratio is 1 or less: The spool meter-in downstream pressure is lower than the
maximum load pressure and oil flows into the compensated side more than the opening area ratio.
10-110 HB215LC-2
Control valve
Shuttle valve in pressure compensation valve (PC220-L6D3-040-K-00-A)

When holding pressure at port (A) becomes higher than LS pressure in spring chamber (B)
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
Operation
• Shuttle valve (3) is pressed to the right side by the pressure of port (A). As a result, port (A) is
disconnected from port (C).
• Holding pressure at port (A) is transmitted to the spring chamber (B) to push piston (4) to the left so that
piston (4) is not separated from valve (2).
HB215LC-2 10-111
Control valve
When traveling
Structure
• Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve
without shuttle valve (5) is adopted.
10-112 HB215LC-2
Control valve
Boom regeneration circuit (PC220-L511-040-K-00-A)

When cylinder head pressure is lower than bottom pressure (hydraulic drift, etc.)
1. Main pump
2. Boom valve spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit is installed across the cylinder bottom and cylinder head to increase flow to the
cylinder head when the boom is lowered.
Operation
• When the cylinder head pressure is lower than the bottom pressure, some of pressurized oil (A) from the
cylinder bottom flows to drain circuit (B) from the notch of boom spool (2).
• The remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder bottom
through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
HB215LC-2 10-113
Control valve
When cylinder head pressure is higher than bottom pressure (digging operation, etc.)
Function
• Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to
the head.
10-114 HB215LC-2
Control valve
Arm regeneration circuit (PC220-L911-040-K-00-A)

When cylinder head pressure is higher than bottom pressure
1. Main pump
2. Arm valve spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit installed between the cylinder head and cylinder bottom increases the oil flowing
to the cylinder bottom (pump discharged volume + regeneration flow) during arm IN operation in order to
accelerate the cylinder.
Operation
• When the cylinder head pressure is higher than the bottom pressure, part of pressurized oil (A) from the
cylinder head flows to drain circuit (B) through the notch of arm spool (2).
• The remaining oil flows to the regeneration circuit (C), opens check valve (6), and flows to the cylinder
bottom through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
HB215LC-2 10-115
Control valve
When cylinder head pressure is lower than bottom pressure
Function
• Check valve (6) installed to regeneration circuit (C) closes and shuts off the oil flowing from the cylinder
head to the bottom.
10-116 HB215LC-2
Control valve
Merge-divider valve (HB205-PP30-040-K-00-A)

When the pumps are merged [When merge-divider selector signals (IS1) and (IS2) are OFF]
A: LS circuit (bucket side)

B: LS circuit (arm side)
C: LS circuit (arm side)
D: LS circuit (bucket side)
1. Main spool
2. Spring
3. LS spool
4. Spring
5. Merge-divider EPC valve (for main spool changeover)
6. Merge-divider EPC valve (for LS spool changeover)
Function
• This valve merges or divides (to each control valve group) the pressurized oil (P1) and (P2) discharged
from 2 pumps.
• This valve merges or divides LS circuit pressure.
Operation
• Since the main spool EPC valve drive signal (IS1) is OFF, the merge-divider EPC valve output pressure is
0 MPa {0 kg/cm2}.
HB215LC-2 10-117
Control valve
• Main spool (1) is pushed to the right by spring (2) to interconnect port (E) with port (F).
• Pressurized oil (P1) and (P2) discharged from 2 pumps are merged in ports (E) and (F) and sent to
required control valve.
• Since EPC valve drive signal (IS2) is OFF, LS spool (3) is pushed to the right by spring (4) to interconnect
LS circuit (bucket side) (A) with (D), and LS circuit (arm side) (B) with (C).
• LS pressure from each control valve spool transmitted to LS circuit (A), (B), (C), and (D) is transferred to
all the pressure compensation valves.
When the pumps are divided [When merge-divider selector signals (IS1) and (IS2) are ON]
Operation
• When EPC valve drive signal (IS1) is ON, main spool (1) is moved to the left by output pressure from
merge-divider EPC valve to disconnect port (E) from (F).
• Pressurized oil discharged from 2 pumps is sent to each control valve group.
P1 pressure: To bucket, left travel, and boom
P2 pressure: To right travel and arm
• When EPC valve drive signal (IS2) is ON, LS spool (3) is moved to the left by output pressure from merge-
divider EPC valve to interconnect LS circuit (bucket side) (A) with LS circuit (arm side) (C) and disconnect
others.
• LS pressure from each control valve spool transmitted to LS circuit (A), (B), (C), and (D) is transferred to
each control valves.
10-118 HB215LC-2
Control valve
Self-pressure reducing valve (PC220-PL30-042-K-00-A)

Function
• This valve serves to reduce the delivery pressure of main pump and provide it for solenoid valves, EPC
valves, etc. for use as the control pressure.
Operation (ALL-PL30-044-K-00-A)
When engine is stopped

• Poppet (11) is pressed against the seat by spring (12), so port (PR) is disconnected from port (TS).
• Valve (14) is pressed to the left by spring (13), so port (P2) is disconnected from (TS).
• Valve (7) is pressed to the left by spring (8), so port (P2) is disconnected from port (A2).
HB215LC-2 10-119
Control valve
10-120 HB215LC-2
Control valve
When load pressure (P2) is low

a When all control levers are in NEUTRAL position, or when load pressure (A2) is lower than output
pressure (PR) of the self-pressure reducing valve
• Force of spring (8) and the force exerted by the pressure (PR) (0 MPa {0 kg/cm 2}, when engine is stopped),
are applied to valve (7) in the direction to disconnect the circuit ports (P2) and (A2).
• When the pressurized oil flows in from port (P2), valve (7) balances at a position where [Force (Area fd x
Pressure P2) = Force of spring (8) + Force (Area fd x Pressure PR)] holds.
• The opening of valve (7) is adjusted so that pressure (P2) remains at a constant level higher than pressure
(PR).
• When pressure (PR) rises above the set pressure, poppet (11) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from
the opening of poppet (11).
• Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the
spool closes the opening between ports (P2) and (PR).
• Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as
pressure (PR).
HB215LC-2 10-121
Control valve
When load pressure (P2) is high

• As load pressure (A2) increases with the digging operation, etc, the pump discharged volume increases
accordingly.
• Pressure (P2) increases, and [Force (Area fd x Pressure P2] becomes larger than [Force of spring (8) +
Force (Area fd x Pressure PR)]. As a result, valve (7) moves fully to the right.
• Since the area of the opening between ports (P2) and (A2) increases, the passage resistance reduces,
reducing the engine horsepower loss.
• When pressure (PR) rises above the set pressure, poppet (11) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from
the opening of poppet (11).
• Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the
spool closes the opening between ports (P2) and (PR).
• Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as
pressure (PR).
10-122 HB215LC-2
Control valve
When abnormally high pressure is generated

• If pressure (PR) of the self-pressure reducing valve becomes abnormally high, ball (16) contracts spring
(15) and separates from the seat.
• This allows the pressurized oil to flow to drain port (TS) from port (PR), lowering pressure (PR).
• As a result, components such as PPC valves and solenoid valves are protected from abnormally high
pressure.
HB215LC-2 10-123
Control valve
Travel junction valve (PC220-C6C0-042-K-00-A)

Function
• When travel control lever is operated for straight-travel, travel junction valve does not receive the pilot
pressure (PST) from travel junction solenoid valve, thus right and left travel circuits interconnect each
other, and equal amount of oil is supplied to right and left travel motors to secure straight-travel ability.
• When travel control lever is operated for turning, travel junction valve receives the pilot pressure (PST)
from travel junction solenoid valve, thus right and left travel circuits are shut off each other, and
independent amount of oil is supplied to right and left travel motors to secure turning ability.
10-124 HB215LC-2
Control valve
Operation (ALL-C6C0-044-K-00-A)
When pilot pressure (PST) is shut off (travel junction)
• If pilot pressure (PST) from the travel junction solenoid valve is shut off, travel junction spool (2) is pressed
back towards right by the force of spring (1). As a result, ports (PTL) and (PTR) are interconnected.
• If the oil flow rates to the R.H. and L.H. travel motors become different from each other, the oil flows
through the opening of travel junction spool (2) from port of higher pressure side to port of lower pressure
side supplying the difference of oil to the lower pressure side so that the oil flow rates to both motors will
be equalized.
HB215LC-2 10-125
Control valve
When pilot pressure (PST) is supplied (travel independent)
• When pilot pressure (PST) from the travel junction solenoid valve is supplied, travel junction spool (2)
compresses spring (1) to the left side and ports (PTL) and (PTR) are disconnected.
• The oil flow rate to both right and left motors becomes independent.
10-126 HB215LC-2
Control valve
Travel PPC shuttle valve (PC220-C6V1-042-K-00-A)
a PPC: Abbreviation for Proportional Pressure Control
Function
• If boom RAISE, arm IN or OUT, bucket CURL or DUMP operation is performed when the machine is
traveling up a steep, the pilot pressure from the travel PPC valve serves to restrict the travel of respective
spools of boom, arm and bucket valves so that the oil flow rates to respective cylinders are restricted.
• To limit the travel of the boom, arm or bucket spool, the pilot pressure from the travel PPC valve passes
through the internal circuit of respective control valves and acts on the spool.
Operation (ALL-C6V1-044-K-00-A)
When travel is neutral
• The oil in stroke limit signal chamber (a) flows through orifices (5) and (6) of pistons (3) and (4) in the travel
spring case, and flows through travel PPC valve and then drained.
• By performing boom RAISE (or arm IN, OUT or bucket CURL, DUMP) operation, spool (1) moves to the
left side until it hits the end surface of spring case (2) (st0).
HB215LC-2 10-127
Control valve
When operating travel
• By performing right travel REVERSE (or FORWARD) operation, the pilot pressure from travel PPC valve
pushes spool (7) to the left side (or right side).
• Spool (7) pushes piston (3) to close orifice (5), and stroke limit signal chamber (a) is blocked from the
travel PPC valve drain circuit.
• By performing right travel REVERSE (or FORWARD) operation, the pilot pressure from travel PPC valve
is transmitted through orifice (6) of piston (4) to the left end surface of piston (8) to push piston (8) to the
right side.
• By performing boom RAISE (or arm IN, OUT or bucket CURL, DUMP) operation, spool (1) moves to the
left side.
• Maximum stroke of spool is reduced by the moving amount of piston (8) to the right side (st2), and
becomes (st1).
10-128 HB215LC-2
Control valve
Boom hydraulic drift prevention valve (PC220-L6C0-042-K-00-A)

Function
• While boom is not operated by the right work equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from boom cylinder bottom through spool (1) to prevent the boom from
drifting hydraulically.
Operation (ALL-L6C0-044-K-00-A)
In boom "RAISE" operation
• When operating boom "RAISE", the pressurized oil from the control valve exerts a left-hand force on the
right side of ring-shaped area (S), of which outside diameter is poppet (5) diameter (d1) and of which
inside diameter is seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, the pressurized oil from the control valve passes through the opening of poppet (5) and flows
to the boom cylinder bottom.
HB215LC-2 10-129
Control valve
In boom "NEUTRAL" operation
• When the boom is operated to "NEUTRAL" position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of boom cylinder bottom exerts a right-hand force on the left side of ring-shaped
area (S), of which outside diameter is poppet (5) diameter (d1) and of which inside diameter is seat
diameter (d2).
• The combined force of right-hand force on area (S) and the spring force of spring (4) moves poppet (5) to
the right.
• The circuit from control valve to boom cylinder bottom shuts off, then the oil pressure of the boom cylinder
bottom side is kept.
10-130 HB215LC-2
Control valve
In boom "LOWER" operation
• When operating boom "LOWER", the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the boom cylinder bottom flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
HB215LC-2 10-131
Control valve
Arm hydraulic drift prevention valve (HB205-L9K0-041-K-00-A)
(if equipped)
Function
• While the arm is not operated, this valve prevents hydraulic drift of the arm due to the leakage of
pressurized oil on the head side of the arm cylinder through spool (1).
Operation (HB205-L9K0-044-K-00-A)
In arm "OUT" operation
• When performing arm "OUT" operation, pressurized oil from control valve acts to the left direction on the
right side of ring-shape area (S) which takes poppet (5) diameter (d1) as outside diameter and takes seat
diameter (d2) as inside diameter.
• The force on area (S) to the left direction compress spring (4), and moves poppet (5) to the left side.
• The pressurized oil from the control valve flows through the opening of poppet (5) to the head side of the
arm cylinder.
10-132 HB215LC-2
Control valve
When arm is in "NEUTRAL"
• When the arm control lever is returned to "NEUTRAL" position, the pressurized oil flowing to inside of
poppet (5) through orifice (a) of poppet (5) is blocked by pilot piston (2).
• The holding pressure in arm cylinder head acts to the right direction on the left side of ring-shape area (S)
which is generated by the difference of poppet (5) outside diameter (d1) and seat diameter (d2).
• The combined force of reaction force of spring (4) and pressured force on area (S) to the right direction
moves poppet (5) to the right side.
• The circuit from the control valve to the arm cylinder head is disconnected, the oil pressure of arm cylinder
head side is held.
HB215LC-2 10-133
Control valve
In arm "IN" operation
• When performing arm "IN" operation, the pilot pressure from PPC valve pushes pilot piston (2).
• The pressurized oil of arm cylinder head flows through orifice (a) and chamber (b), and flows to drain port
(T) through orifice (c).
• Chamber (b) in the poppet and drain port (T) are interconnected, and the pressure in chamber (b)
decreases.
• When the pressure in chamber (b) is lower than that in port (B), poppet (5) opens.
• When poppet (5) opens, the pressurized oil from port (B) is transmitted to port (A), and then flows to the
control valve.
10-134 HB215LC-2
Control valve
Safety valve (PC200_10-L9K2-042-K-00-A)

Function
• when the impact on the cylinders and other components causes abnormal pressure, the safety valve
releases abnormal pressure in order to protect the hydraulic component.
Operation (PC220-L9K2-044-K-00-A)
Operation when abnormally high pressure is generated
• If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B)
opens check valve (6) to actuate safety valve (3).
HB215LC-2 10-135
Control valve
• When the arm hydraulic drift prevention valve (optional) is installed to the arm cylinder head circuit, the
pressurized oil of the boom cylinder bottom circuit pressure or arm cylinder head circuit pressure,
whichever has higher pressure, opens check valve (6) or (6A) to actuate safety valve (3).
Arm quick return valve (PC220-L9K1-042-K-00-A)
Function
• Large amount of oil is returned from the cylinder bottom when arm OUT operation is performed.
• The valve reduces this pressure loss.
Operation (HB205-L9K1-044-K-00-A)
In arm ""OUT"" operation
• When performing arm "OUT" operation, the pilot pressure from PPC valve pushes pilot piston (1).
• The pressurized oil in chamber (b) of valve is drained through orifice (c).
• The pressurized oil of arm cylinder bottom flows through orifice (a) and chamber (b), and flows to drain
port (T) through orifice (c).
• Chamber (b) and drain port (T) are interconnected, and the pressure in chamber (b) decreases.
10-136 HB215LC-2
Control valve
• When the pressure in chamber (b) decreases less than the pressure in port (A), the pressured force on
port (A) side [fd2 area (S2) (area of seat diameter)] is larger than the combined force of spring reaction
force and pressured force on chamber (b) of valve (2) [fd1 area (S1)].
• State becomes (Pressured force on fd2 > pressured force on fd1 + spring reaction force).
• Valve (2) moves to the right side and the pressurized oil is transmitted from port (A) to port (B).
• The pressurized oil in arm cylinder bottom is drained from port (B) to the tank directly.
When arm is in "NEUTRAL"
• When arm control lever is returned to "NEUTRAL" position from "OUT", the pilot pressure from PPC valve
is blocked.
• The pressurized oil drained from orifice (a) of valve (2) is kept by pilot piston (1).
• The holding pressure in arm cylinder bottom acts to the left direction on the right side of ring-shape area
which is generated by the difference of area (S2) and area (S1) of valve (2).
• The combined force of reaction force of spring (3) and pressured force on ring-shape area to the left
direction moves valve (2) to the left side and disconnect port (A) and port (B).
HB215LC-2 10-137
Control valve
Variable back pressure valve (HB205-PQ81-042-K-00-A)

Function
• This valve applies pressure to the drain circuit to prevent cavitation caused by negative pressure of each
actuator (motor, cylinder, etc.)
• During the state other than traveling, this valve decreases pressure to the drain circuit to reduce output
loss.
Operation (HB205-PQ81-044-K-00-A)
When engine is stopped

• The pressurized oil is not supplied from main pump to self-pressure reducing valve (1).
• The oil pressure is not supplied from the variable back pressure solenoid valve (3) to spring chamber (C),
and valve (6) is pushed to the right by the reaction force of spring (5).
• Drain circuit (A) of the control valve is interconnected with port (T) through orifice (b) of valve (6).
10-138 HB215LC-2
Control valve
When engine is running (for travel operation)

• The pressurized oil (PR) output from self-pressure reducing valve (1) flows to variable back pressure
solenoid valve (3).
• Since drive signal (IS3) to variable back pressure solenoid valve (3) is "OFF", the pressurized oil (PR) is
transmitted to spring chamber (C) of variable back pressure valve (4).
• The pressurized oil (PR) transmitted to spring chamber (C) acts on the left end (the area of f d) of valve
(6) to push it to the right as the combined force with the reaction force of spring (5).
• The pressurized oil (PA) of drain circuit (A) of the control valve acts on the right end ( the area of f d1) of
valve (6) to push it to the left.
• Valve (6) balances so that the back pressure is (PA) in the following formula. PA = (the area of fd x
pressure (PR)＋reaction force of spring (5)) / the area of fd1
• The flow rate from drain circuit (A) of control valve to port (T) is adjusted, and set to the set pressure of
variable back pressure valve (4).
HB215LC-2 10-139
Control valve
When engine is running (for other than travel operation)

• The pressurized oil (PR) output from self-pressure reducing valve (1) flows to variable back pressure
solenoid valve (3).
• Since drive signal (IS3) to variable back pressure solenoid valve (3) is "ON", the pressurized oil (PR)
transmitted from self-pressure reducing valve (1) to spring chamber (C) of variable back pressure valve (4)
is drained from variable back pressure solenoid valve (3).
• Only the reaction force of spring (5) acts on valve (6) to push it to the right.
• The pressurized oil (PA) of drain circuit (A) of the control valve acts on the right end ( the area of f d1) to
push it to the left.
• Valve (6) balances so that the back pressure is (PA) in the following formula. PA = reaction force of spring
(5) / the area of fd1
• The flow rate from drain circuit (A) of control valve to port (T) is adjusted, and set to the set pressure of
variable back pressure valve (4).
10-140 HB215LC-2
Control valve
Main relief valve (HB205-PQ91-041-K-00-A)
1. Spring
2. Poppet
Function (PC220-PQ91-042-K-00-A)
• This valve has two selectable settings for its set pressure.
• If the extra power is necessary, this valve is set to the high-pressure setting when pilot pressure (P) is
applied to it from the 2-stage relief solenoid valve.
• The relief valve set pressure is determined by the load at installed height of spring (1). (1st stage set
pressure)
• When the 1st stage set pressure is set correctly, the 2nd stage set pressure does not need to be set.
Setting the 1st stage set pressure completes the setting of the 2nd stage set pressure.
Operation (PC-PQ91-044-K-00-A)
When pilot pressure (P) is shut off (low pressure setting)

• The set pressure is determined by the load at installed height of spring (1).
When pilot pressure (P) is supplied (high pressure setting)

• The load at installed height of spring (1) is added with the force exerted by pilot pressure (P) applied to the
area of diameter (d1) of poppet (2), raising the set pressure to higher level.
HB215LC-2 10-141
Control valve
2-stage suction-safety valve (PC220-PQJ2-041-K-00-A)

[Installed to port (B) of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function (HB205-PQJ2-042-K-00-A)
• The valve has 2 stage of set pressure.
• The pressure setting is set to low by the received pilot pressre from the attachment selector solenoid
valve.
• Depeding on the attachment types (for example, breaker and crusher), turn the pilot pressure ON/OFF to
change the set pressure.
• The valve set pressure depends on spring (1) mounting load.
Operation (ALL-PQJ2-044-K-00-A)
When pilot pressure (P) is shut off (high pressure setting)
• Since pilot pressure (P) is shut off, piston (2) is pressed to the left by force of spring (3). [Load at installed
height of spring (1) < Load at installed height of spring (3).]
• The load at installed height of spring (1) becomes maximum, inducing high-pressure setting.
• Passage (B) is interconnected to the drain circuit via passage (C) and chamber (D).
10-142 HB215LC-2
Control valve
When pilot pressure (P) is supplied (low pressure setting)
• When pilot pressure (P) is supplied, the pilot pressure is transmitted to part (A) through passage (B).
• The pilot pressure acts on the pressure receiving diameter at part (A) [(d1) – (d2)] of piston (2).
• Piston (2) compresses spring (3) by receiving pilot pressure and moves to the right until it contacts holder
(4).
• Since spring (1) is expanded and reducing its load at installed height, the set pressure is lowered.
• The amount of pressurized oil for stroke of piston (2) is drained from passage (C) via chamber (D) .
HB215LC-2 10-143
Travel motor
Travel motor (HB205-C400-041-K-00-A)
L.H. travel motor

B: Plug (break release pressure port)
MA: Port (PA) pressure pickup port
MB: Port (PB) pressure pickup port
P: From travel speed increase solenoid valve
PA: From control valve (left travel FORWARD port)
PB: From control valve (left travel REVERSE port)
R.H. travel motor

B: Plug (break release pressure port)
MA: Port (PA) pressure pickup port
MB: Port (PB) pressure pickup port
P: From travel speed increase solenoid valve
10-144 HB215LC-2
Travel motor
PA: From control valve (right travel REVERSE port)

PB: From control valve (right travel FORWARD port)
HB215LC-2 10-145
Travel motor
1. Regulator piston
2. Regulator valve
3. Motor case
5. Check valve
6. Rocker cam
7. Retainer guide
8. Output shaft
9. Pin
10. Retainer
11. Piston
12. Cylinder block
13. Valve plate
14. Counterbalance valve spool
15. Ring
16. Brake piston
17. Plate
18. Disc
19. Ball retainer
Specifications (HB205-C400-030-K-00-A)
Model HMV120-2
Min. 82
Theoretical displacement (cm3/rev)
Max. 106.2
Rated pressure (MPa {kg/cm2}) 37.3 {380}
Min. 2,579
Rated speed (rpm)
Max. 1,322
Brake releasing pressure (MPa {kg/cm2}) 1.18 {12}
Travel speed selector pressure (MPa {kg/cm2}) 0.78 {8.0}
10-146 HB215LC-2
Travel motor
Operation of travel motor (HB205-C400-044-K-00-A)

Travel speed at low-speed setting (motor swash plate angle is at maximum)
• When the solenoid valve is de-energized, the pilot pressure oil from the self-pressure reducing valve does
not flow to port (P).
• Regulator valve (9) is pushed to the right by spring (10).
• The pressurized oil flowing from the control valve to end cover (8) through check valve (22) is stopped by
regulator valve (9).
• The fulcrum (a) of rocker cam (4) is located eccentric to the point of action (b) for the resultant force of
piston thrusts of cylinders (6).
• The resultant force of piston thrusts acts on rocker cam (4) as a moment that tilts the rocker cam toward
the maximum swash plate angle position.
• The pressurized oil in regulator piston (15) flows through orifice (c) in regulator valve (9), and is drained
into the motor case.
• Rocker cam (4) reaches the maximum swash plate angle position, thus, the motor capacity is maximized
and the travel speed is set to low-speed setting.
HB215LC-2 10-147
Travel motor
Travel speed at high-speed setting (motor swash plate angle is at minimum)
• When the solenoid valve is energized, the pilot pressure oil from the self-pressure reducing valve flows to
port (P).
• Regulator valve (9) is pressed to the left.
• The pressurized oil from the control valve flows through passage (d) of regulator valve (9), and enters
regulator piston (15).
• Regulator piston (15) is pressed to the right.
• Rocker cam (4) tilts toward the minimum swash plate angle position. The motor capacity is minimized and
the travel speed is set to high-speed setting when the rocker cam reaches the position.
10-148 HB215LC-2
Travel motor
Parking brake operation (HB205-C4A0-044-K-00-A)

When starting travel
• When the travel lever is operated, the pressurized oil from the pump acts on counterbalance valve spool
(19) to make the parking brake circuit.
• The oil flows into chamber (e) of brake piston (12), compresses spring (11), and pushes piston (12) to the
left.
• Since the force pressing plate (13) and disc (14) against each other is eliminated, they are separated and
the brake is released.
HB215LC-2 10-149
Travel motor
When stopping travel
• When the travel lever is returned to NEUTRAL, counterbalance valve spool (19) returns to the neutral
position, and the parking brake circuit is blocked.
• The pressurized oil in chamber (e) of brake piston (12) is drained to the case through orifice (f) of brake
piston (12).
• Brake piston (12) is pressed to the right by spring (11).
• Plate (13) and disc (14) are pressed against each other, and the brake is applied.
• When brake piston (12) is returned, the flow of pressurized oil is restricted by slow return valve (22).
• This makes a delay in the application of the parking brake. The parking brake is applied after the machine
has stopped.
10-150 HB215LC-2
Travel motor
Brake valve (ALL-C4Q0-041-K-00-A)
• Brake valve is comprised of suction safety valves (18A) and (18B), and counterbalance valve (18).
Counterbalance valve (PC220-C4N0-042-K-00-A)
Function
• 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.
• Traveling 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.
• 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).
HB215LC-2 10-151
Travel motor
Operation (PC-C4N0-044-K-00-A)
Operation when pressurized oil is supplied
• When the travel lever is operated, the pressurized oil is supplied from the control valve to port (PA).
• The oil opens suction safety valve (18A), and then flows from motor inlet port (MA) to motor outlet port
(MB).
• Since the motor outlet circuit is blocked by suction safety valve (18B) and spool (19), the pressure of the
supply side circuit increases.
10-152 HB215LC-2
Travel motor
• The pressurized oil of the supply side circuit flows through orifices (E1) and (E2) of spool (19) to chamber
(S1).
• When the pressure in chamber (S1) becomes higher than the spool selector pressure (reaction force of
spring (20)), spool (19) is pushed to the right.
• Both motor outlet port (MB) and port (PB) are connected to outlet passage (B1). As the result, the motor
outlet side opens and the motor rotates.
HB215LC-2 10-153
Travel motor
Braking while travelling downhill
• When the machine almost run out of control during downhill travel, the motor runs idle and the pressure of
the inlet side circuit decreases.
• The pressure in chamber (S1) decreases through orifices (E1) and (E2).
• When the pressure in chamber (S1) becomes lower than the spool selector pressure, spool (19) is
returned to the left by the reaction force of spring (20) and outlet passage (B1) is throttled.
• The pressure of the motor outlet side circuit increases and rotational resistance is generated in the motor,
preventing the machine from running out of control.
• Spool (19) moves to a position where the two forces acting on the spool balance with each other; one is
the force exerted by the pressure in the motor outlet port and the other is the sum of the force due to
machine's own weight and the force exerted by the pressure in the motor inlet port.
• Narrowing down the motor outlet side circuit in this way allows the machine to travel at a speed that
matches the pump discharged volume.
10-154 HB215LC-2
Travel motor
Suction safety valve (PC220-C660-042-K-00-A)
Function
• While the machine is stopped (or when it is travelling downhill), the counterbalance valve blocks the
passage between the inlet and outlet circuits of the motor.
• Since the motor is rotated by inertial force, the pressure in the motor outlet port is abnormally increased,
potentially causing damage to the motor and piping.
• The safety valve releases this abnormal pressure to the inlet port of the motor to prevent damage of the
equipment.
Operation (PC-C660-044-K-00-A)
When machine stops traveling (or traveling downhill) (when motor rotating clockwise)
• When the travel lever is set to NEUTRAL position, pressure (PA) in the motor inlet port decreases and the
pressure in chamber (S1) also decreases.
• When pressure drops below the changeover pressure of spool (19), spool (19) is pushed to the left by
reaction force of sprig (20) and narrows outlet passage (B1).
• Since inertial force maintains motor rotation, pressure (MB) of the outlet port side circuit increases.
HB215LC-2 10-155
Travel motor
• The pressurized oil pushes open check valve (17) and flows to the inlet side circuit on the opposite side
through notch (A1) of spool (19).
• If the pressure becomes higher than the set pressure of suction safety valve (18A), poppet (1) opens.
• When motor rotates counterclockwise, it operates reverse for clockwise rotation.
When starting travel (or when traveling normally)
• When the travel lever is operated, the pressurized oil from the pump moves spool (19) to the right.
• The pressurized oil flows to suction safety valve (18B) through check valve (16) and port (A2).
• Since the pressurized oil flowing through the circuit is throttled at notch (20), the pressure difference
between the inlet side and outlet side increases.
• The pump pressure rises and the large drawbar pull is obtained.
10-156 HB215LC-2
PPC valve
PPC valve (ALL-CW10-001-P-00-A)

Work equipment and swing PPC valve (PC-PL28-041-K-00-A)
HB215LC-2 10-157
PPC valve
L.H. work equipment control lever

P1: To control valve (arm OUT port)
P2: To control valve (arm IN port)
P3: To control valve (LEFT swing port)
P4: To control valve (RIGHT swing port)
R.H. work equipment control lever

P1: To control valve (boom LOWER port)
P2: To control valve (boom RAISE port)
P3: To control valve (bucket CURL port)
P4: To control valve (bucket DUMP port)
T: To hydraulic oil tank
10-158 HB215LC-2
PPC valve
HB215LC-2 10-159
PPC valve
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Valve body
9. Filter
Operation (PC-PL28-044-K-00-A)
When valve is in neutral
• Ports (A) and (B) of the valve and ports (P1) and (P2) of the PPC valve are connected respectively
through fine control hole (f) of spool (1) to drain chamber (D).
10-160 HB215LC-2
PPC valve
When valve is in fine control range
(neutral to fine control range)
• When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downward.
• Almost at the same time when fine control hole (f) is disconnected from drain chamber (D), it is connected
to pump pressure chamber (PP).
• The pilot pressure oil of main pump is transmitted from port (P1) to port (A) through fine control hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the stroke of the control lever.
• The pressure in port (P1) also increases in proportion to the stroke of the control lever.
• Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the return spring of the control valve spool.
HB215LC-2 10-161
PPC valve
(when control lever is returned)
• When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the pressure
in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• When the pressure in port (P1) decreases too much, spool (1) is pushed down by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber
(PP) almost at the same time.
• The pump pressure is supplied until the pressure in port (P1) recovers to the pressure corresponding to
the lever position.
• When the spool of control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
chamber (B) to replenish the port with pressurized oil.
10-162 HB215LC-2
PPC valve
When control lever is fully operated
• Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1).
(PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) through fine control hole (f') into drain chamber (D).
HB215LC-2 10-163
PPC valve
Travel PPC valve (PC-C6V0-041-K-00-A)

P1: To control valve (L.H. travel REVERSE port)
P2: To control valve (L.H. travel FORWARD port)
P3: To control valve (R.H. travel REVERSE port)
P4: To control valve (R.H. travel FORWARD port)
10-164 HB215LC-2
PPC valve
1. Plate
2. Case
3. Piston
4. Seal
5. Spool
6. Damper
HB215LC-2 10-165
PPC valve
Operation (PC-C6V0-044-K-00-A)
When valve is in neutral
• Ports (A) and (B) of the valve and ports (P1) and (P2) of the PPC valve are connected respectively
through fine control hole (f) of spool (1) to drain chamber (D).
10-166 HB215LC-2
PPC valve
(neutral to fine control range)
• When piston (4) is pushed by lever (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downwards.
• Almost at the same time when fine control hole (f) is disconnected from drain chamber (D), it is connected
to pump pressure chamber (PP).
• The pilot pressure of control pump is transmitted from port (P1) to port (A) through fine control hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the stroke of the control lever.
• The pressure in port (P1) also increases in proportion to the stroke of the control lever.
• Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the return spring of the control valve spool.
HB215LC-2 10-167
PPC valve
(when control lever is returned)
• When lever (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the
pressure in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• When the pressure in port (P1) decreases too much, spool (1) is pushed down by metering spring (2).
(PP) almost at the same time.
• The pump pressure is supplied until the pressure in port (P1) recovers to the pressure corresponding to
the lever position.
• When the spool of control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
chamber (B) to replenish the port with pressurized oil.
10-168 HB215LC-2
PPC valve
When control lever is fully operated
• Lever (5) pushes down piston (4), and retainer (9) pushes down spool (1).
(PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) through fine control hole (f') into drain chamber (D).
HB215LC-2 10-169
PPC valve
1st-line attachment PPC valve (with EPC valve) (PC200_10-PL29-041-K-00-A)
(Machines ready for installation of attachment)

a For explanation of operation, see "Work equipment and swing PPC valve".
10-170 HB215LC-2
PPC valve
HB215LC-2 10-171
PPC valve

P1: To control valve (service valve 1 port)
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. EPC valve
10-172 HB215LC-2
PPC valve
EPC valve (PC200_10-PL2B-041-K-00-A)


C: To PPC valve (R.H. attachment)
1. Valve body
2. Spool
3. Spring
4. Coil
5. Plunger
6. Push pin
7. Connector
HB215LC-2 10-173
PPC valve
Function (PC-PL2B-042-K-00-A)
• The EPC valve consists of the proportional solenoid part and the hydraulic valve part.
• When a signal current (i) from the pump controller is received, the EPC output pressure proportional to the
amperage of current is generated and outputted to the control valve.
10-174 HB215LC-2
PPC valve
Operation (PC200_10-PL2B-044-K-00-A)
When signal current is zero amp. (coil is de-energized)
• Since the signal current from the controller does not flow through coil (4), coil (4) is de-energized.
• Spool (2) is pushed to the left by spring (3).
• Port (P) is blocked, so the pressurized oil from the front pump does not flow to the control valve.
• The pressurized oil from the control valve is drained to the tank through port (C) and port (T).
HB215LC-2 10-175
PPC valve
• When minute signal current flows through coil (4), coil (4) is energized and the thrust pushing plunger (5)
lightward is generated.
• Push pin (6) pushes spool (2) to the light, and the pressurized oil from port (P) flows to port (C).
• The pressure in port (C) increases and the combined force of the force applied on surface (a) of spool (2)
and the reaction force of spring (3) become larger than the thrust of plunger (5).
• Spool (2) is pressed to the left, so port (P) is disconnected from port (C) and port (C) is connected to port
(T).
• Spool (2) moves to a position where the thrust of plunger (5) is equal to the total of the force exerted by the
pressure in port (C) and the force of spring (3).
• Thus, the circuit pressure between the EPC valve and the control valve is controlled in proportion to the
amperage of the signal current.
10-176 HB215LC-2
PPC valve
• Coil (4) is energized when the signal current flows through coil (4).
• As the signal current is the maximum, the thrust of plunger (5) is also maximized.
• Spool (2) is pushed to the light by push pin (4).
the EPC valve and control valve is maximized.
• Port (T) is blocked, so no pressurized oil flows to the hydraulic tank.
HB215LC-2 10-177
PPC valve
2nd-line attachment PPC valve (PC-PL2A-041-K-00-A)

a For details of operation, see "Work equipment and Swing PPC valve".

10-178 HB215LC-2
PPC valve
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Valve body
HB215LC-2 10-179
Solenoid valve
Solenoid valve (HB205-PQPT-041-K-00-A)
a The figure is for the machines ready for installation of attachment.
P1: From self-pressure reducing valve

A1: To PPC valve
10-180 HB215LC-2
Solenoid valve
A2: To control valve [port (PX1), (PX2)]

A3: To swing motor [port (B)]
A4: To travel motor [port (P)]
A5: To control valve [port (PST)]
A6: To attachment circuit selector valve
ACC: To accumulator (for PPC circuit)
1. PPC lock solenoid valve
2. 2-stage relief solenoid valve
5. Travel junction solenoid valve
6. Attachment selector solenoid valve (for the machines ready for installation of attachment)
Solenoid valve
7. Connector
8. Push pin
9. Coil (ON/OFF type)
10. Valve spool
11. Block
12. Spring
Check valve
13. Plug
14. Plunger
Operation (ALL-PQPT-044-K-00-A)
Operation of check valve
• This valve is installed between port (P) and PPC solenoid valve. When the engine is stopped, the reaction
force of spring (2) pushes plunger (1) to the left and port (ACC) and port (P) is disconnected, thus holding
the pressure in the accumulator.
• When the engine is running, the pilot pressure in port (P) pushes plunger (1) to the right, and port (P) and
port (ACC) are interconnected.
HB215LC-2 10-181
Solenoid valve
Operation of solenoid valve
When solenoid valve is "de-energized" (circuit is disconnected)
• Coil (1) is de-energized when the signal current does not flow to coil (1).
• Spool (2) is pushed back to the left with the reaction force of spring (3).
• Port (P) and port (A) are disconnected and pilot oil does not flow from port (A) to the actuator. At the same
time, port (T) opens and oil from actuator is drained to the hydraulic tank.
When solenoid valve is "energized" (circuit is interconnected)
• Coil (1) is energized when the signal current flows to coil (1).
• Accordingly, spool (2) is pushed to the right by push pin (4).
• Port (P) and port (A) are open and pilot oil flows from port (A) to the actuator. At the same time, port (T)
closes and oil from actuator does not flow to the hydraulic tank.
10-182 HB215LC-2
Attachment circuit selector valve (for high pressure
circuit)
Attachment circuit selector valve (for high pressure circuit) (ALL-PQJ5-041-K-00-A)
PI: From attachment circuit selector solenoid valve

ACC: To accumulator
ATT: To attachment
TS: To hydraulic tank
1. Spool
Function (PC220-PQJ5-042-K-00-A)
• When the breaker is installed, main circuit from the control valve to the breaker and accumulator are
interconnected with this valve.
• When the other attachment (crusher etc.) is installed, main circuit and accumulator are blocked with this
valve.
Operation (ALL-PQJ5-044-K-00-A)
When attachment other than breaker is installed
HB215LC-2 10-183
Attachment circuit selector valve (for high pressure
circuit)
• Spool (1) is pressed to the left side with the force of spring (2).
• Since port (ATT) and port (ACC) are disconnected, no oil flows into the accumulator.
When breaker is installed
• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and
consequently spool (1) moves to the right stroke end.
• Since port (ATT) and port (ACC) are interconnected, oil flows into the accumulator and absorbs the oil
pulsation.
10-184 HB215LC-2
Attachment circuit selector valve (for low pressure
circuit)
Attachment circuit selector valve (for low pressure circuit) (PC-PQJ3-041-K-00-A)
PI: From attachment circuit selector solenoid valve

V: To control valve attachment 1 port
ACC: To accumulator
ATT: To attachment
TS: To hydraulic tank
1. Spool
Function (PC220-PQJ3-042-K-00-A)
• When the breaker is installed, return oil from the breaker is directly drained to the hydraulic tank bypassing
main valve with this valve.
• When the other attachment (crusher etc.) is installed, attachment circuit and main valve are
interconnected with this valve.
HB215LC-2 10-185
circuit)
Operation (PC-PQJ3-044-K-00-A)
When attachment other than breaker is installed
• Spool (1) is pressed to the left by the force of spring (2).

• Port (ATT) is interconnected to port (V) and is disconnected from port (T). Thus, the attachment is
interconnected to the control valve.
10-186 HB215LC-2
circuit)
When breaker is installed
• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and spool (1)
moves to the right to its stroke end.
• Port (ATT) is disconnected from port (V) and is interconnected to port (T).
• The pressurized oil returning from the breaker returns directly to the hydraulic tank via port (T) without
passing through the control valve.
HB215LC-2 10-187
Center swivel joint
Center swivel joint (HB205-J8E0-041-K-00-A)
10-188 HB215LC-2
Center swivel joint
A1: To L.H. travel motor (port (PB))

A2: From control valve (L.H. travel FORWARD port)
B1: To L.H. travel motor (Port (PA))
B2: From control valve (L.H. travel REVERSE port)
C1: To R.H. travel motor (Port (PA))
C2: From control valve (R.H. travel FORWARD port)
D1: To R.H. travel motor (port (PB))
D2: From control valve (R.H. travel REVERSE port)
E1: To L.H. and R.H. travel motor (port (P))
E2: From travel speed increase solenoid valve
DR1: From L.H. and R.H. travel motor (port (T))
DR2: To hydraulic tank
1. Cover
2. Slipper seal
3. Rotor
4. Dust seal
5. Oil seal
6. Cover
7. Shaft
8. O-ring
HB215LC-2 10-189
Accumulator
Accumulator (PC-PL40-001-K-00-A)
PPC accumulator (PC-PL40-041-K-00-A)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications (PC-PL40-030-K-00-A)
Gas to be used Nitrogen gas

Volume of gas (cc) 300
Charged pressure 1.18 {12}
(MPa {kg/cm2}) (at 80°C)
Max. operating pressure
6.86 {70}
(MPa {kg/cm2})
Function (PC-PL40-042-K-01-A)
• This accumulator is installed to the solenoid valve. Even if the engine is stopped while the work equipment
is raised, pilot oil pressure can be supplied to the work equipment control valve with the pressure of the
compressed nitrogen gas in the accumulator to operate the spool and lower the work equipment by its
own weight.
10-190 HB215LC-2
Work equipment
Work equipment (ALL-L000-001-K-00-A)
Work equipment (PC-L410-041-K-00-A)
1. Bucket
2. Bucket link
3. Bucket cylinder
4. Arm
5. Arm cylinder
6. Boom
7. Boom cylinder
HB215LC-2 10-191
Work equipment shim
Work equipment shim (PC220-L413-040-K-00-A)

Outline
• There are two types of the work equipment shims; one is the iron shims and the other is the plastic shims.
• The work equipment shims are inserted so that the clearance in each joint of the work equipment will be
the standard value.
Function
Iron shims
• The iron shims are primarily inserted in the parts that need to be greased every 100 hours.
• One purpose of the iron shims is to reduce the play of the work equipment in the lateral direction.
a The shims need to be inserted on only the right or left side and do not need to be inserted on the
adjustment side, depending on the adjusting quantity of the clearance.
Plastic shims
• The plastic shims are primarily inserted in the parts that need to be greased every 500 hours.
• The purposes of the plastic shims are to reduce the play of the work equipment in the lateral direction and
prevent squeaks and scuffing caused by rubbing of the steel parts at the end faces of the joint portions.
• Combined with the greasing interval extension bushings, the plastic shims prevent squeaks caused by
lack of grease and extend the greasing intervals.
• The plastic shims are inserted in every contact face of each part so that the steel parts at the end faces of
the joint portion will not come in contact with each other.
a Combined with the greasing interval extension bushings and dust seals, the plastic shims extend the
greasing interval to 500 hours.
10-192 HB215LC-2
Bucket play adjustment shim
Bucket play adjustment shim (PC220-LBKB-040-K-00-A)

Outline
• The separated iron shims are used for the connection of arm and bucket.
• By adjusting the number of shims, play at connecting part can be adjusted.
a Play can be reduced by deleting some shims when the play becomes large.
HB215LC-2 10-193
Cab mount and cab tipping stopper
Cab and its attachments (ALL-K000-001-K-00-A)
Cab mount and cab tipping stopper (PC-K138-041-K-00-A)
1. Front damper
2. Rear damper
3. Cab tipping stopper
Structure
• 4 dampers are located in front and rear of cab (2 each), and fix cab and floor frame onto revolving frame.
• Oil-filled damper is used to absorb vibration.
• Cab tipping stopper (3) installed at a place in the rear section aims to secure the cab when the machine
tips over.
• As shown in following table, various dampers are available upon its mounting location.
Location of damper Bent of craw Color of identifying seal
Front left Not bent Yellow
Front right Bent Blue
Rear left Not bent Yellow
Rear right Not bent Yellow
10-194 HB215LC-2
ROPS cab
ROPS cab (PC-K000-041-K-00-A)
a ROPS: Abbreviation for Roll-Over Protective Structure
1. Front window
2. Windshield wiper
3. Head lamp
4. Ceiling window
5. KOMTRAX communication antenna
6. KOMTRAX GPS antenna
7. Radio antenna
8. Door
9. Mirror
Function (PC220-K000-042-K-00-A)
• ROPS cab is a structure which protects the operator fastening a seat belt from being crushed when the
machine tips over.
HB215LC-2 10-195
Electrical control system
Electrical system (ALL-RA1D-001-K-01-A)
Electrical control system (PC220-C050-001-K-00-A)
General system drawing (HB205-C050-051-K-01-A)
10-196 HB215LC-2
HB215LC-2 10-197
Engine control function (PC220-AK60-042-K-00-A)
1. Battery disconnect switch

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Engine shutdown secondary switch
9. Lock lever
10. PPC lock switch
11. Starting motor cut-off relay (for PPC lock)
12. Starting motor cut-off relay (for personal code)
13. Fuel control dial
14. Safety relay
15. Starting motor
16. Fuel supply pump
17. Sensors
18. Machine monitor
19. KOMTRAX terminal
20. Pump controller
Function
• The neutral safety circuit is employed to secure safety when the engine is started.
a The engine does not start until the lock lever is set to the "LOCK" position.
• The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX
terminal receives an engine cut command issued through external operation.
• When you cannot stop the engine due to stuck starting switch (6), engine shutdown secondary switch (7)
is usable for stopping the engine.
Starting the engine

• If starting switch (6) is turned to "ON" position , engine controller (8) sends command current to fuel supply
pump (16).
10-198 HB215LC-2
For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an
electrical failure occurs.
• If starting switch (6) is turned to "START" position when lock lever (9) is in the "LOCK" position, starting
current is supplied to starting motor (15) and the engine starts.
If lock lever (9) is in the "FREE" position, starting motor cut-off relay (11) cuts off the starting current to
starting motor (15), thus the engine does not start. This is the neutral safety mechanism.
• Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the
signal to machine monitor (18).
Machine monitor (18) causes starting motor cut-off relay (12) to cut off the starting current to starting motor
(15), therefore the engine does not start.
Engine speed control

• Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8)
selects lower throttle signal, and sends command current to fuel supply pump (16).
Fuel supply pump (16) adjusts the fuel injection rate to control the engine speed.
Engine stop
• If starting switch (6) is turned to "OFF" position, the current from ACC terminal of starting switch (6) to
engine controller (8) is cut off, and consequently the command current to fuel supply pump (16) is cut off.
Fuel supply pump (16) stops fuel feed, decreasing the engine speed until the engine stops.
Stopping the engine with engine shutdown secondary switch

• If engine shutdown secondary switch (7) is turned to "Stop Engine" position, the current from ACC
terminal of starting switch (6) to engine controller (8) is forcibly cut off.
Above induces the same state as when starting switch (6) is turned to "OFF" position, stopping the engine.
HB215LC-2 10-199
Engine and pump combined control function (HB205-C3W0-042-K-01-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resister for PC–EPC valve
7. Pump controller
9. Machine monitor
10. Emergency pump drive switch
13. Various sensors
16. One-touch power maximizing switch
17. Front pump oil pressure sensor
18. Rear pump oil pressure sensor
10-200 HB215LC-2
19. Oil pressure sensor

20. Oil pressure switch
21. Front pump
21a. Servo
21b. LS valve
21c. PC valve
22. Rear pump
22a. Servo
22b. LS valve
22c. PC valve
23. Control valve
23a. Self-pressure reducing valve
23b. Merge-divider valve
23c. Travel junction valve
24 Front pump PC-EPC valve
25. Rear pump PC-EPC valve
26. LS-EPC valve
27. Inverter (hybrid controller) (*1)
*1:
Input/output signal
a. Front pump PC-EPC valve drive signal
b. Rear pump PC-EPC valve drive signal
c. Solenoid valve ground
d. CAN signal
e. LS-EPC valve drive signal
f. Swash plate sensor signal
g. Oil pressure sensor signal
h. One-touch power maximizing switch signal
i. Oil pressure switch signal
j. 1st throttle signal
k. Fuel supply pump control signal
l. Various sensor signals
HB215LC-2 10-201
Function
• This function allows the operator to select one from the 6 working modes of P, E, L, ATT/P, ATT/E, and B
by using the working mode selector switch on the machine monitor. The operator can select the optimum
engine torque (T) and pump absorption torque in accordance with the type of operation. When "Without
Attachment" is selected at the initial setting of service mode, 4 modes of P, E, L and B are available.
• The pump controller calculates the pump absorption upper limit torque and necessary engine output in
accordance with the engine speed set with the working mode and fuel control dial, the operating distance
of the lever, the operation pattern, the actual engine speed, and the load to control the output command to
the engine controller and the pump so that the engine speed is kept around the matching point set in each
mode even when heavy load is applied.
• When the engine speed decreases, the pump controller reduces the pump absorption torque to prevent
the engine from stalling.
10-202 HB215LC-2
Control method in each mode

P, E, ATT/P, and ATT/E modes
Matching point
Working mode Matching point
P and ATT/P 99.6 kW / 1,700 rpm
(While operating) {134 HP / 1,700 rpm}
E, ATT/E 76.6 kW / 1,560 rpm
(While operating) {103 HP / 1,560 rpm}
• In mode P, E, ATT/P, or ATT/E, the engine speed is kept around the max. matching point set in each mode
corresponding to lever input and the load.
• When the load is light, the engine runs in the low-speed range. As the load increases, the engine speed is
increased and the torque is increased to a matching point where it is balanced with pump absorption
upper limit torque (PT). [(1) in graph]
• If the load increases further, the engine speed decreases. [(2) in graph]
• The controller decreases pump absorption upper limit torque (PT) to reduce the load applied to the engine.
[(3) in the graph]
• As the load on the engine decreases, the engine speed increases. [(4) in the graph]
• The controller increases pump absorption upper limit torque (PT) to keep the engine speed at around the
matching point. [(5) in the graph]
• The controller controls the engine so that the engine matching speed (Nm) is decreased when the load is
light (low flow rate and low torque) to improve the fuel economy. [(6) in the graph]
HB215LC-2 10-203
10-204 HB215LC-2
B and L mode
Working mode Partial output
B 77.5%
L 74%
Matching point
Working mode Matching point
77.2 kW / 1,655 rpm
B
{103 HP / 1,655 rpm}
73.55 kW / 1,650 rpm
L
{98.6 HP / 1,650 rpm}
• In B mode or L mode, engine output is kept constant.
• The controller controls pump absorption upper limit torque (PT) so that the engine torque is kept constant
along the equal engine horsepower curve.
HB215LC-2 10-205
Control function when traveling

• When the machine travels in P mode or ATT/P mode, engine speed (N) increases.
• When the machine travels in E, ATT/E, or B mode, the working mode is kept as it is, and the pump
absorption torque and engine speed (N) increase to the respective values during travel in P mode.
• When the machine travels in L mode, the working mode and engine speed (N) are kept as they are, and
the pump absorption torque increases.
10-206 HB215LC-2
Pump and valve control function (HB205-C3W1-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
13. Various sensors
16. Front pump
16a. Servo
16b. LS valve
HB215LC-2 10-207
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
18d. Main relief valve
18e. Variable back pressure valve
21. LS-EPC valve
22. Merge-divider EPC valve (for main spool)
23. Merge-divider EPC valve (for LS spool)
26. Variable back pressure solenoid valve
*1:
Input/output signal
d. CAN signal
e. LS-EPC valve drive signal
f. Swash plate sensor signal
g. Merge-divider EPC valve (for main spool) drive signal
h. Merge-divider EPC valve (for LS spool) drive signal
i. Travel junction solenoid valve drive signal
j. 2-stage relief solenoid valve drive signal
k. Variable back pressure solenoid valve drive signal
l. 1st throttle signal
m. Fuel supply pump control signal
n. Various sensor signals
10-208 HB215LC-2
Function
• The LS control function, cut-off function, and 2-stage relief function enable the machine to maintain the
optimum matching under various working conditions.
LS control function
• Depending on the operating states of the actuators, the controller shifts the pump discharged volume
change point (LS set differential pressure (DLS) ) of the LS valve by changing the output pressure from
the LS-EPC valve to LS valve.
• The start-up time of the pump discharge is optimized and the combined operation and fine control
performance are improved.
A: 0 MPa {0 kg/cm2}
B: EPC pressure (Psig) = 1.8 MPa {18 kg/cm2}
Cut-off function (P, E, ATT/P, and ATT/E mode)

• This function limits engine output and decreases oil flow at relief, thus improve fuel consumption.
Condition to actuate cut-off function
The mean value of oil pressure sensor of front pump and rear pump is 32.5 MPa {332 kg/cm 2} or more under
the condition that one-touch power maximizing function is disabled.
However, it does not operate when machine is traveling or swing lock switch is "ON".
A: PC-EPC current at cut-off
HB215LC-2 10-209
Cut-off function (B and L mode)

• It increases PC-EPC current (J) and decreases oil flow at relief, thus improve fuel consumption.
Condition to actuate cut-off function
The mean value of oil pressure sensor of front pump and rear pump is 27.9 MPa {285 kg/cm 2} or more under
the condition that one-touch power maximizing function is disabled.
However, it does not operate when machine is traveling or swing lock switch is "ON".
A: PC-EPC current at cut-off

2-stage relief function
• When the actuating condition of 2-stage relief function is satisfied, relief pressure under operation is
increased.
Actuating condition of 2-stage relief function Relief pressure
• During travel 34.8 MPa
• Swing lock switch is "ON" {355 kg/cm2}
• When boom LOWER operation is performed O
• When one-touch power maximizing function is
actuated 37.2 MPa
• When L mode is selected {380 kg/cm2}
Variable back pressure function

• The set pressure of the back pressure valve varies depending on the operating conditions of the machine.
Operating conditions Setting of back pressure valve
Travel High-pressure set
Other than travel Low-pressure set
10-210 HB215LC-2
One-touch power maximizing function (HB205-PT23-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
13. Various sensors
14. One-touch power maximizing switch
17. Front pump
17a. Servo
17b. LS valve
17c. PC valve
18. Rear pump
18a. Servo
18b. LS valve
18c. PC valve
HB215LC-2 10-211
19. Control valve

19d. Main relief valve
*1:
Input/output signal
d. CAN signal
e. 2-stage relief solenoid valve drive signal
f. Pump oil pressure sensor signal
g. One-touch power maximizing switch signal
h. 1st throttle signal
i. Fuel supply pump control signal
j. Various sensor signals
Function
• This function increases the power for certain period by operating one-touch power maximizing switch
which is installed on the knob of L.H. work equipment control lever.
• It is used for digging operation such as digging up of rock etc., which requires larger digging force for
certain period.
• When the one-touch power maximizing switch is pressed while the load pressure is high at P mode, E
mode, ATT/P mode or ATT/E mode, hydraulic force increases approx. 7% and output increases approx.
15%, thus the digging force increases.
• Each function is automatically set as follows.
Function Setting
Engine and pump combined control Matching at rated horsepower point
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Cut-off function Cancellation
a This function continuously increases the power as long as the one-touch power maximization switch is
pressed. This function is automatically cancelled in approx. 8.5 seconds even if the switch is kept pressed.
10-212 HB215LC-2
Auto-deceleration function (HB205-AF60-042-K-00-A)
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Various sensors
9. Main pump
10. Control valve
*1:
Input/output signal
a. CAN signal
b. Oil pressure sensor signal
c. Oil pressure switch signal
d. 1st throttle signal
e. Fuel supply pump control signal
f. Various sensor signals
HB215LC-2 10-213
Function
• When all the control levers are set to NEUTRAL positions while waiting for a dump truck or next work, the
engine speed decreases to the control speed automatically to improve the fuel economy and reduce the
noise.
• If any control lever is operated, the engine speed returns immediately to the speed set with the fuel control
dial.
Operation
When all control levers is in NEUTRAL
• While the engine is running at approx. 1,250 rpm or higher speed, when all the control levers are set to
NEUTRAL position, engine speed is decreased to approx. 1,250 rpm. If such state continues for 4
seconds or more, engine speed is kept at the control speed (approx. 700 rpm) until any control lever is
operated.
• If the capacitor voltage decreases during deceleration, the engine speed increases to approximately1,150
rpm to charge the capacitor. After charging the capacitor, the engine speed decreases to approximately
700 rpm.
When control lever is in operation

• While the engine speed is kept at the control speed (approximately 700 rpm), when any control lever is
operated, the engine speed increases immediately to a level corresponding to the operation distance of
the lever.
A: All work equipment control levers in "NEUTRAL" position

B: Any work equipment control lever is "operated"
C: Engine speed when machine is in operation
D: Engine control speed (approximately 1,250 rpm)
E: Engine speed when deceleration is operated (approximately 700 rpm)
F: Engine speed when generating power (approximately 1,150 rpm)
G: 4 sec.
H: Max. 2 sec.
J: Max. 1 sec.
Engine speed when auto-deceleration is operated
Engine speed
Working mode
First stage Second stage
P
E
1,250 rpm 700 rpm
ATT/P
ATT/E
L Without deceleration function
B 1,250 rpm 1,150 rpm
10-214 HB215LC-2
Engine automatic warm-up function (HB205-AP13-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
10. Air conditioner unit
14. Various sensors
15. Hydraulic oil temperature sensor
16. Front pump
16a. Servo
16b. LS valve
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
HB215LC-2 10-215

Input/output signal
d. CAN signal
e. Hydraulic oil temperature signal
f. 1st throttle signal
g. Fuel supply pump control signal
h. Various sensor signals
10-216 HB215LC-2
Function
• When the coolant temperature is low after the engine is started, the engine speed is increased
automatically to warm up the engine.
• There are 2 kinds of engine automatic warm-up functions; "Heater warm-up" and "Normal warm-up",
depending on the purpose.
• The purpose of the heater warm-up is to increase the coolant temperature to improve the effect of the
heat.
• The purpose of the normal warm-up is to heat the engine to prevent damage on the engine caused by low
temperature.
Operating conditions 1
Machine specification: Air conditioner specification
Air conditioner: Blower "ON"
Coolant temperature: Below 50ºC
Ambient temperature: Below 5ºC
O O
When any of operating conditions 1 is not satisfied When all of operating conditions 1 are satisfied
Heater warm-up is disabled (normal warm-up) Heater warm-up is enabled
Operating conditions 2
(Operates when all of the following conditions are O
satisfied)
Coolant temperature: Below 30ºC
O
Engine speed: Max. 1,200 rpm
O O
Operation Operation
Engine speed: 1,200 rpm Engine speed: Min. 1,400 rpm
O O
Condition for cancellation Condition for cancellation
(Canceled when any of the following conditions is (Canceled when any of the following conditions is
satisfied) satisfied)
Coolant temperature: Min. 30ºC
Automat-
ic Warm-up operation time: Min. 10
minutes Coolant temperature: Min. 55ºC
Fuel control dial: Held at 70% or more of Ambient temperature: Min. 10°C
Manual High idle (MAX) position for 3 seconds or
more.
O O
Release
Engine speed: Any
HB215LC-2 10-217
Overheat prevention function (HB205-B717-042-K-00-A)

Overheat prevention function of engine and hydraulic component
a For the system circuit diagram, see "Engine automatic warm-up function".
• When the coolant temperature or the hydraulic oil temperature increases too high during operation, the
pump load is reduced and the engine speed is lowered to prevent overheat and protect the engine and
hydraulic components.
Operating condition Operation and remedy Condition for cancellation

Hydraulic oil temperature:
Below 93°C
Working mode: Travel o Engine speed: Kept as it is o • When above condition is
Hydraulic oil temperature: Pump discharge: Throttled satisfied, state before
Min. 95°C operation is restored
(automatic restoration).

Working mode: P, E, ATT/P, Coolant temperature: Below
Engine speed: Kept as it is 100ºC
ATT/E
Pump discharge: Throttled Hydraulic oil temperature:
Coolant temperature: Min. o o
• Pump absorption torque is Below 100°C
100ºC
lowered and engine load is • When above condition is
or
reduced according to the satisfied, state before
Hydraulic oil temperature: torque control signal. operation is restored
Min. 100°C (automatic restoration).

Coolant temperature: Below
Working mode: P, E, ATT/P,
Engine speed: Kept as it is 102ºC
ATT/E
Pump discharge: Throttled Hydraulic oil temperature:
Coolant temperature: Min. o o
102ºC • Pump absorption torque is Below 102°C
lowered and engine load is • When above condition is
or
reduced according to the satisfied, state before
Hydraulic oil temperature: torque control signal. operation is restored
Min. 102°C (automatic restoration).

Working mode: B mode 102ºC
Coolant temperature: Min. Engine speed: Kept as it is Hydraulic oil temperature:
102ºC o o Below 102°C
Pump discharge: Throttled
or • When above condition is
Alarm monitor: Lights up
Hydraulic oil temperature: satisfied, state before
Min. 102°C operation is restored
(automatic restoration).
10-218 HB215LC-2
Operating condition Operation and remedy o Condition for cancellation

105ºC
Working mode: All modes Hydraulic oil temperature:
Coolant temperature: Min. Engine speed: Low idle Below 105°C
105ºC Fuel control dial: Return to Low
Alarm monitor: Lights up
or idle (MIN) position.
Alarm buzzer: Sounds
Hydraulic oil temperature: • When above condition is
Min. 105°C satisfied, state before
operation is restored
(manual restoration).
Overheat prevention function of hybrid component
• This function reduces the workload on hybrid system to prevent overheat and protect hybrid components
when temperature of hybrid system becomes too high during operation.
• When this function is operated, the alarm buzzer sounds and hybrid temperature monitor lights up.
• When overheat is not prevented by this function, the components overheat, alarm buzzer sounds, the
error is displayed on the monitor, and hybrid system stops.
Turbocharger protection function (HB205-AA90-042-K-00-A)
a For the system circuit diagram, see "Engine automatic warm-up function".
• This function limits the engine speed to prevent seizure of the turbocharger when the engine speed is
increased suddenly just after the engine is started.
Operating condition Operation

o Protection of turbocharger
Engine oil pressure: Below 50 kPa {0.51 kg/cm2}
(See figure below)
A: Starting of engine
B: Turbocharger protection time (approximately 0 to 20 seconds)
C: Modulation time (approximately 1 second)
D: 500 rpm
E: Approximately 1,000 rpm
F: Engine speed corresponding to the operation
HB215LC-2 10-219
Swing control function (HB205-JA01-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Swing parking brake cancel switch
7. Swing lock switch
8. Pump controller
9. Machine monitor
12. Main pump
13. Control valve
14. Swing motor
16. Starting switch
17. Engine shutdown secondary switch
*1:
10-220 HB215LC-2
Input/output signal
a. Swing parking brake cancel switch signal
b: Swing parking brake solenoid valve drive signal
c. CAN signal
d. Swing lock switch signal
e. Oil pressure sensor signal
f. Oil pressure switch signal
g. Starting switch ACC signal
Function
Swing lock and swing parking brake function
• With the swing lock (manual) function, the operator can lock the swing at any place by setting swing lock
switch (1) to "ON" position.
• The swing parking brake (automatic) is interlocked with the swing operation and prevents hydraulic drift
after swing is stopped.
• To reduce the load on the swing device during digging work, the swing parking brake is released when the
R.H. or L.H. work equipment control lever or attachment control pedal is operated.
Swing lock
OFF ON
switch
Swing lock
Goes out Lights up
monitor
Function Swing parking brake Swing lock
• When the R.H. and L.H. work equipment • The swing parking brake operates to lock
control levers and attachment control the swing.
pedal are set to NEUTRAL, the swing • Even if the L.H. work equipment control
parking brake operates approximately 5 lever is operated to swing, the swing
seconds later. parking brake is not released and the
Operation
• When the R.H. and L.H. work equipment upper structure does not swing.
control levers or attachment control pedal
are operated, the swing parking brake is
released and the upper structure becomes
free to swing.
HB215LC-2 10-221
A: Operate work equipment control lever or attachment control pedal (Swing parking brake is "released".)
B: Set work equipment control lever or attachment control pedal to "NEUTRAL" position
C: Swing parking brake "operates"
D: Approximately 5 seconds
Swing parking brake release function
• If the swing parking brake does not operate normally and the upper structure cannot swing because of
trouble in the controller, etc., the operator can swing by releasing the swing parking brake with swing
parking brake cancel switch (2).
a: Release (when abnormal)
b: Normal (when normal)
Swing parking Released Normal
brake cancel
(When controller is abnormal) (When controller is normal)
switch
Swing lock switch ON OFF ON OFF
Swing parking brake Swing parking brake
Swing brake Swing lock operates Swing lock operates
is released operates
a When swing lock switch is set to "ON" position, the swing parking brake is not released even if swing
parking brake cancel switch (2) is set to "RELEASE (a)" position.
a If the swing parking brake is released on slope, the upper structure may swing due to its own weight. Take
care.
a Swing parking brake cancel switch (2) is momentary type. While it is set to ""RELEASE"" (a) position, the
swing lock monitor on the machine monitor flashes.
k If the swing lock is released while hybrid system is under abnormal state, there will be no function
to stop the swing.
If this operation is performed on a slope etc., upper structure swings down by its own weight and it
may cause serious accident. Accordingly, never perform this operation.
10-222 HB215LC-2
Quick warm-up function

• When swing lock switch (1) is set to "ON" position, pump cut-off function is cancelled and main relief
pressure increases.
• When the work equipment circuit is relieved with main relief pressure increased, the hydraulic oil
temperature rises fast, thus warm-up time can be shortened.
Operating condition Main relief pressure
34.8 MPa {355 kg/cm2}
• Swing lock switch: ON O
37.2 MPa {380 kg/cm2}
HB215LC-2 10-223
Travel control function (HB205-C7H1-042-K-02-A)
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Various sensors
10. Travel alarm
11. Front pump
11a. Servo
11b. LS valve
11c. PC valve
12. Rear pump
12a. Servo
12b. LS valve
12c. PC valve
13. Control valve
14. Travel motor
10-224 HB215LC-2

17. LS-EPC valve
Input/output signal
a. Oil pressure sensor signal
b. CAN signal
c. LS-EPC valve drive signal
d. Solenoid valve ground
e. Travel junction solenoid valve drive signal
f. Travel speed increase solenoid valve drive signal
g. Oil pressure sensor signal
h. Travel alarm operation signal
i. 1st throttle signal
j. Fuel supply pump control signal
k. Various sensor signals
Travel speed selector function

1. "Manual" change of travel speed
• The operator can change the travel speed by setting the travel speed selector switch to "Hi" or "Mi" or
"Lo" position to change the motor capacity.
Lo Mi Hi
Travel speed selector switch
(Low speed) (Middle speed) (High speed)
Motor flow (%) 75 70 100
Motor capacity Max. Min. Min.
Travel speed (km/h) 3.0 4.1 5.5
2. "Automatic" change of travel speed
1) Automatic change according to engine speed
• Set the engine speed to 1,500 rpm or below with the fuel control dial while traveling in "Mi", the
travel speed does not change to "Hi", but if it is set while traveling in "Hi", the travel speed changes
to"Mi" automatically.
2) Automatic change according to pump discharged pressure
• While traveling with the travel speed selector switch at "Hi" position, if the load increases on uphill
slope, etc., and the travel pressure is 30.4 MPa {310kg/cm2} or higher for 0.5 seconds or more, the
motor capacity is changed automatically and the travel speed is changed to a middle speed (a
speed equivalent to "Mi") (however, travel speed selector switch is kept at "Hi" position).
• While traveling at low speed set by the automatic travel speed change with load, when the load
decreases on a flat or downhill slope and the travel pressure is 16.7 MPa {170 kg/cm 2} or less for
0.5 seconds or more, the motor capacity is changed automatically and the travel speed is returned
to the set speed of "Hi".
HB215LC-2 10-225
A: 16.7 MPa {170 kg/cm2}

B: 30.4 MPa {310 kg/cm2}
C: 0.5 seconds or more
D: 0.5 seconds or more
Pump control function when traveling
a For details, see "Engine and pump combined control function".
Travel junction function

• When the travel lever is operated, the pilot pressure is sensed to judge if the machine is driven straight or
steered.
• When the machine is driven straight, a signal is sent to the travel junction solenoid valve to set the flow
rates to the right and left travel motors to almost the same level to prevent travel deviation and improve the
straight travel performance.
• When the machine is steered, the signal to the travel junction solenoid valve is cut out to set the flow rates
to the right and left travel motors independently to improve the travel performance during steering.
10-226 HB215LC-2
PPC lock function (PC-PX16-042-K-00-A)

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
Function
• Interlocked with the lock lever, PPC lock switch is turned off when the lock lever is moved to "LOCK"
position.
• 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 10-227
System operating lamp function (HB205-AW1Q-042-K-01-A)

2. Battery
3. Fusible link
4. Fuse box
5. System operating lamp
6. Machine monitor
8. Pump controller
9. KOMTRAX terminal
*1:
Function
• The operating condition of each controller can be checked with the system operating lamp to prevent the
abnormal end of the disconnection of the battery power supply circuit while the controllers are in
operation.
a Before shutting off the battery power supply circuit, turn the starting switch to "OFF" position, and check
that the system operating lamp goes out, then turn the battery disconnect switch to "OFF" position.
a If the battery disconnect switch is turned to "OFF" position (battery power supply circuit is OFF) while the
system operating lamp is lit, data loss error of controller may occur. Never operate the battery disconnect
switch while the system operating lamp is lit.
a The system operating lamp goes out in max. 2 minutes after the starting switch is turned to "OFF" position.
a The system operating lamp may sometimes light up while the starting switch is turned to "OFF" position
because KOMTRAX terminal may maintain its communication under this condition.
ON/OFF of system operating lamp

• Voltage of 24 V is always applied to the one end of the system operating lamp (LED).
• When any controller is in operation, the output from the controller to the system operating lamp becomes
Low (0 V). This allows electric current to flow through the diode, lighting up the system operating lamp.
• When all controllers are resting, the output from each controller to the system operating lamp becomes Hi
(24 V). The electric current does not flow through the diode, and the system operating lamp goes out.
a The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the
minute leakage of current and not an abnormal phenomenon.
• KOMTRAX terminal performs communication periodically even if the starting switch is kept in "OFF"
position, thus it starts and stops repeatedly.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the
communication state and machine stop time. So the lamp can be lit as long as approximately 1 hour.
10-228 HB215LC-2
a When you want to cut off the battery circuit for maintenance but the system operating lamp is kept lit,
turn the starting switch to "ON" position once, and then turn it to "OFF" position, and the lamp goes out
in max. 2 minutes.
After the system operating lamp goes out, turn the battery disconnect switch immediately to "OFF"
position.
HB215LC-2 10-229
Attachment flow control function (PC-PT24-042-K-00-A)
(Machine with provision for attachment)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resistor for PC-EPC valve
7. Pump controller
9. Machine monitor
13. Sensors
15. Front pump
15a. Servo
15b. LS valve
15c. PC valve
16. Rear pump
16a. Servo
16b. LS valve
16c. PC valve
17. Control valve
10-230 HB215LC-2

18. Attachment selector solenoid valve
20. Oil flow rate adjuster EPC valve for attachment
21. Front pump PC-EPC valve
23. Attachment circuit selector valve (high pressure side)
24. Attachment circuit selector valve (low pressure side)
25. Attachment
26. Accumulator
Input and output signals
c. Solenoid valve GND
d. CAN signal
e. Attachment selector solenoid valve drive signal
f. Oil flow rate adjuster EPC valve drive signal for attachment
g. Oil pressure switch signal
h. 1st throttle signal
i. Fuel supply pump control signal
j. Sensor signals
Function
• Setting of the working mode and oil flow rate on the machine monitor allows controlling the oil flow rate to
the attachment when the attachment control pedal is fully depressed.
• Attachment operation switches depending on the working mode as shown below.
Working mode Attachment operation
ATT/P, ATT/E Double-acting
B Single-acting
Auto idle stop function (HB205-AF87-042-K-01-A)
HB215LC-2 10-231

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Relay
8. Lock lever
9. PPC lock switch
10. Pump controller
11. Machine monitor
13. KOMTRAX terminal
15. Hydraulic oil temperature sensor
16. Coolant temperature sensor
Input/output signal
a. CAN signal
b. BR Signal
c. Lock lever signal
d. Various sensor signals
Function
• When the auto idle stop function is enabled and the conditions for operation are satisfied, the engine is
stopped after the set time.
• The auto idle stop function stops the engine when the pump controller sends the engine stop signal to the
engine controller.
• When the engine is stopped by the auto idle stop function while it is running at high speed, a message to
turn ON the auto-deceleration function is displayed on the machine monitor and the auto-deceleration
function is set to ON.
• The length of time when the auto idle stop function operates is set on the user menu or service menu on
the machine monitor.
10-232 HB215LC-2
Conditions for starting operation

The auto idle stop function starts when all of the following conditions are satisfied at the same time.
1. Engine is running
2. Lock lever is in LOCK position
3. Working mode is "P", "E", "ATT/P", "ATT/E", and "B" mode
(Auto idle stop function does not operate when working mode is "L" mode.)
4. Engine automatic warm-up function is not in "Normal warm-up" mode.
5. Engine coolant is not overheating (below 102ºC)
6. Hydraulic oil is not overheating (below 102ºC)
7. Hybrid components are not overheating
8. Auto idle stop time on machine monitor is not reset.
9. Machine monitor is not set in service mode. (*1)
10.None of the following failure codes are occurring.
Failure codes related to operating condition 10. are as follows.
Failure codes Failure (Displayed on screen)
B@BCNS Engine Water Overheat
B@HANS Hyd Oil Overheat
CA144 Coolant Temp Sens High Error
CA145 Coolant Temp Sens Low Error
D8AQKR CAN2 Disconnection (KOMTRAX)
DA2RKR CAN1 Disconnection (Pump Controller)
DA2QKR CAN2 Disconnection (Pump Controller)
DAFQKR CAN2 Disconnection (Monitor)
DB2RKR CAN1 Disconnection (Engine Controller)
DB2QKR CAN2 Disconnection (Engine Controller)
DGH2KA Hyd Oil Sensor Open Circuit
DGH2KB Hyd Oil Sensor Short Circuit
GA00NS HYB Equipment Overheat
GA1HKZ Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir
GA1JKZ Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir
GA1KKZ Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir
GA1NNS Swing Motor Driver IGBT Overheat
GA1UKZ Capacitor Temp. Sensor Opn/Short Cir
GA1TNS Capacitor Overheat
GA1XKZ Boost. Ind. Temp. Sens. Open/Shrt. Circ.
GA1YNS Booster Inductor Overheat
GA1ZKZ Booster IGBT Temp. Sens.Opn/Shrt Circ.
GA1ZNS Booster IGBT Temperature Sensor Overheat
GA22NS Booster IGBT Junction Overheat
GA23KZ Gen. Mot. Dr. Temp. Sen. 0 Opn/Short Cir.
GA24KZ Gen. Mot. Dr. Temp. Sen. 1 Opn/Short Cir.
GA2RKR CAN1 Disconnection (Hybrid Controller)
GA2QKR CAN2 Disconnection (Hybrid Controller)
GA25NS Gen. Motor Driver IGBT 0 Overheat
GA26NS Gen. Motor Driver IGBT 1 Overheat
GA61KZ Gen. Motor Temp. Sens.Opn/Short Cir.
GA61NS Generator Motor Temperature Sensor Overheat
GA70NS Hybrid Swing Motor Overheat
GA71KZ HYB Swing Mot. Temp. Sens. Opn/Shrt Cir.
*1: See Setting time.
HB215LC-2 10-233
Setting time
• The set time for the auto idle stop function is set in the following menus.
For setting of each menu, see Testing and adjusting.
Setting auto idle stop (service menu)

Setting Contents of setting
The auto idle stop function does not operate, and the related items are not
OFF displayed on service menu and user menu.
Set the minimum menu selecting time of auto idle stop time fixing menu and auto
1 min. idle stop time setting menu to 1 minute.
3 min. idle stop time setting menu to 3 minutes.
5 min. idle stop time setting menu to 5 minutes.
Fixing auto idle stop time (service menu)
In auto idle stop time setting menu, operator can select OFF or minimum set time
Variable in auto idle stop setting to maximum time of 60 minutes. (Default)
The auto idle stop function does not operate, and the auto idle stop time setting
OFF menu is not displayed.
In auto idle stop time setting menu, operator can select minimum set time in auto
Fix to X min. idle stop setting to X minutes (set time at left). (Cannot select OFF)
Fixing auto idle stop time (user menu)
OFF Auto idle stop function does not operate. (Default)
Stop the engine at Y minutes (set time as shown left) after setting the lock lever to
Y min. LOCK position.
k When "Fix to X min." is selected in the Fixing auto idle stop time menu, the screen changes to the
operator screen automatically and the auto idle stop function operates 60 minutes after the lock
lever is set to LOCK position, even if the Service menu is being used.
When performing work with the Service menu, always check the set value of the auto idle stop
function.
10-234 HB215LC-2
Sensing abrupt engine stop

• When the engine is stopped by the auto idle stop function, if the auto-deceleration function is OFF and the
fuel control dial is at a position above MIN., abrupt engine stop is sensed and the failure code is sent.
• The failure code is recorded in the mechanical system abnormality record.
• If abrupt engine stop is sensed, the auto-deceleration function is turned ON automatically.
k When the auto-decelerator setting is OFF, the auto-decelerator function does not turn ON
automatically and it may constantly detect a sudden engine stop.
• The failure code displayed at abrupt engine stop varies with the number of occurrence, and the message
displayed on the machine monitor varies according to the failure code.
Action level Failure codes Failure (Displayed on screen)
L00 A900N6 Abrupt Engine Stop by Auto Idle Stop 1
L01 A900NY Abrupt Engine Stop by Auto Idle Stop 2
L03 A900FR Abrupt Engine Stop by Auto Idle Stop 3
• When failure code A900FR of action level L03 is sent, the turbocharger assembly must be replaced since
the durability of the engine may decrease.
• After replacing the turbocharger assembly, reset the number of occurrence by using reset number of
abrupt stops by auto idle stop in "Inspection" on the service menu.
a If the number of sudden stop occurrence caused by auto idle stop is not reset, the failure code "A900FR"
is sent again next time and after. Accordingly, be sure to reset after replacing the turbocharger assembly.
HB215LC-2 10-235
System component parts (ALL-RA1C-001-K-00-A)
Engine controller (PC220-AP70-041-K-00-A)
Input and output signals of engine controller (HB205-AP70-03C-K-00-A)

• The symbols in the signal category column of the input/output signal table are as follows.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DRC26-60P(1)[ECM J1(CN-CE01)]
Pin No. Signal name Signal category
1 (*1) -
2 (*1) -
3 Crankcase pressure sensor B
4 (*1) -
5 Charge temperature sensor B
6 Mass air flow and temperature sensor B
7 (*1) -
8 CAN_B (+) (KOMNET/r) E
9 Bkup (camshaft) speed sensor (+) B
10 (*1) -
11 (*1) -
12 (*1) -
13 GND C
14 Coolant temperature sensor B
15 Charge pressure sensor B
10-236 HB215LC-2

16 Ambient pressure sensor B
17 (*1) -
18 CAN_B (-) (KOMNET/r) E
19 (*1) -
20 (*1) -
21 Sensor power supply (12 V) A
22 GND C
23 Mass air flow (MAF) sensor B
24 Water-in-fuel sensor B
25 (*1) -
26 Ne (crankshaft) speed sensor (+) B
27 (*1) -
28 (*1) -
29 (*1) -
30 IMV (+) D
31 Engine oil pressure switch B
32 GND C
33 (*1) -
34 (*1) -
35 (*1) -
37 NE (crankshaft) speed sensor (-) C
38 (*1) -
39 (*1) -
40 IMV (-) C
41 (*1) -
42 (*1) -
43 (*1) -
44 Injector #3 (+) D
47 (*1) -
49 (*1) -
50 (*1) -
51 (*1) -
52 (*1) -
53 (*1) -
54 Injector #3 (-) C
57 (*1) -
59 GND C
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(2)[ECM J2(CN-CE02)]
1 VFT motor (V) B
2 VFT motor (U) B
3 EGR valve motor (W) B
HB215LC-2 10-237

4 EGR valve motor (V) B
5 EGR valve motor (U) B
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 VFT motor (W) B
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 GND C
19 (*1) -
20 (*1) -
21 GND C
22 (*1) -
23 (*1) -
24 CAN_B (+) E
25 CAN_B (-) E
26 (*1) -
27 (*1) -
28 (*1) -
29 (*1) -
32 (*1) -
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
41 EGR valve sensor (V) D
42 EGR valve sensor (W) D
43 VFT sensor (V) D
44 Common rail pressure sensor B
45 (*1) -
46 (*1) -
47 GND C
48 (*1) -
49 (*1) -
50 (*1) -
51 EGR valve sensor (U) D
52 VFT sensor (U) D
53 VFT sensor (W) D
54 (*1) -
55 (*1) -
10-238 HB215LC-2

56 (*1) -
57 (*1) -
58 (*1) -
59 (*1) -
60 (*1) -
DRC26-60P(3)[CN-CE03]
1 Continuous power supply (24 V) A
3 Starting switch ACC signal B
4 Electrical intake air heater relay (+) D
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 System operating lamp D
10 (*1) -
13 GND C
14 (*1) -
15 (*1) -
16 (*1) -
17 CAN_A (+) (KOMNET/c) E
18 CAN_A (-) (KOMNET/c) E
19 GND C
20 (*1) -
21 GND C
22 GND C
23 (*1) -
24 (*1) -
25 (*1) -
26 (*1) -
27 (*1) -
28 (*1) -
29 (*1) -
30 (*1) -
31 GND C
32 GND C
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
41 GND C
HB215LC-2 10-239

43 GND C
44 (*1) -
45 (*1) -
46 (*1) -
47 (*1) -
48 (*1) -
49 Idle validation signal 1 B
50 Idle validation signal 2 B
51 Throttle signal B
53 (*1) -
54 (*1) -
55 (*1) -
56 (*1) -
57 (*1) -
58 (*1) -
59 (*1) -
60 (*1) -
10-240 HB215LC-2
Pump controller (PC-C3V1-041-K-00-A)
HB215LC-2 10-241
Input and output signals of pump controller (HB205-C3V1-03C-K-00-A)

AMP-81P [CN-CP01]
Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
2 Continuous power supply return Input
3 Window washer Output
5 Continuous power supply return Input
6 Potentiometer power supply (5 V) Output
7 CAN (R)_H Input/output
8 Service oil pressure sensor Input
9 (*1) -
10 (*1) -
11 Front pump oil pressure sensor Input
12 Swing RIGHT PPC oil pressure sensor Input
13 Boom LOWER PPC oil pressure sensor Input
14 Arm IN PPC oil pressure sensor Input
15 Left travel REVERSE PPC oil pressure sensor Input
16 (*1) -
17 (*1) -
18 GND (analog signal) -
19 (*1) -
20 (*1) -
21 Machine model selection 3 Input
22 (*1) -
23 (*1) -
24 Starting switch ACC signal Input
25 (*1) -
26 CAN (R)_L Input/output
27 (*1) -
28 Hydraulic oil temperature sensor Input
29 (*1) -
30 Rear pump oil pressure sensor Input
31 Swing LEFT PPC oil pressure sensor Input
32 Boom RAISE PPC oil pressure sensor Input
33 (*1) -
34 Left travel FORWARD PPC oil pressure sensor Input
35 Service PPC oil pressure switch Input
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
41 (*1) -
42 One-touch power maximizing switch Input
44 (*1) -
45 CAN (C)_H Input/output
46 GND (analog signal) Input
47 (*1) -
48 (*1) -
49 Front pump swash plate sensor Input
50 Bucket DUMP PPC oil pressure sensor Input
10-242 HB215LC-2

51 Arm OUT PPC oil pressure sensor Input
52 (*1) -
53 Right travel REVERSE oil pressure sensor Input
54 (*1) -
55 (*1) -
56 Wiper motor reverse (W) Input
57 (*1) -
60 (*1) -
61 Starting switch C signal Input
62 External starting signal Input
63 Potentiometer power supply (5 V) Output
64 CAN (C)_L Input/output
65 (*1) -
66 (*1) -
67 (*1) -
68 Rear pump swash plate sensor Input
69 Bucket CURL PPC oil pressure sensor Input
70 GND (analog signal) Input
71 (*1) -
72 Right travel FORWARD PPC oil pressure sensor Input
73 (*1) -
74 (*1) -
75 Wiper motor stop (P) Input
76 Cab front window open limit switch Input
78 (*1) -
79 PPC lock switch Input
81 (*1) -
AMP-40P [CN-CP02]
82 (*1) -
83 (*1) -
84 (*1) -
85 Travel junction solenoid valve Output
86 Attachment selector solenoid valve Output
87 (*1) -
88 LS-EPC valve Output
89 Merge-divider EPC valve (LS) Output
90 (*1) -
91 Auto idle stop actuation Output
92 (*1) -
93 Travel speed increase solenoid valve Output
94 (*1) -
95 (*1) -
96 Front pump PC-EPC valve Output
97 Attachment flow adjustment EPC valve Output
98 (*1) -
HB215LC-2 10-243

99 (*1) -
100 System-in-use signal Output
101 Swing parking brake solenoid valve Output
102 (*1) -
103 (*1) -
104 Rear pump PC-EPC valve Output
105 (*1) -
106 (*1) -
107 Travel alarm Output
108 Battery relay drive Output
109 2-stage relief solenoid valve Output
110 (*1) -
111 (*1) -
112 Merge-divider EPC valve (main) Output
113 Variable back pressure solenoid valve Output
114 Wiper motor (-) Output
115 GND (solenoid) Input
116 Solenoid power supply Input
119 Wiper motor (+) Output
10-244 HB215LC-2
Inverter (HB205-PQGK-041-K-00-A)
HB215LC-2 10-245
Input and output signals of hybrid controller (HB205-PQGK-03C-K-00-A)

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) -
6 Starting switch (ACC) Input
7 Battery relay terminal M power supply (24 V) Input
8 Swing parking brake solenoid Output
9 Capacitor contactor (-) -
10 NC (*1) -
13 Battery relay terminal M power supply GND -
14 Power from battery relay output Output
15 PPC lock lever Input
16 NC (*1) -
17 Power supply GND -
18 Service connector Input
19 NC (*1) -
20 NC (*1) -
21 Pump controller output Input
22 System operating lamp output Output
23 Power supply GND -
24 NC (*1) -
DRC26-40P [CN-HC02]
1 CAN line H (C) Input/output
2 NC (*1) -
3 Hybrid system stop switch Input
4 SRM position sensor Input
5 Resolver R1 OUT Output
6 Resolver S1 IN Input
7 Sensor power supply (5 V) Output
8 NC (*1) -
9 Swing RIGHT PPC oil pressure sensor Input
10 NC (*1) -
11 CAN line L (C) Input/output
12 NC (*1) -
13 NC (*1) -
14 Interlock input Input
15 Resolver R2 OUT Output
17 Analog signal GND -
18 PM motor temperature Input
19 Swing LEFT PPC oil pressure sensor Input
20 NC (*1) -
21 CAN line H (R) Input/output
22 Sub monitor Input/output
10-246 HB215LC-2

23 NC (*1) -
24 Interlock output Output
25 Sensor power supply (5 V) Output
27 Capacitor Base Temperature Input
28 SR motor temperature Input
29 NC (*1) -
30 NC (*1) -
31 CAN line L (R) Input/output
32 Sub monitor Input/output
33 Digital signal GND -
34 Swing lock switch signal Input
35 Swing parking brake cancel switch signal Input
37 Capacitor bus bar temperature Input
40 NC (*1) -
HB215LC-2 10-247
Fuel control dial (PC-AGJ7-041-K-01-A)
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function (PC-AGJ7-042-K-00-A)
• This dial is installed in the right console box. Turning knob (1) causes potentiometer (5) shaft to rotate.
• As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes
and a throttle signal is sent to the engine controller.
• The hatched areas in the graph are abnormality detection areas. If the throttle voltage is within the area,
the engine speed drops down to low idle.
10-248 HB215LC-2
Resister for PC-EPC valve (PC200_10-C3VR-041-K-00-A)

1. Resistance
2. Connector
Specifications (PC220-C3VR-030-K-00-A)
Resistance: 20 z
Function (PC-C3VR-042-K-00-A)
• When the emergency pump drive switch or the emergency work equipment drive switch is turned to "ON"
position, this resistor sends an electric current to each PC-EPC valve that is appropriate for their condition.
a No electric current flows in the normal condition.
HB215LC-2 10-249
CAN terminating resistor (PC220-Q2V1-041-K-00-A)
a CAN: Abbreviation for Controller Area Network
1. Connector (with built-in resistor)
Specifications (PC220-Q2V1-030-K-00-A)
Resistance: 120 z
Function (PC220-Q2V1-042-K-00-A)
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.
10-250 HB215LC-2
Engine oil pressure switch (PC-ABK6-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Specifications (PC220-ABK6-030-K-00-A)
Contact type: Normally closed
Function (PC-ABK6-042-K-00-A)
• This oil pressure switch is installed to the cylinder block. It detects engine oil pressure, and turns the
switch to "ON" position when the pressure goes below the specified value.
PPC oil pressure switch (PC-E610-041-P-00-A)
1. Plug
2. Switch
HB215LC-2 10-251
3. Connector
Specifications (PC220-E610-030-P-00-A)
Contact type: Normally open
Operating (ON) pressure: 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
Function (PC220-E610-042-P-00-A)
• Two sensors are installed to attachment PPC valve. They detect PPC oil pressure during attachment
operation and turn the switch to "ON" position if the pressure is equal or higher than the specified
pressure.
10-252 HB215LC-2
Machine monitor system
Machine monitor system (HB205-Q170-042-K-00-A)
1. Machine monitor
2. Battery
3. Pump controller
5. Air conditioner controller
7. KOMTRAX terminal
8. Sensors and switches
9. Wiper motor and window washer motor
10. Camera
*1:
Input/output signal
a: Power supply
HB215LC-2 10-253
b. CAN signal
c. Sensor signals and switch signals
d. Drive signal
e. Camera signal
Function
• The monitor system keeps the operator informed of all the machine conditions, by monitoring them by
using the sensors and switches installed in various parts of the machine and processing them instantly to
display on the machine monitor.
The information displayed on the machine monitor falls into the following types:
1. Alarm when the machine has problem
2. Machine state display (coolant temperature, hydraulic oil temperature, fuel level, etc.)
3. Display of camera image
• The switches on the machine monitor have functions to control the machine.
10-254 HB215LC-2
Machine monitor (PC-Q180-042-K-01-A)
Function
• The machine monitor has monitor display function, mode selection function and switch function for
electrical parts etc. Also it has an alarm buzzer.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the
information.
• The machine monitor consists of a display and switches: the display is of LCD type, and the switches are
of flat sheet switch.
• If a failure occurs in the machine monitor itself, controller or wiring circuit between monitor and controller,
the monitor does not display properly.
Precautions on the machine monitor display

• One of the features of liquid crystal display panels is that there may be black spots (spots that do not light
up) or white spots (spots that stay lit up) on the screen. If there are fewer than 10 black or white spots, this
is not a failure or a defect. Products having 10 or less black or bright spots conform the product
specification; such the condition is quite normal.
• When the engine is started, the battery voltage may drop suddenly, depending on the ambient
temperature and the condition of the battery. In this case, the machine monitor display may go off for a
moment. However, this phenomenon is not a failure.
• Continuous operation of the machine monitor may display blue bright spots on the screen having a black
background; it is quite normal.
Blue bright spots 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.)
HB215LC-2 10-255
Input and output signals (PC-Q180-03C-K-00-A)

070-18P[CN-CM01]
Pin No. Signal name Input/Output signal
3 GND (continuous power supply) -
4 GND (continuous power supply) -
5 External start signal Input
6 Starting motor cut-off relay (for personal code) Output
7 (*1) -
8 (*1) -
9 Lamp switch Input
11 Starting switch (C) Input
12 Preheating Input
13 (*1) -
14 (*1) -
15 Fuel level sensor Input
16 Charge level (Alternator R terminal) Input
17 (*1) -
18 (*1) -
070-12P [CN-CM02]
1 Seat belt alarm switch Input
2 Engine oil level sensor Input
3 Radiator coolant level sensor Input
4 Air cleaner clogging sensor Input
5 Swing lock switch Input
6 Quick coupler Input
7 CAN (C) terminating resistor terminal -
8 CAN (C)_H Input/Output
9 CAN (C)_L Input/Output
10 CAN (R) terminating resistor terminal -
11 CAN (R)_H Input/Output
12 CAN (R)_L Input/Output
070-20P [CN-CM03]
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
10-256 HB215LC-2

13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
070-8P [CN-CM04]
1 Camera power supply (8 V) Output
2 Camera NTSC signal 1 Input
5 GND (Camera power supply) -
6 Switching camera 2 to original/mirror image Output
7 Switching camera 3 to original/mirror image Output
8 Shield GND -
HB215LC-2 10-257
Display (HB205-Q1LA-042-K-01-A)
A: Standard screen
B: Check before starting screen
C: Maintenance time warning screen
10-258 HB215LC-2
D: Warning screen
E. Hybrid system stop switch operating screen
F: Guidance screen
G: Camera image screen
a Camera image screen (F) shows the image when multiple cameras are mounted.
1. Message monitor
2. Engine stop monitor
3. Seat belt monitor
4. Air conditioner monitor
5. Wiper monitor
6. Swing lock monitor
7. Preheating monitor
8. Service meter
9. Auto-deceleration monitor
10. Working mode monitor
11. Travel speed monitor
12. Fuel level gauge
13. Fuel level monitor
14. ECO gauge
15. Fuel consumption gauge
16. Hybrid temperature monitor (*1)
17. Hybrid temperature gauge (*1)
18. Hydraulic oil temperature monitor
19. Hydraulic oil temperature gauge
20. Engine coolant temperature monitor
21. Engine coolant temperature gauge
22. Fuel consumption monitor
23. Radiator coolant level monitor
24. Charge level monitor
25. Engine oil pressure monitor
26. Hybrid temperature monitor (*1)
27. Engine oil level monitor
28. Air cleaner clogging monitor
29. Water separator monitor
30. Hybrid monitor (*1)
31. Clock
32. Maintenance time warning monitor
33. System state monitor
34. Action level monitor
35. Hybrid system stop monitor
36. ECO guidance
*1:
HB215LC-2 10-259
Gauge
Gauge Item displayed Description Remarks
Temperature Monitor • Indicates
Range
(°C) background corresponding
(*1) W1 105 Red temperature range.
W2 102 Red • The alarm buzzer
Engine coolant sounds at 105°C or
temperature W3 100 Blue higher.
gauge W4 85 Blue • If the monitor
W5 60 Blue background is white,
W6 30 White warm up the engine.
Temperature Monitor • Indicates
Range
(°C) background corresponding
H1 105 Red temperature range.
(*1) • The alarm buzzer
H2 102 Red
sounds at 105°C or
Hydraulic oil H3 100 Blue higher.
temperature H4 85 Blue • If the monitor
gauge H5 40 Blue background is white,
warm up the
H6 20 White hydraulic
components.
Temperature Monitor
Range
(°C) background
• Indicates
(*1) (*2) E1 102 Red corresponding
Hybrid E2 100 Red temperature range.
temperature E3 95 Blue • The alarm buzzer
gauge E4 50 Blue sounds at 102°C or
higher.
E5 20 Blue
E6 0 White
Monitor
Range Quantity (l)
background
F1 304 Blue
(*1) F2 245 Blue • Indicates
corresponding level
Fuel level gauge F3 200 Blue range.
F4 100 Blue
F5 60 Blue
F6 41 Red
Segment Load level • Displays
Light to instantaneous fuel
Green 1 to 8 consumption
medium
(average fuel
consumption per 3
(*3) seconds) in 10 steps.
ECO gauge (Displays when "ECO
Orange 9, 10 Heavy Guidance" o
"Configurations" o
"ECO Gauge
Display" in user menu
is "ON".)
• Indicates
accumulated engine
operating hours
(alternator is
Service meter 00000.0 h to 99999.9 h generating).
(Press F4 switch to
change to clock
display.)
10-260 HB215LC-2
Gauge Item displayed Description Remarks

• Displays time.
• 12-hour system display (AM/PM) (Press F4 switch to
Clock • 24-hour system display change to service
meter display.)
• Displays average fuel
consumption.
(Day/Split can be
(*3) selected in user
• 1 Day menu "ECO
Fuel
• Split Time Guidance" o
consumption • None
gauge "Configurations" o
"Average Fuel
Consumption
Display".)
*1: If the gauge signal is not available due to an open circuit in the CAN communication line, the gauge
pointer disappears.
*2: Hybrid temperature gauge indicates the thermal load of the hybrid equipments. (For details, refer to the
other page.)
*3: Fuel consumption gauge can be selected in user menu "ECO Guidance" o "Configurations".
Alarm monitor
Description
Monitor
Symbol Item displayed display Action level Remarks
Range
(Background monitor
color)
Min. 102°C Lights up (red) L02 • The monitor
Min. 30°C, Lights up background color
- changes depending
below 102°C (blue)
on the temperature
detected.
Coolant
• The alarm buzzer
temperature
Lights up sounds at 105°C or
Below 30ºC - higher.
(white)
• If the monitor
background is white,
warm up the engine.
Min. 102°C Lights up (red) L02 • The monitor
Min. 20°C, Lights up background color
- changes depending
below 102°C (blue)
on the temperature
detected.
Hydraulic oil
sounds at 105°C or
temperature:
Lights up higher.
Below 20ºC - • If the monitor
(white)
background is white,
warm up the
hydraulic
components.
Below 41 l Lights up (red) - • The monitor
background color
Fuel level Lights up changes depending
Min. 41 l (blue)
-
on the remaining fuel
level.
Min. 100ºC Lights up (red) -
(*2) • The monitor
Hybrid Lights up background color
Below 100ºC - changes depending
temperature (blue)
HB215LC-2 10-261
Description
Monitor
Range
(Background monitor
color)
on the temperature
detected.
sounds at 100ºC or
higher.
When
abnormal • Monitor lights up
(*1) (*2)
(above Lights up (red) L02 when abnormality is
Hybrid standard detected while engine
temperature value) is running
When normal Goes out -
When
(*1) Lights up (*4)
(below (yellow) when abnormality is
Radiator coolant specified L01 detected while engine
level level) is stopped.
When charge
is defective • Monitor lights up and
(*1) (charge Lights up (red) alarm buzzer sounds
L03
voltage < when abnormality is
Battery charge battery detected while engine
voltage) is running.
When
abnormal • Monitor lights up and
(*1) alarm buzzer sounds
(when below Lights up (red) L03
Engine oil when abnormality is
specified
pressure detected while engine
pressure) is running.
When
Lights up (*4)
(*1) (below when abnormality is
(yellow) L01
Engine oil level specified detected while engine
level) is stopped.
When
(*1) Lights up (*4)
(when above (yellow) when abnormality is
Air cleaner specified L01 detected while engine
clogging pressure) is running
When
abnormal
(There is • Monitor lights up
(*1) water Lights up (red) - when abnormality is
collected
Water separator above the detected while engine
is running
specified
amount.)
10-262 HB215LC-2
Description
Monitor
Range
(Background monitor
color)
When • The display changes
maintenance Lights up (red) - depending on the
due time is elapsed time of the
over maintenance due
time.
Maintenance • After starting switch is
(*3)
time warning turned to "ON"
When Lights up position, the monitor
maintenance -
(yellow) lights up if the lighting
notice time is condition is satisfied,
over and also goes out in
30 seconds.
When action • Monitor lights up
level "L04" or Lights up (red) L04 and L03 when abnormality is
"L03" is detected in machine
State of system detected system.
• When the
When action Lights up (*4) background color is
level "L01" is (yellow) L01 red, the alarm buzzer
detected
sounds.
When hybrid • Monitor lights up
(*1) (*2) system is Lights up (red) L03 when abnormality is
State of hybrid abnormal detected while engine
system When normal Goes out - is running
"L03" is detected in engine
State of engine detected system.
system • When the
detected
sounds.
"L03" is detected in hydraulic
State of detected system.
hydraulic system • When the
detected
sounds.
level "L03" is Lights up (red) L03 when abrupt engine
detected stop by auto idle stop
Abrupt stop by
function is detected.
auto idle stop
When action Lights up (*4) When the
function
level "L01" is (yellow) background color is
detected L01 red, the alarm buzzer
sounds.
• The monitor lights up
Engine When engine and the alarm buzzer
Lights up (red) L02 sounds when the
overspeed overspeeds
engine overspeed is
detected.
• Monitor lights up
When air Lights up (*4) when abnormality is
State of air
conditioner is (yellow) detected in air
conditioner L01
abnormal conditioner system.
HB215LC-2 10-263
Description
Monitor
Range
(Background monitor
color)
When action
level "L04" is Lights up (red) L04
detected
• Monitor lights up
When action
Lights up (red) when abnormality is
level "L03" is L03
detected in machine.
detected
Action level When the
When action
Lights up (red) background color is
level "L02" is L02
red, the alarm buzzer
detected
sounds.
When action Lights up (*4)
level "L01" is (yellow)
detected L01
*1: This is included in the Check before starting items. After the staring switch is turned to "ON" position, the
monitor is lit for 2 seconds, and the screen changes to the standard screen if there is no abnormality in the
check.
*2:
*3: Maintenance notice time can be changed on "Maintenance Mode Display Setting" of service mode.
*4: Be lit for 2 seconds, and then goes out.
Pilot monitor
Symbol Item displayed Description Remarks
• Operates automatically at
low temperature.
Automatic (be lit for approximately 30
preheating seconds at longest)
• Goes out after engine is
started.
Elapsed time
after turning
starting switch Monitor • Displays the
Preheating to "HEAT display operation state of
(preheat)" preheating.
Manual position
preheating 0 to 30 Lights up
seconds
30 to 40
Flashes
seconds
40 seconds or
longer Goes out
One-touch
power Monitor display
maximizing
switch • Displays the
One-touch
Lights up operation state of
power
one-touch power
maximizing (The light goes out after
ON maximizing function.
approximately 8.5 seconds if
switch is kept pressed)
OFF Goes out
Swing parking Monitor
Swing lock
brake cancel display
switch
switch • Displays operation
Swing lock OFF OFF Goes out state of swing lock.
ON OFF Lights up
OFF ON Flashes
10-264 HB215LC-2
Symbol Item displayed Description Remarks

ON ON Flashes
INT: Intermittent operation • Displays the
Wiper ON: Continuous operation operation state of
Monitor goes out: Stopped front window wiper.
• Displays the
Lights up: ON operation state of air
Air conditioner
Monitor goes out: OFF conditioner and
blower.
Lights up: Not fastened • Displays whether the

Seat belt
Monitor goes out: Fastened seat belt is fastened.
Lights up: When engine is stopped • Displays the

Stopping engine operation state of
Monitor goes out: When the engine is running engine.
Message Lights up: There is unread message. • Displays the state of

(Unread) Monitor goes out: No message the message.
Message
(No return Lights up: There is a read message which
has not been replied. • Displays the state of
message, the message.
already-read Monitor goes out: No message
message)
Lights up: ON • Displays operation

Auto-
state of auto-
deceleration Monitor goes out: OFF deceleration function.
P: Heavy-duty operation
E: Low-fuel consumption operation
L: Fine control operation
• Displays the set
Working mode B: Breaker operation working mode.
ATT-P: 2-way attachment operation
ATT-E: 2-way attachment operation with low
fuel consumption
Lo: Low-speed travel
• Displays the set
Travel speed Mi: Medium-speed travel
mode of travel speed.
Hi: High-speed travel
• Idling stop guidance
• Deterrence guidance of hydraulic relief • Displays the
• E-mode recommendation guidance guidance to support
ECO guidance
• Reduce travel speed recommendation operation of the
guidance machine.
• Low fuel level guidance
HB215LC-2 10-265
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 Capacitor
temperature % IGBT base IGBT JCT inductor
Cell temperature
temperature temperature temperature
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
Generator
Hybrid device Swing motor Motor-generator Swing inverter
temperature % driver
Coil temperature temperature JCT temperature
temperature
E1 102 140 180 95 134
E2 100 120 170 85 133
E3 95 100 130 60 110
E4 50 80 110 40 90
E5 20 0 0 0 0
E6 0 -30 -30 -30 -30
10-266 HB215LC-2
Switches (HB205-Q1C0-042-K-01-A)
HB215LC-2 10-267
No. Name Function Operation

Switches between ON and OFF of
Auto-deceleration • When the working mode is "L", it is
the auto-deceleration.
1 switch kept "OFF" after the engine is started.
Lights up: ON
[Numeral key pad: 1] OFF io ON
Goes out: OFF
P: Heavy-duty operation
E: Low-fuel consumption operation
(*1)
L: Fine control operation
Working mode selector Displays working mode selection
2 switch B: Breaker operation
screen.
[Numeral key pad: 2] ATT-P: 2-way attachment operation
ATT-E: 2-way attachment operation with
low fuel consumption
Selects travel speed.
Travel speed selector • Changes as follows in order.
Lo lights up: Low-speed travel
3 switch Lo (low speed) o Mi (medium speed)
Mi lights up: Medium-speed travel o Hi (high speed) o Lo (low speed)
[Numeral key pad: 3]
Hi lights up: High-speed travel
Stops the alarm buzzer. • The alarm buzzer stops sounding.
Buzzer cancel switch • When abnormality which turns on the
4 (Some alarm buzzer does not stop
[Numeral key pad: 4] alarm buzzer is detected again, the
even if the switch is pressed.) alarm buzzer sounds.
Operates front window wiper. • Each time the switch is pressed,
(*2)
INT: Intermittent operation operation of the wiper changes.
5 Wiper switch
ON: Continuous operation OFF (stop) o INT(intermittent) o ON
Goes out: Stopped (continuous) o OFF (stop)
ON: Washer fluid spouts out and the
wiper operates continuously.
[When wiper is stopped]
(*2) OFF: When the switch is released, the
wiper continues to operate for 2 cycles,
6 Window washer switch Sprays washer fluid to the front
window. then stops.
[When wiper is intermittent operation]
OFF: When the switch is released, the
wiper continues to operate for 2 cycles,
then returns to intermittent operation.
Fan switch (Increase) • The air flow increases immediately
7a Adjusts the air flow of the air after the air conditioner adjustment
conditioner in six levels. screen appears.
(Low, Medium 1, Medium 2, • The air flow decreases immediately
7b Fan switch (Decrease) Medium 3, Medium 4, High) after the air conditioner adjustment
screen appears.
Temperature control • The preset temperature increases
8a switch (High) Adjusts the temperature inside the immediately after the air conditioner
[Numeral key pad: 8] air-conditioned cab. adjustment screen appears.
Temperature control (18.0ºC to 32.0ºC: Settable by • The preset temperature decreases
8b switch (low) 0.5ºC) immediately after the air conditioner
[Numeral key pad: 0] adjustment screen appears.
• Automatically controls the air flow, air
(*3) Operates the air conditioner and air vent, and FRESH/RECIRC air
blower with automatic operation. changeover according to the set
9 Auto switch
AUTO lights up: Automatic temperature, immediately after the air
[Numeral key pad: 9] operation conditioner adjustment screen
appears.
Switches between ON and OFF of • Switches to the air conditioner
(*4) the air conditioner. adjustment screen, and pressing it
10 A/C lights up: Manual operation
Air conditioner switch again switches ON/OFF.
Goes out: Stopped OFF io ON
10-268 HB215LC-2

• Switches to the air conditioner
adjustment screen, and pressing it
FRESH/RECIRC air
11 Selects FRESH/RECIRC air. again switches FRESH/RECIRC.
selector switch
RECIRC io FRESH
HB215LC-2 10-269

Selects air vent mode from 6
modes.
1. Front
• Switches to the air conditioner
2. Front and rear adjustment screen, and pressing it
12 Vent selector switch
3. Front, rear, and foot again switches air vent mode.
4. Foot 1o2o3o4o5o6o1
5. Foot and defroster
6. Defroster
Stops fan and air conditioner.
13 OFF switch • The fan and air conditioner stop.
Goes out: OFF
14a Guidance icon
See "Guidance icon and function switch." section.
14b Function switch
*1: When the working mode is changed, the auto-deceleration function is turned "ON".
*2: Windshield wiper and window washer do not operate while the front window is open, even if the switch is
pressed.
*3: If temperature is set to 18.0°C or 32.0°C, the air flow from the fan is always set to "HIGH" and does not
change even if the set temperature is reached.
*4: When the fan is stopped, the air conditioner does not start even if the switch is pressed.
10-270 HB215LC-2
Guidance icon and function switch (HB205-Q1C1-042-K-01-A)

• Functions available with the function switch vary depending on the guidance icon displayed above the
switch.
• No function is available if no guidance icon appears above the function switch.
• The following is the list of guidance icons and the functions displayed above the function switches.
Guidance
Item Function
icon
Selects user menu screen.
Transmitted information can be checked with the background
colors.
• Gray: When condition is normal
Select user menu screen • Red: When soot accumulation abnormality (L3) is detected, or
maintenance due time is over
• Yellow: When soot accumulation abnormality (L1) is detected, or
maintenance notice time is exceeded
• Green: When there are unread KOMTRAX messages
Select clock or service

Selects clock or service meter
meter
Select camera image Selects camera image
(*1)
Switching to the energy Switches to the energy monitor display
monitor display
Enters selected item or set item.
Transmitted information can be checked with background colors.
Enter
• Gray: When condition is normal
• Green: When ECO guidance is displayed
Return Returns to previous screen or status.
Moves selection to the above item.

Move selected item
(Moves selection to the bottom item when at the top item)
Moves selection to the below item.

Move selected item
(Moves selection to the top item when at the bottom item)
Green arrow: Moves to the right tab.

Move selected item White arrow: Moves to the right.
(Moves selection to the leftmost item when at the rightmost item)
Green arrow: Moves to the left tab.
Move selected item White arrow: Moves to the left.
(Moves selection to the rightmost item when at the leftmost item)
Moves selection to the above page.

Move selected item
(Moves selection to the bottom page when at the top page)
HB215LC-2 10-271
Guidance
Item Function
icon
Moves selection to the below page.

Move selected item
(Moves selection to the top page when at the bottom page)
Clear Clears selected item or displayed item.
Returns selected item to default value.

Return to default setting
(Used for screen adjustment.)
Set Executes setting.
Executes starting.
Start (Used for starting split fuel consumption measurement for fuel
consumption display)
Executes stopping.
Stop (Used for stopping split fuel consumption measurement for fuel
consumption display)
Save Saves setting.
Select name setting screen Selects name setting screen.
Select ATT1 oil flow setting Selects the 1-attachment oil flow setting screen.
screen (Only effective when 2-attachment installation is set)
Select ATT2 oil flow setting Selects the 2-attachment oil flow setting screen.
screen (Only effective when 2-attachment installation is set)
Holds value of monitoring item.

Hold
(Used during monitoring)
Cancels held value of monitoring item.

Cancel holding
(Used during monitoring)
Change "Average Fuel

Changes graph on "Average Fuel Consumption Logs" screen.
Consumption Logs" screen
Select oil flow setting Selects the attachment and breaker oil flow setting screen.
screen
10-272 HB215LC-2
Guidance
Item Function
icon
Selects "Error List" screen.
Transmitted information can be checked with background colors.
Select "Error List" screen
• Red: When action level of L2, L3, or L4 is displayed.
• Yellow: When action level of L0 is displayed.
Display image of camera Selects image of camera No. 1.

No. 1

No. 2

No. 3
Display images of cameras

No. 1 and No. 2 Displays images of cameras No. 1 and No. 2 simultaneously.
simultaneously
*1:
HB215LC-2 10-273
Operator mode functions (HB205-Q193-042-K-02-A)

• The functions with which the operator can display or set by operating switches in normally displayed
screen.
Display and setting of some functions require special operation of the switch.
• Items available in the operator mode are as follows:
Category Display order (*2)
Item
(*1) V W X Y Z
Display of KOMATSU logo 1 1 1 1 1
Display of password input 2 - - - -
Display to check breaker mode - - 2 - -
Display of Check before starting 3 2 3 2 2
Display of warning after check before starting - - - 3 -
A
Display of maintenance due time over - - - - 3
Display to check working mode and travel speed 4 3 4 4 4
Display of standard screen 5 4 5 5 5
Display of engine shutdown secondary switch screen
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Stop operation of alarm buzzer
Operation of windshield wiper
Operation of window washer
Operation of air conditioner
B Operation to display camera mode
Operation to display clock and service meter
Check of maintenance information
Setting and display of user menu
• ECO Guidance
• Machine Setting
• Maintenance
• Monitor Setting
• Display of message (including KOMTRAX messages for user)
Display of ECO guidance
C Display of caution monitor
Display of action level and failure code
Checking function by LCD (Liquid Crystal Display)
D Function to check service meter
Function of usage limitation setting/change password
*1: The operator mode items are classified as follows.
A: Display from the time when the starting switch is turned to "ON" position to the time when display changes
to the standard screen, and display after starting switch is turned to "OFF" position
B: Display when the machine monitor switch is operated
C: Display when condition is satisfied
D: Display that requires special operations of switches
*2: Display sequence from the time when the starting switch is turned to "ON" position to the time when the
standard screen appears varies depending on the settings and conditions of the machine as follows:
V: When the engine start lock is set ON
W: When the engine start lock is set OFF
X: When the working mode is set to "Breaker Mode" (B) at start of engine
Y: When any abnormality is detected by the Check before starting
Z: When any item is detected as the maintenance due time is over.
10-274 HB215LC-2
a For how to operate the operator mode functions, see "Operator mode (Outline)" section in Testing and
adjusting or the Operation and Maintenance Manual.
a For the operating method of the engine start lock function, see Password setting and canceling manual.
HB215LC-2 10-275
Service mode functions (HB205-Q194-042-K-01-A)

• These functions are not displayed normally. A technician can display and set them special operation of
switches.
This function is used for special setting, testing, adjusting, or troubleshooting.
• Items available in the service mode are as follows:
Monitoring / Pre-defined
Monitoring / Custom
Abnormality Record Mechanical Systems
Electrical Systems
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Default Key-on Mode
Unit
With/Without Attachment
Camera
Auto Idle Stop Timer Fixing
Diagnostic Tests Cylinder Cut-out
Reset Number of Abrupt Engine Stop by AIS
Discharge Capacitor
Adjustment Pump Absorption Torque (F)
Pump Absorption Torque (R)
Low Speed
Attachment Flow Adjustment
Cal F pump swash plate sensor
Cal R pump swash plate sensor
Swing Motor Starting Torque
Hoist Swing Adjustment
No Injection
KOMTRAX Settings Terminal Status
GPS & Communication Status
Modem Status
Service Message
a For operating method of the service mode functions, see "Service mode" section in Testing and adjusting.
10-276 HB215LC-2
KOMTRAX system
KOMTRAX system (PC-Q210-042-K-00-A)
• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna.
• This system transmits various machine information by use of the radio communication. This system allows
the KOMTRAX operator to refer the information and provide various services to the customers.
• Information transmittable from the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
4. Abnormality record
a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
HB215LC-2 10-277
KOMTRAX system
KOMTRAX terminal (PC220-Q220-042-K-00-A)
Type: TC330
1. GPS antenna connection

2. Machine harness connection (070-18P)
3. Machine harness connection (070-12P)
4. Communication antenna connection
Input and output signals (PC220-Q220-03C-K-00-A)

070-18P[CN-CK01]
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 CAN (C)_H Input/Output
11 CAN (C)_L Input/Output
12 (*1) -
13 (*1) -
14 External start signal Input/Output
15 System operation lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
070-12P [CN-CK02]
1 GND -
2 GND -
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -
10-278 HB215LC-2
KOMTRAX system

9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -
Function (PC-Q220-042-K-00-A)
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of "KOMTRAX setting" in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
a When operating the system in Japan, install a terminal dedicated for use in Japan.
HB215LC-2 10-279
Sensor
Sensor (ALL-E700-001-P-00-A)
Ambient pressure sensor (ENG-AAP2-041-K-00-A)
1. Connector
2. Sensor
Function (HB205-AAP2-042-K-00-A)
• This sensor, installed to the top surface of intake manifold, senses the ambient pressure, and outputs it as
a variable voltage.
Output characteristics
10-280 HB215LC-2
Sensor
Charge (boost) pressure and temperature sensor (ENG-AAM7-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-AAM7-042-K-00-A)
• This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its
temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for
temperature.
a "Charge pressure and temperature" are the engine intake air pressure and temperature of a turbocharged
engine. These are also referred to as "boost pressure and temperature" or "intake air pressure and
temperature".
HB215LC-2 10-281
Sensor
Coolant temperature sensor (ENG-BA87-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-BA87-042-K-00-A)
• This sensor, installed on the cylinder head of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.
Ne (crankshaft) speed sensor (ENG-AG42-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG-AG42-042-K-00-A)
• This sensor, installed to the crankshaft pulley on the engine front cover, outputs the pulse voltage due to
the gear rotation.
10-282 HB215LC-2
Sensor
Bkup (camshaft) speed sensor (ENG-AG62-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG-AG62-042-K-00-A)
• This sensor, installed to the ring of camshaft on the engine front cover, outputs the pulse voltage due to
the gear rotation.
Common rail pressure sensor (ENG-AE28-041-K-00-A)
1. Connector
2. Sensor
Function (ENG-AE28-042-K-00-A)
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.
HB215LC-2 10-283
Sensor
Exhaust manifold pressure sensor (ENG-AAN5-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG-AAN5-042-K-00-A)
• This sensor, installed to the pressure outlet tube installed to the exhaust manifold of the engine, detects
the exhaust pressure to output the corresponding variable voltage.
EGR orifice temperature sensor (ENG-A9U5-041-K-00-A)
EGR: Abbreviation for Exhaust Gas Recirculation
1. Connector
2. Sensor
3. Washer
Function (ENG-A9U5-042-K-00-A)
• This sensor, installed on the EGR gas piping between EGR cooler and EGR valve of the engine, converts
the temperature variation into the resistance variation, and outputs the corresponding signals.
10-284 HB215LC-2
Sensor
VFT motor (with built-in position sensor) (ENG95-AA56-041-K-00-A)
a VFT: Abbreviation for Variable Flow Turbocharger

1. VFT motor (brushless motor with built-in position sensor)

2. Turbine part
3. Connector
Function (ENG95-AA56-042-K-00-A)
• Controls the flow control valve with a DC motor.
• The VFT motor has a position sensor in it to sense the valve position.
HB215LC-2 10-285
Sensor
EGR valve (with built-in position sensor) (ENG95-AA57-041-K-00-A)

1. EGR valve motor (with built-in position sensor)

2. Connector
3. Body
Function (ENG95-AA57-042-K-00-A)
• Small-sized EGR valve driven with a DC motor.
• The EGR valve motor has a position sensor in it to sense the valve position.
10-286 HB215LC-2
Sensor
Mass air flow and temperature sensor (ENG-A96H-041-K-00-A)
1. Connector
2. O-ring
3. Sensor
Function (ENG-A96H-042-K-00-A)
• This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The "MAF (Mass Air Flow)" means the "intake air flow".
Crankcase pressure sensor (ENG-A18C-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-A18C-042-K-00-A)
• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.
HB215LC-2 10-287
Sensor
Engine oil level sensor (ENG-AB45-041-K-00-A)
1. Connector
2. Bracket
3. Float
4. Switch
Function (ENG-AB45-042-K-00-A)
• This sensor, installed on the side face of the oil pan, turns "OFF" by the lowered float, if the oil level
becomes lower than specified.
10-288 HB215LC-2
Sensor
Fuel level sensor (PC-AD41-041-K-00-A)
1. Connector
2. Float
3. Arm
4. Valve body
5. Spring
6. Variable resistor
Function (PC-AD41-042-K-00-A)
• 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 activates 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.
HB215LC-2 10-289
Sensor
Coolant level sensor (PC-B252-041-K-00-A)
1. Float
2. Sensor
3. Connector
4. Reservoir tank
Function (PC-B252-042-K-00-A)
• This sensor is integrated with reservoir tank, and is activated by the lowered float, if the coolant level
becomes lower than specified.
10-290 HB215LC-2
Sensor
Hydraulic oil temperature sensor (PC-PMT1-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function (PC-PMT1-042-K-00-A)
• This sensor, installed on the suction pipe of main pump, senses the temperature variation as the change
in thermistor resistance, and outputs the corresponding signals.
Front pump oil pressure sensor (PC-C3W4-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC-C3W4-042-K-00-A)
• The sensor is installed in the control valve. It detects the delivery pressure of the front pump and outputs
variable voltage signal.
HB215LC-2 10-291
Sensor
Rear pump oil pressure sensor (PC-C3W5-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC-C3W5-042-K-00-A)
• The sensor is installed in the control valve. It detects the delivery pressure of the rear pump and outputs
variable voltage signal.
10-292 HB215LC-2
Sensor
PPC oil pressure sensor (PC-E720-041-P-00-A)
1. O-ring
2. Sensor
3. Connector
Function (HB205-E720-042-P-00-A)
• The PPC oil pressure sensor is installed to 10 places in the junction block of the pilot circuit between PPC
valve and control valve and 4 places of travel PPC valve. It detects the pilot pressure and outputs it as a
variable voltage.
HB215LC-2 10-293
Sensor
Air cleaner clogging sensor (PC-A968-041-K-01-A)
1. Adapter
2. Hood
3. Indicator
4. Connector
Function (HB205-A968-042-K-00-A)
• This sensor, installed to the tip of the pressure outlet hose of air cleaner outlet, set switch to "ON" position
when air cleaner is clogged and pressure becomes below the specified pressure (negative pressure).
10-294 HB215LC-2
Sensor
Front pump swash plate sensor (PC-C3W9-041-K-00-A)
1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)
Function (PC200_10-C3W9-042-K-00-A)
• This senor is installed to the front pump side of the main pump. It detects the stroke of servo piston and
outputs variable voltage signal.
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.
• The relation between stroke and output voltage is as shown in the following graph.
• The relation between oil flow of pump and output voltage is as shown in the following graph.
HB215LC-2 10-295
Sensor
10-296 HB215LC-2
Sensor
Rear pump swash plate sensor (PC-C3WB-041-K-00-A)
1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)
Function (PC200_10-C3WB-042-K-00-A)
• This senor is installed to the rear pump side of the main pump. It detects the stroke of servo piston and
outputs variable voltage signal.
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.
• The relation between stroke and output voltage is as shown in the following graph.
• The relation between oil flow of pump and output voltage is as shown in the following graph.
HB215LC-2 10-297
Sensor
Water-in-fuel sensor (PC-AEB3-041-K-00-A)
1. Connector
2. Tube
3. Sensor
4. O-ring
Function (PC-AEB3-042-K-00-A)
• This sensor is installed to the cup of fuel prefilter.
• This sensor outputs a signal when detecting water exists in the fuel beyond the specified level.
10-298 HB215LC-2
SHOP MANUAL
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
20 Standard value tables

4 20 Standard value tables
HB215LC-2 20-1
Table of contents

20 Standard value tables.................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
Standard value table for electrical system............................................................................. 20-20
20-2 HB215LC-2
Standard value table for engine
Standard service value table (ALL-A000-001-K-00-A)
Standard value table for engine (HB205-A000-033-K-01-A)

HB215LC-2
Machine model HB215LC-2
Engine SAA4D107E-2
Standard value
Item Measurement condition Unit for new Repair limit
machine
• Coolant temperature: 60 to High idle 1,250 ± 70 1,250 ± 70
100°C Low idle 1,850 ± 70 (*2) 1,850 ± 70 (*2)
• Auto-deceleration switch:
OFF (at high idle)
Engine speed • Auto-deceleration switch: rpm
ON, Swing lock switch: OFF Rated speed 2,000 2,000
(at low idle)
• Swing lock switch: ON (at
rated speed)
Boost • Coolant temperature: 60 to 100°C
pressure • Hydraulic oil temperature: 45 to 55°C Min. 160 Min. 133
kPa
• Swing lock switch: ON
(Aftercooler {mmHg} {Min. 1,200} {Min. 1,000}
• Arm digging relief + One-touch power
inlet pressure) maximizing ON
• Coolant temperature: 60 to At sudden - Max. 1.2
Exhaust gas 100°C acceleration Bosch
color • Measure at KDOC outlet (tail index
High idle - Max. 1.2
pipe outlet)
Intake valve 0.25 0.152 to 0.381
Valve • Coolant temperature:
mm
clearance Normal temperature Exhaust valve 0.51 0.381 to 0.762
Compression • Engine oil temperature: 40 to 60°C MPa Min. 2.41 Min. 1.69
pressure • Engine speed: Min. 170 rpm {kg/cm2} {Min. 24.6} {Min. 17.2}
kPa Max. 0.98 Max. 1.96
Blowby • Coolant temperature: 60 to 100°C
{mmH2-
pressure • Hydraulic oil temperature: 45 to 55°C {Max. 100} {Max. 200}
O}
At rated Min. 0.29 Min. 0.25
Engine oil • Coolant temperature: 60 to horsepower MPa {Min. 3.0} {Min. 2.5}
pressure 100°C {kg/cm2} Min. 0.10 Min. 0.07
• SAE15W-40 oil Low idle
{Min. 1.0} {Min. 0.7}
Engine oil
Whole speed range (inside oil pan) °C 80 to 110 Max. 120
temperature
• Between compressor pulley and fan pulley
Fan belt • Deflection when pressed with finger at 98 N - Auto-tensioner Auto-tensioner
tension {10 kg}
Air • Between compressor pulley and fan pulley
conditioner • Deflection when pressed with finger at 60 N mm 6.3 to 8.7 6.3 to 8.7
compressor {6.2 kg}
belt tension
*1: P mode with auto-deceleration OFF: 1,250 rpm

*2: B mode with travel control lever fine control: 1,850 rpm
HB215LC-2 20-3
Standard value table for engine
Engine SAA4D107E-2
Standard value
Item Measurement condition Unit for new Repair limit
machine
207 to 650 {2.11 207 to 650 {2.11
Low- High idle
to 6.63} to 6.63}
pressure
207 to 500 {2.11 207 to 500 {2.11
circuit Cranking
to 5.1} to 5.1}
Low-
kPa
pressure
• Coolant {kg/cm2}
circuit High idle Max. 81 {0.83} Max. 81 {0.83}
Fuel pressure temperature: (pressure
60 to 100°C difference)
Return High idle
Max. 18.6 {0.19} Max. 18.6 {0.19}
circuit Cranking
Negative kPa Max. –40.7 Max. –40.7
pressure High idle
{mmHg} Max. {–305} Max. {–305}
circuit
• Coolant temperature: 60 to
Supply pump Cranking (Min.
100°C
discharged 150 rpm) Min. 70 Min. 70
• Discharged volume for 30
volume
seconds
Return rate • Coolant temperature: 60 to
100°C Cranking (Min.
from supply Max. 575 Max. 575
• Discharged volume for 60 150 rpm)
pump ml
seconds
Fuel return • Coolant temperature: 60 to Low idle Max. 125 Max. 125
rate from 100°C Cranking (Min.
injector • Return rate for 30 seconds 150 rpm) Max. 45 Max. 45
Leakage from • Coolant temperature: 60 to Low idle Max. 8 Max. 8
pressure 100°C Cranking (Min.
• Leakage for 30 seconds Max. 5 drops Max. 5 drops
limiter 150 rpm)
20-4 HB215LC-2
Standard value table for machine
Standard value table for machine (HB205-0000-033-K-01-A)

HB215LC-2
Engine speed
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Coolant temperature: 60 to 100°C
• Hydraulic oil temperature: 45 to 55°C
Engine speed at 2- • Engine: High idle rpm 1,700 ± 100 1,700 ± 100
pump relief • Working mode: P mode
• Swing lock switch OFF position
• At arm IN relief
Engine speed at 2- • Hydraulic oil temperature: 45 to 55°C
pump relief + One- • Engine: High idle rpm 1,920 ± 100 1,920 ± 100
touch power • Working mode: P mode
maximizing is ON • Arm IN relief + One-touch power
maximizing ON
Engine speed • Engine: High idle
when auto- • Coolant temperature: 60 to 100°C rpm
deceleration is 700 ± 50 700 ± 50
• Auto-deceleration switch ON
operated • All control levers in NEUTRAL
Control valve spool stroke

Standard
value for Repair limit
new
machine
Boom control RAISE 11.5 ± 0.5 11.5 ± 0.5
valve LOWER 9.5 ± 0.5 9.5 ± 0.5
Arm control IN 11.5 ± 0.5 11.5 ± 0.5
valve • Engine: Stopped OUT 9.5 ± 0.5 9.5 ± 0.5
• For measuring point, see "Control CURL mm
Bucket control
valve" (*1). 9.5 ± 0.5 9.5 ± 0.5
valve DUMP
Forward
Travel control
Reverse 9.5 ± 0.5 9.5 ± 0.5
valve
*1: (Machine posture and procedure for measuring performance)
HB215LC-2 20-5
Travel of control lever

Standard
value for Repair limit
new
machine
Boom control
85 ± 10 85 ± 10
lever
Arm control
• Engine: Stopped 85 ± 10 85 ± 10
lever
Bucket control • Center of lever grip
• Read max. value through travel end 85 ± 10 85 ± 10
lever
Swing control (excluding play at NEUTRAL) mm 85 ± 10 85 ± 10
lever
Travel control
115 ± 12 115 ± 12
lever
• Engine: Stopped Work
Play of control equipment Max. 15 Max. 20
• Center of lever grip
lever • Read max. value through travel end Travel Max. 20 Max. 25
Operating effort of control lever and pedal

for new machine
15.7 ± 3.9
Boom control lever Max. 24.5 {2.5}
{1.6 ± 0.4}
15.7 ± 3.9
Arm control lever Max. 24.5 {2.5}
{1.6 ± 0.4}
12.7 ± 2.9
Bucket control lever • Engine: High idle Max. 21.6 {2.2}
• Lever: At center of grip N {1.3 ± 0.3}
• Pedal: At tip of pedal {kg} 12.7 ± 2.9
Swing control lever • Read max. value through travel end Max. 21.6 {2.2}
{1.3 ± 0.3}
24.5 ± 5.9
Travel control lever Max. 39.2 {4.0}
{2.5 ± 0.6}
74.5 ± 18.6
Travel control pedal Max. 107.6 {11}
{7.6 ± 1.9}
20-6 HB215LC-2
Hydraulic pressure
for new machine
• Engine: High idle
Control circuit oil MPa 3.23 (+0.2 / -0.3) 2.75 to 3.43
pressure a Self-pressure reducing valve outlet {kg/cm2} {33 (+2 / -3)} {28 to 35}
pressure with all control levers in
NEUTRAL position
Work
equipment 0 {0} 0 {0}
control lever:
PPC valve output • Hydraulic oil MPa
NEUTRAL
pressure temperature: 45 to 55° {kg/cm2}
Work
C 3.23 (+0.2 / -0.3) 2.75 to 3.43
equipment
control lever: {33 (+2 / -3)} {28 to 35}
Full stroke
• Engine: High idle MPa 3.5 ± 1.0 3.5 ± 1.0
Unload pressure
• Working mode: P mode {kg/cm2} {36 ± 10} {36 ± 10}
• All control levers: NEUTRAL
34.8 (+1.5 / -1.2) 33.1 to 37.2
{355 (+15 / -12)} {338 to 380}
Boom relief
pressure *37.3 (+1.5 /
*36.1 to 39.7
• Hydraulic oil temperature: 45 to 55°C -1.2)
• Engine: High idle {368 to 405}
{380 (+15 / -12)}
• Working mode: P mode 34.8 (+1.5 / -1.2) 33.1 to 37.2
• Hydraulic pressure during One-touch
power maximizing is marked with * {355 (+15 / -12)} {338 to 380}
Arm relief pressure (reference). *37.3 (+1.5 /
MPa *36.1 to 39.7
• As a condition for travel relief pressure, -1.2)
travel speed is set to Hi position. {kg/cm 2} {368 to 405}
{380 (+15 / -12)}
a Hydraulic pump discharged pressure 34.8 (+1.5 / -1.2) 33.1 to 37.2
with all measurement circuits relieved {355 (+15 / -12)} {338 to 380}
Bucket relief
pressure a Do not steer abruptly during travel *37.3 (+1.5 /
*36.1 to 39.7
operation. -1.2)
{368 to 405}
{380 (+15 / -12)}
Travel relief 38.7 (+1.0 / -2.0) 36.8 to 40.2
pressure {395 (+10 / -20)} {375 to 410}
• Hydraulic oil All levers in 3.5 ± 1.0 3.5 ± 1.0
temperature: 45 to 55° NEUTRAL {36 ± 10} {36 ± 10}
C
LS differential • Working mode: B mode MPa
pressure • Travel speed: Hi {kg/cm 2} 1.8 (+0.05 /
Travel lever at 1.8 (+0.05 / - 0.1)
• Run either track idle -20.1)
half stroke {18 (+0.5 / -1.0)}
• LS differential pressure {18 (+0.5 / -1.0)}
= Pump pressure - LS
pressure
HB215LC-2 20-7

for new machine
Front pump 36.1 to 38.8 36.1 to 38.8
• Hydraulic oil discharged
{368 to 395} {368 to 395}
temperature: 45 to 55° pressure
PC valve outlet C Servo piston Above value x Above value x
pressure • Engine: High idle inlet pressure MPa approx. 0.6 approx. 0.6
(servo piston inlet • Working mode: P mode Rear pump {kg/cm2}
36.1 to 38.8 36.1 to 38.8
pressure) • Swing lock switch: ON discharged
• Work equipment pressure {368 to 395} {368 to 395}
control: Arm IN relief Servo piston Above value x Above value x
inlet pressure approx. 0.6 approx. 0.6
• Hydraulic oil Approx. 2.9 Approx. 2.9
PC mode selector temperature: 45 to 55° {Approx. 30} {Approx. 30}
C Low idle
pressure MPa (Reference (Reference
(PC-EPC valve • Working mode: P mode {kg/cm2} value) value)
output pressure) • Swing lock switch: ON
• Work equipment control High idle 0 {0} 0 {0}
lever: NEUTRAL
• Hydraulic oil Control lever 2.9 to 4.9 2.9 to 4.9
temperature: 45 to 55° and pedal: {30 to 50} {30 to 50}
LS valve output C NEUTRAL (*2) (*2)
pressure • Engine: High idle MPa
(servo piston inlet • Working mode: B mode {kg/cm2}
pressure) • Front pump circuit: Right or left Pump pressure x Pump pressure
Right track track: Idle turn Approx. 0.6 x Approx. 0.6
• Rear pump circuit: Left
track
temperature: 45 to 55° Travel speed: {Approx. 30} {Approx. 30}
LS set selector C Lo (Reference (Reference
pressure • Engine: High idle MPa value) value)
(LS-EPC valve • Working mode: P mode {kg/cm2}
output pressure) • Swing lock switch: OFF Travel speed:
• Travel control lever: 0 {0} 0 {0}
Hi
Fine control
• Hydraulic oil Solenoid: OFF 0 {0} 0 {0}
temperature: 45 to 55°
C
Solenoid valve • Engine: High idle MPa
• For ON/OFF conditions 2.9 (+0.6 / -0.2) 2.9 (+0.6 / -0.3)
outlet pressure Solenoid: ON {kg/cm2}
of the solenoid, see {30 (+5.5 / -1.5)} {30 (+5.5 / -3.0)}
Testing and adjusting,
"Testing outlet pressure
of solenoid valve".
*2: Almost same as pump pressure
20-8 HB215LC-2
Swing
for new machine
• Working mode: P mode
Overswing deg. Max. 100 Max. 130
• Overswing of swing circle after 1 swing
• For measuring posture, see "Swing 1"
(*1).
• Hydraulic oil temperature: 45 90 deg. 3.1 ± 0.3 Max. 3.7
to 55°C
Time required to
• Time required to pass 90 sec.
start swinging 180 deg. 4.4 ± 0.4 Max. 5.5
deg. and 180 deg. points
after starting swing
• For measuring posture, see
"Swing 1" (*1).
Time required to
• Time required to complete 5 swings sec. 24.2 ± 2.5 Max. 30
finish swinging
after 1 swing
(*1).
• Engine: Stopped
• On slope of 15 deg., set upper
structure crosswise and put
Swing drift on a matchmarks on inner race and outer
mm 0 0
slope race of swing circle.
• Distance that matchmarks move apart
after 5 minutes
(*1).
HB215LC-2 20-9
Travel
for new machine
• Hydraulic oil temperature: 45 55.9 (+3.9 /
to 55°C Lo -7.3) 48.6 to 63.8
• Working mode: B mode Mi 40.8 ± 4.1 36.7 to 48.9
Travel speed (idle
• Time required for 5 turns Hi sec.
running)
after 1 idle turn of track off
ground 30.5 ± 1.6 28.9 to 34.1
"Travel 1" (*1).
• Hydraulic oil temperature: 45
Lo 24 (+1.7 / -3.1) 20.9 to 26.7
to 55°C
• Engine: High idle Mi 17 ± 2.5 14.5 to 20.5
Travel speed • Working mode: P mode
sec.
(actual running) • Time required for traveling
20 m after running up 10 m Hi 13 ± 1.0 12.0 to 15.0
"Travel 2" (*1)
• Travel speed: Lo
Travel deviation • Travel deviation (x) in travel of 20 m mm Max. 150 Max. 250
after running up 10 m on firm and level
ground
• For measuring posture, see "Travel 2"
and "Travel 3" (*1).
• Engine: Stopped
• Place machine on slope of 12 deg. with
Machine drift on a sprocket on uphill side.
mm 0 0
slope • Travel distance by machine drift on a
slope for 5 minutes
(*1).
Leakage from • Engine: High idle
• Lock sprocket with pin, etc. l/min 13.6 27.2
travel motor
• Leakage in 1 minute during travel relief
20-10 HB215LC-2
Work equipment
for new machine
Hydraulic drift
of whole work
equipment mm Max. 600 Max. 900
(hydraulic drift
of tooth tip) • Hydraulic oil temperature: 45 to 55°C
Hydraulic drift
Hydraulic drift of work equipment
• Level and flat ground

of boom • Load: Heaped up of soil (2:1 slope) or
cylinder rated load in bucket (0.8 m3:1,440kg) mm Max. 18 Max. 27
(retraction • Engine: Stopped
amount of • Work equipment control lever in
cylinder) NEUTRAL position
Hydraulic drift • Hydraulic drift for 15 minutes as
of arm measured every 5 minutes starting
cylinder immediately after initial setting
• For measuring posture, see "Work mm Max. 160 Max. 240
(retraction
amount of equipment 1" (*1).
cylinder) (Horizontal boom top face, fully
Hydraulic drift retracted arm cylinder, fully extended
of bucket bucket cylinder)
cylinder
mm Max. 40 Max. 58
(retraction
amount of
cylinder)
• Hydraulic oil temperature: 45 RAISE 3.8 ± 0.4 Max. 4.8
to 55°C
• Time required to move boom
Boom speed sec.
between RAISE stroke end LOWER 3.0 ± 0.3 Max. 3.7
and ground touch point of
bucket
"Work equipment 2" (*1).
Work equipment speed
• Hydraulic oil temperature: 45 IN 3.7 ± 0.4 Max. 4.5

to 55°C
• Time required to move arm
Arm speed sec.
between OUT stroke end and OUT 2.7 ± 0.3 Max. 3.5
IN stroke end
• Hydraulic oil temperature: 45 CURL 2.6 ± 0.3 Max. 3.3
to 55°C
• Time required to move
Bucket speed sec.
bucket between DUMP DUMP 2.0 ± 0.2 Max. 2.7
stroke end and CURL stroke
end
• Engine: Low idle
Time lag

Boom time lag sec. Max. 1.0 Max. 1.2
• Set the boom to the maximum RAISE
position. Move boom control lever to
LOWER position. Measure time from
HB215LC-2 20-11

for new machine
when work equipment touches the
ground until front side of machine rises.
• For measuring posture, see "Work
equipment 5" (*1).
• Set the arm to the maximum OUT
position. Move arm control lever to IN
Arm time lag side. Measure the time before the arm sec. Max. 2.0 Max. 2.8
starts moving to the IN side again after
the arm tentatively stops near the
vertical position.
equipment 6" (*1).
• Set the bucket to the maximum DUMP
position. Move bucket control lever to
Bucket time
CURL side. Measure the time before the sec. Max. 1.0
lag Max. 3.6
bucket starts moving to the CURL side
again after the bucket tentatively stops
near the vertical position.
equipment 7" (*1).
Oil leakage
for new machine
Cylinder
Oil leakage
internal oil 4.5 20

leakage • Engine: High idle
• Working mode: P mode cc/min
Center swivel • Leakage for 1 minute during relief of
joint oil cylinder to be measured or travel motor 10 50
leakage
Performance of combined operation

for new machine
Travel deviation in • Working mode: P mode
combined • Travel speed: Lo
operation of work • Travel deviation (x) in travel of 20 m mm Max. 200 Max. 220
equipment and after running up 10 m on firm and level
travel ground
and "Travel 3" (*1).
20-12 HB215LC-2
Pump swash plate sensor

for new machine
• Hydraulic oil All control
temperature: 45 to 55° levers in 1.35 ± 0.20 1.35 ± 0.63
Pump swash plate C NEUTRAL
sensor output • Engine: High idle When running V
voltage • Working mode: P track idle off
mode ground (lever 3.35 ± 0.20 3.35 ± 0.63
• Travel speed: Hi at full stroke).
• Run either track idle
Characteristics of PC flow control

for new machine
•Hydraulic oil temperature: 45 to 55°C
•Engine: High idle
•Working mode: P mode
•Rated load of bucket (0.8 m3: 1,440 kg)
Time required to
•On hard and level ground, set arm
swing from 0 to 90
vertically and lower back of bucket to
deg. with combined sec. 4.3 ± 0.4 (reference value)
the ground
operation of boom
• Time required to swing from 0 to 90
RAISE and swing
deg. with combined operation of boom
RAISE and swing
equipment 8"
HB215LC-2 20-13
Main pump
for new machine
• Pump speed (rpm): 1,700 rpm
• PC-EPC current value (mA): 440 mA
• Test pump discharged pressure (MPa
Main pump {kg/cm2}): P1 Q Q
performance • Other pump discharged pressure (MPa l/min
(See graph) (See graph)
{kg/cm2}): P2
• Average discharged pressure (MPa
{kg/cm2}): Pp=(P1+P2) / 2
a Bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring.
a 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 discharged volume and the engine speed at
the time of measurement, and use them as a base for calculating the pump discharged volume at the
specified speed.
20-14 HB215LC-2
Water pressure
for new machine
• Turn starting switch to ON position or
start engine.
• Battery voltage (monitoring code
(03203))): 20 V or higher
Water pump MPa
• Read value (A) displayed in monitoring Min. 0.04 Min. 0.04
performance {kg/cm2}
code (01142) "Service Press. Sensor
(HYB W Pump)", and convert it by the
following calculation formula.
Water pressure (P) = A / 500(MPa)
HB215LC-2 20-15
Posture of machine for measuring performance and measurement

procedure (PC220_10-0000-321-K-00-A)
Control valve: Spool travel
Swing 1: Overrun when stop swinging, time required to start swinging, time required to finish swinging
Swing 2: Swing drift on a slope
20-16 HB215LC-2
Travel 1: Travel speed (idle running)
Travel 2: Travel speed (actual run), travel deviation
Travel 3: Travel deviation
Travel 4: Hydraulic drift of travel
HB215LC-2 20-17
Work equipment 1: Hydraulic drift of the work equipment
Work equipment 2: Boom speed
Work equipment 3: Arm speed
Work equipment 4: Bucket speed
20-18 HB215LC-2
Work equipment 5: Boom time lag
Work equipment 6: Arm time lag
Work equipment 7: Bucket time lag
Work equipment 8: PC flow characteristics control
HB215LC-2 20-19
Standard value table for electrical system
Standard value table for electrical system (D155-E000-001-P-00-A)
Controller (HB205-RA1E-033-K-00-A)
Equipment name Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector CE03.
Continuous 4. Turn the battery disconnect switch to ON position.
Engine power 5. Measure voltage with starting switch at OFF position and when starting
controller supply engine.
voltage Between CE03 (1) and (21) 20 to 30 V
Between CE03 (2) and (31) 20 to 30 V
Voltage
Continuous 3. Disconnect connector CP01 and connect T-adapter to female side.
power 4. Turn the battery disconnect switch to ON position.
supply 5. Turn starting switch to ON position.
voltage
Between CP01 (female) (1) and (2) 20 to 30 V
Voltage
Pump
controller 1. Turn starting switch to OFF position.
Solenoid 3. Disconnect connector CP02 and connect T-adapter to female side.
voltage Between CP02 (female) (116) and ground 20 to 30 V
Voltage Between CP02 (female) (118) and ground 20 to 30 V
Between CP02 (female) (121) and ground 20 to 30 V
Continuous 3. Insert T-adapter into connector CM01.
Machine power 4. Turn the battery disconnect switch to ON position.
monitor supply 5. Turn starting switch to ON position.
voltage
Between CM01 (1) and (3) 20 to 30 V
Voltage
Continuous 3. Disconnect connector HC01 and connect T-adapter to female side.
supply 5. Measure voltage with starting switch at OFF position and when starting
voltage engine.
Between HC01 (5) and (17) 20 to 30 V
Voltage
Inverter Between HC01 (11) and (23) 20 to 30 V
Battery relay 3. Disconnect connector HC01 and connect T-adapter to female side.
M power 4. Turn the battery disconnect switch to ON position.
Between HC01 (1) and ground 20 to 30 V
Voltage
Between HC01 (7) and ground 20 to 30 V
20-20 HB215LC-2
Engine control (HB205-AG10-033-K-00-A)

2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
EGR valve solenoid Between EGR V (male) (6) and (7) 1 to 5 z
Resistance Between EGR V (male) (7) and (8) 1 to 5 z
Between EGR V (male) (8) and (6) 1 to 5 z
2. Disconnect connector VFT and connect T-adapter to male side.
VFT solenoid Between VFT (male) (6) and (7) 8 to 15 z
Resistance Between VFT (male) (7) and (8) 8 to 15 z
Between VFT (male) (8) and (6) 8 to 15 z
2. Disconnect connector P23, and connect T-adapter to male side.
3. Turn starting switch to ON position.
When air
cleaner is
Air cleaner clogging
normal
switch
(Air cleaner
Resistance Between P23 (male) (1) and (2) Max. 1 Ω
suction
resistance:
Max. -3,430 Pa
{-350 mmH2O})
2. Disconnect connector COOLANT TEMP, and connect socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700 z to 37
kz when coolant temperature is min. 0°C.
Coolant temperature
sensor 0°C 30 to 37 kz
25°C 9.3 to 10.7 kz
Between COOLANT TEMP
Resistance (male) (1) and (2) 50°C 3.2 to 3.8 kz
80°C 1.0 to 1.3 kz
95°C 700 to 800 z
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male
side.
a Regard charge temperature sensor as normal if its resistance is 80 z to 48
kz.
Charge temperature -40°C 41 to 48 kz
sensor -20°C 14 to 16 kz
Between BOOST PRESS &
IMT (male) (3) and (4) 0°C 5.4 to 6.1 kz
Resistance 30°C 1.6 to 1.8 kz
a Charge thermal 60°C 560 to 600 z
characteristics
90°C 230 to 250 z
130°C 80 to 90 z
2. Disconnect connector P55 and connect T-adapter to male side.
-30°C 25 to 28 kz
Intake air temperature 0°C 5.5 to 6.1 kz
Between P55 (male) (3) and (4)
sensor 25°C 1.9 to 2.1 kz
Resistance a Intake air temperature-
40°C 1.1 to 1.2 kz
resistance characteristics
180 to 185 z
100°C
HB215LC-2 20-21

2. Disconnect connector EXHAUST GAS TEMPERATURE, and connect T-
adapter to male side.
-30°C 760 to 880 kz
0°C 380 to 515 kz
Between EXHAUST GAS
25°C 155 to 225 kz
TEMPERATURE (male) (1) and
EGR orifice temperature (2) 80°C 21 to 29 kz
sensor 200°C 900 to 1,050 z
Resistance a Temperature-Resistance 300°C 150 to 200 z
characteristics
400°C 40 to 56 z
500°C 15 to 22 z
Whole range between EXHAUST GAS
TEMPERATURE (male) (2) and ground (sensor Min. 100 kz
body)
2. Disconnect connector INLET METERING VALVE and connect T-adapter to
male side.
Supply pump actuator
Between INLET METERING VALVE (male) (1)
(IMV/PCV1)
and (2) 1 to 5 z
Resistance
Between INLET METERING VALVE (male) (1)
and ground Min. 100 kz

2. Disconnect connector INJECTOR CYL1&2, and connect T-adapter to male
side.
No. 1 injector
Between INJECTOR CYL1&2 (male) (3) and (4) Max. 2 z
Resistance Between INJECTOR CYL1&2 (male) (3) and
ground Min. 100 kz

side.
No. 3 injector
ground Min. 100 kz

side.
No. 2 injector
ground Min. 100 kz

side.
No. 4 injector
ground Min. 100 kz

Charge (Boost) pressure 2. Insert T-adapter into connector ECMJ1.
sensor 3. Turn starting switch to ON position.
Voltage Between ECMJ1 (15) and (59) Sensor output 0.3 to 4.7 V
2. Disconnect connector OILPRESSURE SWITCH and connect T-adapter to
Engine oil pressure switch male side.
Between OILPRESSURE SWITCH (male) (1)
Voltage
and ground Max. 10 z
Engine oil level sensor 1. Turn starting switch to OFF position.

20-22 HB215LC-2

Resistance Between P44 (male) (1) and ground Max. 1 z
Between FULL
Coolant level sensor Max. 1 z
and LOW lines
Resistance Between P24 (male) (1) and (2)
Below LOW
Min. 1 Mz
line
2. Insert T-adapter into connector ECMJ1.
Ambient pressure sensor
Exhaust manifold 2. Disconnect connector ECMJ2 and connect T-adapter to female side.
pressure sensor 3. Turn starting switch to ON position.
2. Disconnect connector P47 and connect T-adapter to female side.
Water-in-fuel sensor 3. Turn starting switch to ON position.
installed to fuel prefilter a If water is in fuel prefilter, drain it.
Between P47 (female) (1) and (2) 10 to 100 kz
Resistance
Between P47 (female) (1) and ground Min. 100 kz
Common rail pressure 2. Insert T-adapter into connector ECMJ2.
2. Insert T-adapter into connector P57.
Crankcase pressure 3. Turn starting switch to ON position.
sensor
Between P57 (female) (3) and
Voltage Sensor output 0.3 to 4.7 V
(2)
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
HB215LC-2 20-23
Machine control (HB205-E000-033-P-00-A)

Travel speed selector 2. Disconnect connector V04, and connect T-adapter to male side.
solenoid Resis- Between V04 (male) (1) and (2) 20 to 60 z
tance Between V04 (male) (1) and ground Min. 1 Mz
Swing parking brake 2. Disconnect connector V03, and connect T-adapter to male side.
2. Disconnect connector V05, and connect T-adapter to male side.
Travel junction solenoid
Resis- Between V05 (male) (1) and (2) 20 to 60 z
2. Disconnect connector V01 and connect T-adapter to male side.
PPC lock solenoid
2-stage relief solenoid
Variable back pressure 2. Disconnect connector V25, and connect T-adapter to male side.
Attachment return selector 2. Disconnect connector V06, and connect T-adapter to male side.
F-PC-EPC solenoid
2. Disconnect connector V12 and connect T-adapter to male side.
R-PC-EPC solenoid
LS-EPC solenoid
Attachment oil flow
adjustment EPC solenoid Between V30 (male) (1) and (2) 3 to 14 z
Resis-
20-24 HB215LC-2

Merge-divider (main) EPC 2. Disconnect connector V23, and connect T-adapter to male side.
Merge-divider (LS) EPC 2. Disconnect connector V24, and connect T-adapter to male side.
10°C Approx. 90 kz
Hydraulic oil temperature Between P22 (male) (1) and (2)
30°C Approx. 35 kz
sensor Resis- a Temperature-Resistance
80°C Approx. 6.5 kz
tance characteristics
100°C Approx. 3.5 kz
Between P22 (male) (2) and ground Min. 1 Mz
Front pump pressure 2. Insert T-adapter into connector P25.
Voltage Between P25 (2) and (1) Sensor output 0.5 to 4.5 V
Rear pump pressure 2. Insert T-adapter into connector P26.
Arm IN PPC pressure 2. Insert T-adapter into connector P04.
Bucket CURL PPC 2. Insert T-adapter into connector P01.
Boom RAISE PPC 2. Insert T-adapter into connector P06.
Boom LOWER PPC 2. Insert T-adapter into connector P02.
Swing RIGHT PPC 2. Insert T-adapter into connector P07.
Swing LEFT PPC 2. Insert T-adapter into connector P03.
Arm OUT PPC pressure
sensor
HB215LC-2 20-25

Bucket DUMP PPC 2. Insert T-adapter into connector P05.
Travel Forward L.H. PPC 2. Insert T-adapter into connector P09.
Travel Forward R.H. PPC 2. Insert T-adapter into connector P11.
Travel Reverse L.H. PPC 2. Insert T-adapter into connector P10.
Travel Reverse R.H. PPC 2. Insert T-adapter into connector P12.
Between P27 (male) (A) and (B) Approx. 6 kz
Resis- Between P27 (female) (B) and (C) Approx. 6 kz
tance Between P27 (female) (A) and (C) Approx. 170 z
Between P27 (male) (C) and ground Min. 1 Mz
Front pump swash plate 3. Turn starting switch to ON position.
sensor Voltage Between P27 (C) and (B) Sensor output Approx. 3 V
4. Starting engine
Between P27 (C) and (B)
a Shifts the pump swash plate Approx. 1.4 V
Voltage angle toward the minimum Sensor output
position with control lever in
neutral.
20-26 HB215LC-2

Between P28 (male) (A) and (B) Approx. 6 kz
Resis- Between P28 (female) (B) and (C) Approx. 6 kz
tance Between P28 (female) (A) and (C) Approx. 170 z
2. Insert T-adapter into connector P28
Rear pump swash plate 3. Turn starting switch to ON position.
sensor Voltage Between P28 (C) and (B) Sensor output Approx. 3 V
4. Starting engine
Between P28 (C) and (B)
a Shifts the pump swash plate
Voltage angle toward the minimum Sensor output Approx. 1.4 V
position with control lever in
neutral.
HB215LC-2 20-27
Machine monitor (HB205-Q170-033-K-00-A)

3. Insert T-adapter into connector CM01.
Battery charge 4. Turn the battery disconnect switch to ON position.
5. Start engine and perform troubleshooting while running engine at medium
speed or higher.
Voltage Between CM01 (16) and (3) 20 to 30 V
4. Disconnect heater relay terminal R16A.
Preheating a To prevent current from flowing through heater when starting switch is
turned to HEAT position
5. Turn the battery disconnect switch to ON position.
6. Turn starting switch to HEAT position.
2. Disconnect connector CM01, and connect T-adapter to male side.
Fuel Level (fuel level Between CM01 (female) (15) FULL Approx. 12 z
sensor) and ground
Resistance Approx. 85 to
a Fuel level sensor EMPTY
110 z
characteristics
20-28 HB215LC-2
SHOP MANUAL
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
30 Testing and adjusting

5 30 Testing and adjusting
HB215LC-2 30-1
Table of contents

30 Testing and adjusting .................................................................................................................... 30-1
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
Testing engine speed ........................................................................................................... 30-8
Testing boost pressure ....................................................................................................... 30-10
Testing exhaust gas color ................................................................................................... 30-13
Testing and adjusting valve clearance .................................................................................. 30-14
Testing compression pressure............................................................................................. 30-17
Testing blowby pressure ..................................................................................................... 30-21
Testing engine oil pressure ................................................................................................. 30-22
Testing fuel pressure .......................................................................................................... 30-23
Testing fuel discharge, return and leakage............................................................................ 30-28
Bleeding air from fuel system .............................................................................................. 30-30
Testing fuel circuit for leakage ............................................................................................. 30-32
Handling cylinder cutout mode operation.............................................................................. 30-33
Handling no-injection cranking operation.............................................................................. 30-34
Testing and adjusting air conditioner compressor belt tension ................................................ 30-35
Replacing fan belt .............................................................................................................. 30-36
Hybrid system .......................................................................................................................... 30-37
Precautions related to hybrid equipment .............................................................................. 30-37
Bleeding air from hybrid cooling system ............................................................................... 30-38
Testing water pressure of hybrid coolant............................................................................... 30-40
Testing swing parking brake ................................................................................................ 30-42
Cleaning and replacing oil filter of electric swing motor .......................................................... 30-43
Power train............................................................................................................................... 30-44
Testing swing circle bearing clearance ................................................................................. 30-44
Testing and adjusting track tension ...................................................................................... 30-45
Releasing remaining pressure from hydraulic circuit .............................................................. 30-46
Testing oil pressure of control circuit .................................................................................... 30-50
Testing and adjusting oil pressure in work equipment and travel circuits .................................. 30-51
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-54
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-58
Testing outlet pressure of solenoid valve .............................................................................. 30-66
Testing PPC valve outlet pressure ....................................................................................... 30-70
Adjusting play of work equipment and swing PPC valves....................................................... 30-72
Testing pump swash plate sensor ........................................................................................ 30-73
Isolating the parts causing hydraulic drift in work equipment................................................... 30-74
Testing oil leakage ............................................................................................................. 30-76
Bleeding air from hydraulic circuit ........................................................................................ 30-78
Cab and its attachments ............................................................................................................ 30-80
Testing cab tipping stopper ................................................................................................. 30-80
Adjusting mirrors ................................................................................................................ 30-81
Electrical system ...................................................................................................................... 30-84
Special functions of machine monitor ................................................................................... 30-84
KOMTRAX terminal start-up procedure .............................................................................. 30-156
Adjusting rearview camera angle ....................................................................................... 30-159
Handling voltage circuit of engine controller........................................................................ 30-161
Handling battery disconnect switch .................................................................................... 30-162
Testing diodes ................................................................................................................. 30-163
Pm clinic ................................................................................................................................ 30-164
Pm Clinic service ............................................................................................................. 30-164
30-2 HB215LC-2
Related information on testing and adjusting
Related information on testing and adjusting (ALL-3831-001-A-00-A)
Tools for testing and adjusting (HB205-5320-304-A-00-A)
Testing/Adjusting Sym- Q-
Part No. Part name 'ty Remarks
item bol
-101 to 200 kPa
Testing boost 799-201-2202 Boost gauge kit 1 {-760 to 1,500 mmHg}
pressure A
779–300–1530 Elbow
1 799-201-9002 Handy smoke checker 1
Testing exhaust
gas color B Commercially Bosch index: 0 to 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjustment of
C Commercially
valve clearance 2 Feeler gauge 1
available
Compression gauge
1 795-502-1590 assembly 1 0 to 7 MPa {0 to 70 kg/cm2}
Testing 2 795-799-6700 Puller 1
compression D 3 795-790-4411 Adapter 1
pressure 4 6754-11-3130 Gasket 1
Commercially Inside diameter: Approximately
6 Hose 1
available 15 mm
1 799-201-1506 Blowby checker 1 0 to 5 kPa {0 to 500 mmH2O}
Testing blowby Commercially Plug
2 3 Hose inside diameter: 24 mm
pressure E available
Commercially Plug Pipe outside diameter: 25.4mm,
3 3 pipe inside diameter: 20.4 mm
available
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
1 799–101–5160 • Nipple
799–101–5150 • Hose
Testing engine oil
pressure F 790–261–1150 • Hose
2 Pressure range: 70 MPa {700
790-261-1205 Digital hydraulic tester 1 kg/cm2}
Pressure range: 1.0 MPa {10
3 799-401-2320 Gauge 1 kg/cm2}
799–101–5160 • Nipple
1
799–101–5150 • Hose
790–261–1150 • Hose
799–101–5140 • Gauge
2 Pressure range: 70 MPa {700
790-261-1205 Digital hydraulic tester 1 kg/cm2}
Testing fuel 795-790-4430 Adapter 2 Size: M10x10 o R1/8
H 3
pressure 6215-81-9710 O-ring 1
4 795-790-5110 Screw 1 Size: M12 x 1.25 mm
Pressure range: 1.0 MPa {10
5 799-401-2320 Gauge 1 kg/cm2}
6 795-790-5120 Screw 1 Size: M14 x 1.5 mm
799-201-2202 Boost gauge kit 1
799–101–5160 • Nipple
7
799–401–2610 • Hose
799–401–2311 • Gauge
HB215LC-2 30-3
item bol
1 795-790-4700 Tester kit 1
2 6164-81-5790 Joint 1
3 07206-30812 Joint bolt 1
4 6745-71-1130 Seal washer 1
Testing fuel Commercially Stopwatch
5 1
discharge, return J available
and leakage Commercially Inside diameter: Approximately
6 Hose 1
available 14 mm
Commercially Measuring cylinder
7 1
available
Commercially Inside diameter: Approximately
8 Hose 1
available 8 mm
1 Commercially Adapter 1 Equivalent to Snap on SRD 6
available
Replacing fan belt U 12.7 angle,number of teeht 45
Commercially
2 Ratchet handle 1 or more,lenbth approximately
available
450ｍｍ
Developer for dye
Testing fuel circuit Commercially penetrant
for leakage L 1
available (color checker)
Testing swing
Commercially Dial gauge
circle bearing K 1
available
clearance
Testing and 799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
adjusting oil 1
Pressure range: 70 MPa {700
pressure in work M 790-261-1205 Digital hydraulic tester 1 kg/cm2}
equipment and
2 799-101-5220 Nipple 1 Size: M10 x 1.25 mm
travel circuits
3 07002-11023 O-ring 1
Testing oil 1
pressure of control N 790-261-1205 Digital hydraulic tester 1 kg/cm2}
circuit
2 799-101-5220 Nipple 1 Size: M10 x 1.25 mm
3 07002-11023 O-ring 1
Measuring and 1
adjusting oil Pressure range: 70 MPa {700
P 790-261-1205 Digital hydraulic tester 1 kg/cm2}
pressure in pump
PC control circuit 2 799-101-5220 Nipple 1 Size: M10 x 1.25 mm
3 07002-11023 O-ring 1
1
Measuring and 790-261-1205 Digital hydraulic tester 1 kg/cm2}
adjusting oil Pressure range: 50 MPa {500
Q 2 796T-440-1101 Sensor adapter 1 kg/cm2}
pressure in pump
LS control circuit
3 799-101-5220 Nipple 1 Size: M10 x 1.25 mm
4 07002-11023 O-ring 1
5 799-401-2701 Differential pressure gauge 1
30-4 HB215LC-2
item bol
1
Testing outlet 790-261-1205 Digital hydraulic tester 1 kg/cm2}
pressure of R 799-401-3100 Adapter 1 Size 02
solenoid valve 2
02896-11008 O-ring 1
799-401-3200 Adapter 1 Size 03
3
02896-11009 O-ring 1
1
Measuring PPC 790-261-1205 Digital hydraulic tester 1 kg/cm2}
valve output S Adapter
799-401-3100 1 Size 02
pressure 2
02896-11008 O-ring 1
799-401-3200 Adapter 1 Size 03
3
02896-11009 O-ring 1
796-403-1100 Pressure checker 1
Testing water 796-403-1110 • Pressure sensor 1
pressure of hybrid V 195-40-31670 • Plug 1
coolant 07002-11823 • O-ring 1
796-403-1120 • Tool box 1
Testing oil leakage Commercially Measuring cylinder
T 1
available
Testing coolant
temperature and - 799-101-1502 Digital thermometer 1 -99.9 to 1,299°C
oil temperature
Testing operating - 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
effort and
depressing effort - 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Testing stroke and Commercially
- Ruler 1
hydraulic drift available
Testing work Commercially Stopwatch
- 1
equipment speed available
Testing voltage - Commercially
Multimeter 1
and resistance available
Removal and
installation of
charge (boost) Commercially 3.26 mm TORX wrench
- Torx wrench 1 (KTC Q4T15 or equivalent)
pressure and available
temperature
sensor
Removal and
installation of
- 795-799-6210 Socket 1 27 mm deep socket
engine oil
pressure switch
Removal and
installation of 19 mm deep socket
engine coolant - 795T-981-1010 Socket 1 (MITOLOY 4ML-19 or
temperature equivalent)
sensor
HB215LC-2 30-5
Sketch of tools for testing and adjusting (PC300-3531-061-A-00-A)
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
Q1: Sensor adapter
F1, N1, P1, and Q1 : Nipple(Subpart of sensor adapter in the above figure)
30-6 HB215LC-2
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
-: Socket
HB215LC-2 30-7
Engine and cooling system
Testing engine speed (PC200_10-A000-360-K-00-A)
a Check the engine speed by using the Testing high idle speed (at B mode with travel
"Monitoring/Pre-defined" or "Monitoring lever fine control)
Function" of the machine monitor. 1. Display monitoring code (01002) "Engine speed".
For details, see "Special functions of machine
a Check the engine speed under the following monitor".
conditions. 2. Start the engine, and set the fuel control dial to
• Coolant temperature: 60 to 100 °C High idle (MAX) position.
• Hydraulic oil temperature: 45 to 55 °C 3. Set the working mode to "B" and set the auto-
deceleration to OFF.
Testing (HB205-A000-388-K-01-A)
Testing low idle speed a Swing lock switch may be set in either ON or
1. Display monitoring code (01002) "Engine speed". OFF.
monitor". k
4. Operate the travel lever finely (within the

insensible range (machine does not move off))
to increase the engine speed. Measure the
engine speed after rotation becomes steady.
a Do not supply the oil to the travel motor and
measure the engine speed while machine
does not move off.
k If the travel lever is tilted too much

(beyond the insensible range), machine
starts moving off to the direction as of the
lever operation. Accordingly, secure the
safety for just in case the machine moves
2. Start the engine, and set the fuel control dial to
off.
Low idle (MIN) position.
3. Set the working mode to "P", auto-deceleration a For standard values, see "Standard value table",
switch to ON, and swing lock switch to OFF. "Standard value table for engine".
4. Set all the levers and pedals for work equipment
control, swing control, and travel to NEUTRAL Measuring engine speed at 2-pump relief
position, and test the engine speed. 1. Display monitoring code (01002) "Engine speed".
a For standard values, see "Standard value table", monitor".
"Standard value table for engine". 2. Start the engine and operate the arm cylinder to
arm IN stroke end.
Testing high idle speed (at P mode with auto-
deceleration OFF) 3. Set the fuel control dial to High idle (MAX)
1. Display monitoring code (01002) "Engine speed". position.
For details, see "Special functions of machine 4. Set the working mode to "P" and set the swing
monitor". lock switch to OFF.
2. Start the engine, and set the fuel control dial to 5. Operate the L.H. work equipment lever to make
High idle (MAX) position. arm IN relief and check the engine speed.
3. Set the working mode to "P" and set the auto- a For standard values, see "Standard value table",
deceleration to OFF. "Standard value table for engine".
a Swing lock switch may be set in either ON or Checking speed (around rated speed) at 2-pump
OFF. relief + one-touch power maximizing function
4. Set all the levers for work equipment control, 1. Display monitoring code (01002) "Engine speed".
swing control, and travel to NEUTRAL position, For details, see "Special functions of machine
and test the engine speed. monitor".
a For standard values, see "Standard value table", 2. Start the engine and operate the arm cylinder to
"Standard value table for engine". arm IN stroke end.
3. Set the fuel control dial to High idle (MAX)
position.
30-8 HB215LC-2
4. Set the working mode to "P" mode.

5. While operating the L.H. work equipment control
lever to make arm IN relief and pressing the
one-touch power maximizing switch, check the
engine speed.
a The one-touch power maximizing function is
reset automatically in approximately 8.5
seconds even if the switch is kept pressed.
Accordingly, test the engine speed in that period.
a Swing lock switch can be set in ON.
a For standard values, see "Standard value table",
"Standard value table for engine".
Measuring the engine speed when auto-

deceleration is activated
1. Display monitoring code (01002) "Engine speed".
monitor".
2. Start the engine, and set the fuel dial to High idle
(MAX) position.
3. Set the working mode to "P", auto-deceleration
switch to ON, and swing lock switch to OFF.
4. Set all the levers and pedals for work equipment
control, swing control, and travel in neutral and
test the engine speed when the auto-decelerator
operates.
a When setting all control levers and pedals to
NEUTRAL positions, the engine speed lowers to
the waiting speed (approximately 1,250 rpm)
temporarily. When this state remains for 4
seconds or more, the engine speed lowers again
to the deceleration speed (approximately 700
rpm). Check the engine speed at that time.
(Reference: See Electrical device "Auto-
deceleration function" in Chapter 10 "Structure
and Operation".)
a For standard values, see "Standard value table",
"Standard value table for engine".
HB215LC-2 30-9
Testing boost pressure (PC160-A900-360-K-01-A)
a Testing tools
Sym-
Part No. Part name
bol
1 799-201-2202 Boost gauge kit
A
2 799-301-1530 Elbow
k Place the machine on a level ground, and

lower the work equipment to the ground.
k Be careful not to touch any hot part when

installing or removing the testing tools.
a Check this item under the following conditions.

3. Install nipple [1] of boost gauge kit A1 and
• Coolant temperature: 30 to 100°C connect them to gauge [2].
• Arm IN relief + One-touch power maximizing
ON
Testing (HB205-A900-362-K-01-A)
Testing with machine monitor
a Display "Monitoring/Defined" or monitoring code
(36500) "Change pressure". For details, see
"Special functions of machine monitor".
4. Run the engine at middle or higher speed and

drain oil from the hose.
a Repeat opening the self-sealing portion on
the hose by inserting approximately half of
the connection part of the gauge into the
hose to drain oil.
a When Pm kit (A) is prepared, you can use air
bleeding coupling (790-261-1130) in the kit.
a If oil is left in the hose, the gauge does not
Testing by using the testing tools work. Accordingly, be sure to drain the oil.
1. Open the engine hood and remove boost 5. Set the working mode to P mode, auto-
pressure pickup plug (1). deceleration switch to OFF, and swing lock
switch to ON.
a If the swing lock switch is turned to ON
position, the main relief valve is set for high-
pressure relief.
6. Set the fuel control dial to the "MAX" position
and measure the boost pressure with arm IN
relief + One-touch power maximizing ON.
a For standard values, see "Standard value
table for engine".
2. Install elbow A2.
30-10 HB215LC-2
7. After finishing the test, remove the testing tools,

and restore the machine.
3 Pickup port plug (1):
2 to 3.9 Nm {0.2 to 0.4 kgm}
HB215LC-2 30-11
How to fully open engine hood (PC200_10-H540-

100-K-00-A)
a If more room to work is needed, the engine hood

can be opened to a maximum of approx. 90
degrees according to the following procedure.
1. Open engine hood (1).
a The figure shows the engine hood opened
normally (at the first slit).
2. Loosen bolt (2).
a Just loosen bolt (2). Do not remove it.
a When closing engine hood (1), hold lock

plate (3) at hole (a), and tighten bolt (2).
3 Bolt (2):
59 to 74 Nm {6 to 7.5 kgm}
a At this time, locating pin (4) of lock plate (3) is

disengaged.
3. Use pin (5) to bring and hold lock plate (3) at
hole (b), and tighten bolt (2).
a The position of lock plate (3) must be

changed to close engine hood (1), otherwise
lock plate (3) will interfere with stay (6).
4. Open engine hood (1) wider and fix stay (6) at

the position shown in the figure (at the second
slit).
30-12 HB215LC-2
Testing exhaust gas color (HB205-A900-360-K-00-A)
a Testing tools 2) Connect the power cable to an AC 100 V

Sym- receptacle.
Part No. Part name
bol a Before connecting the power cable, make
1 799-201-9002 Handy smoke checker sure that the power switch of the smoke
B Commercially meter is turned OFF.
2 Smoke meter
available 3) Insert probe [1] of smoke meter B2 into
k Place the machine on a level ground and exhaust pipe (1).
k Be careful not to touch any hot part when

installing or removing the testing tools.

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
smoke meter B2.
Testing (HB205-A900-385-K-00-A)
4) Turn ON the power switch of smoke meter
1. Measuring by using handy smoke checker B1 B2.
1) Place a sheet of filter paper to smoke 5) Start the engine, accelerate it quickly or run it
checker B1. at high idle, and depress the accelerator
2) Insert the exhaust gas intake pipe into pedal of smoke meter B2 to collect exhaust
exhaust pipe (1). gas on the filter paper.
3) Start the engine, accelerate it quickly and run
it at high idle, and operate the handle of
smoke checker B1 to absorb the exhaust gas
into the filter paper.
a Suction time: 1.4 ± 0.2 second
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
4) Remove the filter paper and compare it with tools, and restore the machine.
the attached scale for judgment.
5) After finishing the test, remove the testing
tools, and restore the machine.
2. Testing by using smoke meter B2
1) Connect the probe hose, receptacle of the
accelerator switch and air hose to smoke
meter B2.
a The supplied air pressure must be 1.5
MPa {15 kg/cm2} or below.
HB215LC-2 30-13
Testing and adjusting valve clearance (ALL-A700-001-K-00-A)
a Testing tools a For details, see "Disassembly and

Sym- assembly".
Part No. Part Name
bol
1 795-799-1131 Gear
C Commercially Feeler gauge
2
available
k Park the machine on a level ground and

k Turn the battery disconnect switch to OFF

position and remove the key.
a Test and adjust the valve clearance under the

following condition.
• Coolant temperature: Normal temperature 4. Remove covers (7) and (8).
Testing (HB205-A700-361-K-00-A)
1. Open the engine hood and remove step (1)
5. Remove plug (9) under the starting motor and

insert gear C1.
2. Disconnect EGR gas temperature sensor

connector (EXHAUST GAS TEMPERATURE)
(2), and remove hose (3) and tube (4).
3. Remove cylinder head cover (5).

a The O-ring is fitted to the mating face of
blowby duct (6). Take care that it does not fall
off when the blowby duct is removed.
a Since the O-ring is fitted to the flywheel
housing side of blowby duct (6), blowby duct
(6) may be removed together with cylinder
head cover (5).
30-14 HB215LC-2
6. Rotate the crankshaft forward with gear C1, and engine oil pan mounting bolt (13), and then
align the yellow paint (line) of vibration damper adjust the valves marked with q in the valve
(10) with engine oil pan mounting bolt (11) so layout drawing.
that their positions become straight line.
a If the valves marked with q in the valve
a The end of engine oil pan mounting bolt (11) layout drawing are checked in step 9, check
is painted yellow. the valves marked with Q.
a When the crankshaft is set as above, the
piston in the No. 1 or No. 4 cylinder is not set
to the compression top dead center (TDC)
k Be sure to remove gear C1.
(76 to 88 deg. before top dead center). Take
care. 3 Clamp of hose (3) in EGR circuit:
10.5 ± 0.5Nm {1.07 ± 0.05 kgm}
3 The mounting bolt of tube (4) in EGR
circuit (flange side and clamp)
24 ± 4Nm {2.45 ± 0.41 kgm}
3 Cylinder head cover (5) mounting nut:
24 ± 4Nm {2.45 ± 0.41 kgm}
Adjusting (HB205-A700-27D-K-00-A)
After testing, adjust the valve clearance according

to the following procedure, if necessary.
1. While fixing adjustment screw (14), loosen lock
7. Check the movement of the rocker arm of the No. nut (15).
1 cylinder to inspect the valve clearance. 2. Insert feeler gauge C2 in the clearance between
a The valve clearance is normal if it is within rocker arm (16) and crosshead (17) and adjust
the range of the following standard value. the valve clearance with adjustment screw (14).
Intake valve 0.152 to 0.381 mm a With feeler gauge C2 inserted, turn the
Exhaust valve 0.381 to 0.762 mm adjustment screw (14) and adjust it (14) until
the feeler gauge C2 can move lightly.
a If you can move the rocker arm of air intake a Adjust the valve clearance to the range of the
valves (IN) with the hand by the valve following standard value.
clearance amount, check the valves marked
with Q in the valve layout drawing. Intake valve 0.25 ± 0.05 mm
a If you can move the rocker arm of exhaust Exhaust valve 0.51 ± 0.05 mm
valves (EX) with the hand by the valve
3. While fixing adjustment screw (14), tighten lock
clearance amount, check the valves marked
nut (15).
with q in the valve layout drawing.
3 Lock nut (15):
a Valve layout drawing
24 ± 4 Nm {2.45 ± 0.41 kgm}
a After tightening lock nut (15), check the valve
clearance again.
8. If the valves marked with Q were adjusted,

rotate the crankshaft forward 1 turn and align the
yellow paint (line) of crankshaft pulley (12) with
HB215LC-2 30-15
4. After finishing the adjustment, remove the

testing tools, and restore the machine.
k Be sure to remove gear C1.

3 The mounting bolt of tube (4) in EGR
circuit (flange side and clamp)
24 ± 4Nm {2.45 ± 0.41 kgm}
3 Clamp of hose (5) in EGR circuit:
10.5 ± 0.5Nm {1.07 ± 0.05 kgm}
3 Cylinder head cover (6) mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
30-16 HB215LC-2
Testing compression pressure (HB205-A000-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1 795-502-1590 Gauge assembly
2 795-799-6700 Puller
3 795-790-4411 Adapter
D
4 6754-11-3130 Gasket
Commercially Inside diameter of hose:
5 Approximately 15 mm
available
k Place the machine on a level ground and

6. Remove retaining nut (6) and remove inlet
k When testing the compression pressure, be connector (7).
careful not to burn yourself by touching the 7. Remove holder (8).
exhaust manifold or KDOC, or get caught in a 8. Remove injector (9).
rotating part.
a Remove injector (9) with the impacts of the
a Check this item under the following conditions. slide hammer by using puller D2.
• Engine oil temperature: 40 to 60°C a Do not pry the top of injector (9) to remove.
Testing (HB205-A000-36B-K-01-A)
1. Remove the cylinder head cover and set the

piston in the target cylinder of testing to the
compression top dead center. For details, see
"Testing and adjusting valve clearance".
a Check that both the intake rocker arm and
exhaust rocker arm at the compression top
dead center are movable by hand by the
distance equivalent to the valve clearance.
2. After removing fuel spray prevention cap (1),
remove the sleeve nut and disconnect high-
pressure pipe (2).
a When measuring compression pressure, fuel
spurts from the disconnected portion of the
common rail side. Therefore you must
connect hose D5 and drain fuel to an oil pan.
k Do not bend high-pressure pipe to correct

before installing.
3. Loosen injector terminal nuts (3) and remove the
harness terminals from the injector.
a Insulate the terminals with tape etc. so that
the adjacent ones of them do not touch each
other. 9. Install gasket D4 to the tip of adapter D3 and
4. Remove rocker arm assembly (4). insert them into the injector mounting portion.
a When removing rocker arm assembly (4), be 10.Fix adapter D3 with holder (8).
careful not to drop the support and shaft. a Tighten the holder (8) mounting bolts
5. Remove crosshead (5). alternately.
3 Holder (8) mounting bolt:
8 ± 0.8 Nm {0.82 ± 0.08 kgm}
11.Install crosshead (5) and rocker arm assembly
(4).
HB215LC-2 30-17
3 Rocker arm assembly (4) mounting 15.Measure the compression pressure when the
bolt: engine is cranked by the starting motor.
36 ± 5 Nm {3.67 ± 0.51 kgm} a Read the compression pressure when the
12.Adjust the valve clearance. gauge pointer stands still.
a See "Testing and adjusting valve clearance". a For standard values, see "Standard value
table", "Standard value table for engine".
16.After finishing the test, remove the testing tools,
a Install the injector and high-pressure pipe
according to the following procedure.
1) Install the injector to the cylinder head while
facing its fuel inlet hole to the air intake
manifold.
a Join protrusion (a) with holder notch (b)
before setting the injector to the cylinder
head.
13.Connect gauge assembly D1 to adapter D3.
a If a small amount of oil is applied to the
connecting parts of gauge assembly D1 and
adapter D3, air will not leak easily.
2) Tighten holder mounting bolt (19) by 3 to 4

threads.
3) Set inlet connector (7).
a Press it in until you feel the ring clicks in.
4) Check inlet connector (7) for the following
14.Select "No-injection Cranking" by operating the items. If anything wrong is found, replace it.
machine monitor.
1] When burrs or wear is found in the inlet
a Turn the battery disconnect switch to ON connector top-end (a) and rear-end (b)
position, and then turn the starting switch to portions.
ON position. 2] When foreign matters are found in the
a For the method to set to "No-injection edge filter at rear-end (c) of the inlet
Cranking", see "Special functions of machine connector.
monitor". 3] When there are cracks or deterioration on
the O-ring of the inlet connector upper (d)
part.
30-18 HB215LC-2
8) Tighten retaining nut (6) of inlet connector

(7).
3 Retaining nut (6) (tightening to the
specified torque):
50 ± 5 Nm {5.1 ± 0.51 kgm}
4] When there is wear or uneven seat

contact on seat surface (e) at front-end of
inlet connector.
a If high-pressure fuel leaks through the
inlet connector, seat surface has fine
streaks or cracks.
9) Tighten sleeve nuts (20) of high-pressure
pipe (2) in the order of cylinder head (21)
side and common rail (10) side.
3 Sleeve nut (20):
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
5) Apply engine oil to the O-ring of inlet

connector (7) and its head side.
2 O-ring and head side of inlet
connector (7)
Engine oil (EO10W30-LA)
10)Install fuel spray prevention cap (1).
6) Tighten inlet connector (7) lightly with
11)Install crosshead (5) and rocker arm
retaining nut (6).
assembly (4).
a After tightening each of them lightly,
3 Rocker arm assembly (4) mounting
tighten it to the specified torque. If
bolt (22):
tightening torque is insufficient or too
much, it will cause fuel leakage inside the 36 ± 5 Nm {3.67 ± 0.51 kgm}
engine. 12)Adjust the valve clearance.
a Install the inlet connector in so that the a See "Testing and adjusting valve
positioning ball of inlet connector (7) clearance".
comes to the guide groove on the 13)Tighten injector terminal nut (3).
cylinder head side. 3 Terminal nut (3):
3 Retaining nut (6) (tightening 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
lightly):
a Check that the injector wiring harness
15 ± 5 Nm {1.53 ± 0.51 kgm} does not interfere with the rocker arm.
7) Tighten mounting bolts (19) for holder (8)
alternately.
3 Holder (8) mounting bolt (19):
8 ± 0.8 Nm {0.82 ± 0.08 kgm}
HB215LC-2 30-19
14)Install the cylinder head cover.

3 Cylinder head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
30-20 HB215LC-2
Testing blowby pressure (PC200_10-A000-360-K-01-A)
a Testing tools
Sym-
Part No. Part name
bol
1 799-201-1506 Blowby checker
Commercially Plug (hose inside
2 diameter: 24 mm)
available
E
Plug (pipe outside
Commercially diameter: 25.4 mm, pipe
3
available inside diameter: 20.4 mm)

a Measure the blowby pressure under the

following conditions.
• Coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
Testing (HB205-A000-36C-K-00-A)
1. Open the engine hood and remove step (1).
4. Start the engine, set the work equipment mode

to power mode (P), and turn the swing lock
switch ON.
a If the swing lock switch is turned to ON
position, the main relief valve is set for high-
pressure relief.
5. Measure the blowby pressure when the
2. Disconnect hose (2) on the KCCV gas outlet hydraulic relief is made by arm IN operation at
side and plug the hose by using plug E2, and engine high idle.
plug the KCCV hose insertion pipe by using plug a Read the value of blowby pressure when
E3. indicator becomes stable. For standard value,
3 Clamp of hose (2): see "Standard value for engine" in "Standard
value table".
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
3. Disconnect hose (3) on the KCCV gas inlet side,
plug the KCCV hose insertion pipe with E3,
install tool and adapter [1] of blowby checker E1
to hose (3), and connect gauge [2].
3 Clamp of hose (3):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}

3 Clamps of hoses (2) and (3):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
HB215LC-2 30-21
Testing engine oil pressure (PC200_10-AB00-360-K-00-A)
a Tools for testing and adjusting

Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
799-101-5160 • Nipple
1
799-101-5150 • Hose
F 790-261-1150 • Hose
2 790-261-1204 Digital hydraulic tester
Gauge (1.0 MPa {10 kg/
3 799-401-2320 cm2})

lower the work equipment to the ground. 4. After finishing the test, remove the testing tools,
a Measure the engine oil pressure under the
following condition.
• Coolant temperature: 60 to 100 °C
Testing (HB205-AB00-362-K-00-A)
1. Open the side cover on the right side of the

machine. Install nipple [1] and hose [2] of
hydraulic tester F1 to the engine oil pressure
pickup port and connect the hose to gauge F3.
a The hose of digital hydraulic tester F2 can
also be used.
2. Start the engine, and turn the auto-decelerator

OFF.
3. Run the engine and measure the engine oil
pressure at high idle and low idle.
30-22 HB215LC-2
Testing fuel pressure (PC160-AE20-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
799-101-5160 • Nipple
1 799-101-5150 • Hose
790-261-1150 • Hose
799-101-5140 • Gauge
2 790-261-1204 Digital hydraulic tester
795-790-4430 Adapter
3
H 6215-81-9710 O-ring
4 795-790-5110 Screw
5 799-401-2320 Gauge
6 795-790-5120 Screw
799-201-2202 Boost gauge kit
799-101-5160 • Nipple
7
799-401-2610 • Hose
799-401-2311 • Gauge
k When removing or installing testing tools, stop the engine and wait for at least 30 seconds until the
remaining pressure is released from the fuel circuit. (Do not start the work immediately after the
engine is stopped since there is remaining pressure.)
k Place the machine on a level ground and lower the work equipment to the ground.
a Measure only the fuel pressure in the low-pressure circuit from the feed pump through the main fuel filter
to the supply pump, and in the return circuit between the supply pump/common rail/ injector and fuel tank.
k Since the pressure in the high-pressure circuit from the supply pump through the common rail to
the injector is very high and dangerous, do not measure it.
HB215LC-2 30-23
A: Low-pressure circuit measuring position (main fuel filter inlet side)

B: Low-pressure circuit measuring position (main fuel filter outlet side)
C: Return circuit measuring position (supply pump drain port)
D: Negative pressure circuit measuring position (supply pump inlet)
Testing (HB205-AE20-362-K-00-A) 3 Adapter H3:
Testing low-pressure circuit (fuel main filter inlet 32 ± 4 Nm {3.26 ± 0.41 kgm}
side)
a Use gauge [3] of 2.5 MPa {25 kg/cm2}.
engine and remove fuel pressure pickup plug (1) a The nipple and hose of digital hydraulic tester
on the inlet side of the fuel main filter. H2 can also be used.
2. Install adapters H3, and install nipple [1] and 3. Start the engine and measure the pressure in
hose [2] of hydraulic tester H1 and connect the the low-pressure circuit with the engine at high
hose to gauge [3]. idle.
a When installing adapter H3, be sure to fit the
O-ring.
30-24 HB215LC-2
a If the engine cannot be started, you may a The nipple and hose of digital hydraulic tester
perform the measurement while rotating the H2 can also be used.
engine by using the starting motor. However,
to protect the starting motor, do not rotate the
engine for more than 20 seconds
continuously.
a The pressure in the low-pressure circuit (on
the inlet side of the fuel main filter) is correct
when it is within the standard value range.
For the standard values, see Standard value
table in "Standard value table for engine".
3. Start the engine and measure the pressure on

the inlet side and outlet side of the low-pressure
circuit with the engine at high idle.
a If the engine cannot be started, you may
perform the measurement while rotating the
continuously.
3 Fuel pressure pickup plug (1):
32 ± 4 Nm {3.26 ± 0.41 kgm}
Testing low-pressure circuit (pressure

difference)
1. Remove fuel pressure pickup plug (1) at the
main fuel filter inlet side and fuel pressure pickup
plug (2) on the outlet side.
4. Calculate the pressure difference in the low-

pressure circuit.
a Pressure difference in low-pressure circuit =
Pressure on fuel main filter inlet side -
Pressure on fuel main filter outlet side
a The pressure in the low-pressure circuit (on
the inlet side of the fuel main filter) is correct
when it is within the standard value range.
For the standard values, see Standard value
table in "Standard value table for engine".
2. Install adapters H3 to the fuel pressure pickup
ports on the inlet side and outlet side, and then a If it exceeds the standard value, the fuel main
install nipples [1] and hoses [2] of hydraulic filter may be clogged. In this case, replace
tester H1 and connect the hoses to gauges [3]. the fuel main filter and measure the pressure
again.
a When installing adapter H3, be sure to fit the
O-ring.
3 Adapter H3:
3 Fuel pressure pickup plugs (1), (2):
32 ± 4 Nm {3.26 ± 0.41 kgm}
32 ± 4 Nm {3.26 ± 0.41 kgm}
a Use gauge [3] of 2.5 MPa {25 kg/cm2}.
HB215LC-2 30-25
Testing return circuit a If the engine cannot be started, you may

1. Remove cover (1). perform the measurement while rotating the
continuously.
2. Remove joint bolt (2) of the fuel return hose

between the supply pump and fuel cooler.

3 Joint bolt (2):
19.6 to 29.4 Nm {2 to 3 kgm}
Testing negative-pressure circuit

1. Remove joint bolt (3) of the fuel hose between
the fuel prefilter and supply pump.
3. Install screw H4, and nipple [1] and hose [2] of
hydraulic tester H1 instead of joint bolt (2), and
connect hose to gauge H5.
a When installing screw H4, be sure to install
the seal washer.
3 Screw H4:
19.6 to 29.4 Nm {2 to 3 kgm}
a The nipple and hose of digital hydraulic tester
H2 can also be used.
2. Install screw H6, and nipple [1] and hose [2] of

boost gauge kit H7 instead of joint bolt (3), and
connect the hose to gauge [3].
a When installing screw H6, be sure to install
the seal washer.
3 Screw H6:
25.4 to 34.3 Nm {2.59 to 3.5 kgm}
a The nipple and hose of digital hydraulic tester
H2 can also be used.
4. Start the engine and measure the pressure in
the return circuit with the engine at high idle.
30-26 HB215LC-2
3. Start the engine and measure the pressure in

the negative pressure circuit with the engine at
high idle.
a If it exceeds the standard value, the fuel
prefilter may be clogged. In this case,
replace the fuel prefilter and measure the
pressure again.

3 Joint bolt (3):
25.4 to 34.3 Nm {2.59 to 3.5 kgm}
HB215LC-2 30-27
Testing fuel discharge, return and leakage (PC160-AE20-360-K-01-A)
a Testing tools
Sym-
Part No. Part name
bol
1 795-790-4700 Tester kit
2 6164-81-5790 Joint
3 07206-30812 Joint bolt
4 6745-71-1130 Seal washer
Commercially Stopwatch
5
J available
Commercially Hose (inside diameter:
6 approximately 14mm)
available
Commercially Measuring cylinder
7
available
Commercially Hose (inside diameter:
8 approximately 8mm)
available
a Since some fuel flows out during test, prepare a container of approximately 20 l.
k When removing or installing testing tools, stop the engine and wait for at least 30 seconds until the
remaining pressure is released from the fuel circuit. (Do not start the work immediately after the
engine is stopped since there is remaining pressure.)
A: Measuring position of supply pump discharged volume

B: Measuring position of supply pump return rate
C: Measuring position of leakage from pressure limiter
D: Measuring position of injector return rate
30-28 HB215LC-2
a When the engine cannot be started, you may

Testing (HB205-AE20-363-K-00-A)
perform the measurement while cranking the
Testing fuel return rate from injector engine by the starting motor. However, to
a The fuel return rate from the injector is measured protect the starting motor, do not crank the
while spill tube (3) of the pressure limiter is engine for more than 20 seconds
connected. Accordingly, before measuring the continuously. "Crank the engine for 15
return rate from the injector, check that the seconds, stop for 15 seconds and then crank
leakage from the pressure limiter is normal. it again for 15 seconds." Perform the
measurement according to this procedure.
1. Remove bracket (1).
2. Remove check valve (2) on the cylinder head,
and disconnect spill tube (3).

3. Install cap nut [1] of tester kit J1 to spill tube (3)
side to prevent outflow of fuel.
a When installing cap nut [1], be sure to install
the seal washer.
4. Install joint J2 to the cylinder head side with joint
bolt J3.
a When installing joint J2, be sure to install the
seal washer.
3 Joint bolt J3:
24 ± 4 Nm {2.45 ± 0.41 kgm}
5. Install hose J8 to joint J2.
3 Spill tube (3) mounting check valve
(2):
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Mounting bolt of bracket (1):
24 ± 4 Nm {2.45 ± 0.41 kgm}
6. Start the engine, and measure the fuel return

rate in 30 seconds by using measuring cylinder
J7 with the engine at low idle.
HB215LC-2 30-29
Bleeding air from fuel system (ALL-AD00-001-K-00-A)
a If fuel is used up or if a fuel circuit component is removed and installed, bleed air from the fuel circuit
Bleeding air (HB205-AD00-231-K-00-A)
1. Fill the fuel tank with fuel.

a Fill it with fuel until the fuel level monitor
becomes blue. (Turn the starting switch to
ON position and check the fuel level on the
monitor.)
machine.
3. Loosen hand primer (1), pull it out, and move it
back and forth.
a Continue the above operation until the
operation of hand primer (1) becomes heavy.
a You may not remove the plug on the top
surface of the main fuel filter.
4. After the air bleeding, push hand primer (1) in,

and tighten it.
30-30 HB215LC-2
Route for bleeding air from fuel circuit

Fuel tank → prefilter → feed pump → main filter → metering unit → fuel tank
HB215LC-2 30-31
Testing fuel circuit for leakage (ALL-AD00-001-K-01-A)
a Testing tools a Relieve the arm circuit at the arm IN stroke

Sym- end.
Part No. Part name 9. Check the fuel piping and devices for fuel
bol
Developer leakage.
Commercially
L
available
for dye penetrant check a Check the high-pressure circuit for fuel
(color checker) leakage focusing on the area to which color
checker L is sprayed.
k Very high pressure is generated in the high-
pressure circuit of the fuel system. If fuel a If any fuel leakage is detected, repair it and
leaks while the engine is running, it presents perform the checks from step 1 again.
a serious danger that could result in a fire. a If no fuel leakage is detected, check is
After testing the fuel system and removing or complete.
installing the tools for the test, test it for fuel
leakage according to the following procedure.

a Clean the engine and the parts around it and

degrease them in advance so that you can
check easily for fuel leakage.
Testing (PC-AD00-364-K-00-A)
1. Spray color checker (developer) L to the fuel

supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep it at low idle , and stop it
when the engine speed is stabilized.
3. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
a If any fuel leakage is detected, repair it and
perform the checks from step 1 again.
4. Start the engine, and keep it running at low idle.
leakage.
6. Start the engine, and keep it running at high idle.
leakage.
8. Start the engine and keep it running at high idle,
then apply a load to the engine.
30-32 HB215LC-2
Handling cylinder cutout mode operation (PC400-AD00-34F-K-00-A)
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:
• Compression leak from cylinder head gasket
• Defective injection from injector
• Defective piston, piston ring or cylinder liner
• Defective valve mechanism (valve operating
system)
• 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 30-33
Handling no-injection cranking operation (PC-A000-25L-K-00-A)
a No-injection cranking means to crank the engine

by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
No-injection cranking is performed to lubricate
the engine parts and to protect them from
seizure. It is performed before the engine is
started, or after the machine has been stored for
a long period.
a When performing no-injection cranking operation,
see "Special functions of machine monitor".
30-34 HB215LC-2
Testing and adjusting air conditioner compressor belt tension (ALL-K5A0-001-K-00-

A)
k Park the machine on a level ground and

Testing (HB205-K5A0-285-K-00-A)
1. Open the engine hood and remove belt guard

(1).
2. Move compressor (3) in direction A to tense the

belt.
a To loosen the belt, move compressor (3) in
direction (B).
2. Press the belt at the intermediate point between

the fan pulley and compressor pulley with your
finger and measure deflection (a).
• Belt pressing force: 60 N {6.2 kg}
• Belt deflection: 6.3 to 8.7 mm
3. When the belt tension becomes appropriate,

tighten bolts (2) (2 pieces).
3 Bolt (2):
98 to 123 Nm {10 to 12.5 kgm}
4. Check that the belt tension is proper. If it is out of
the proper range, adjust it again.
3. After finishing the test, restore the machine. a Check each pulley for breakage, wear of the
Adjusting (HB205-K5A0-27C-K-01-A)
V-groove, and contact of the V-belt with V-
groove.
a If the belt deflection is improper, adjust it
according to the following procedure. a Replace the V-belt with a new one if it is too
stretch to be adjusted, or has slipping sound
1. Loosen bolts (2) (2 pieces).
or squeaks because of cuts or cracks of the
a Be careful not to loosen bolts (2) too much. belt.
a When the V-belt is replaced, check and
adjust its tension again after running the
engine for 1 hour.
5. After finishing the adjustment, restore the
machine.
HB215LC-2 30-35
Replacing fan belt (PC200_10-B430-360-K-00-A)
Replace (HB205-B430-923-K-00-A) k Be careful not to get your fingers caught

1. Open the engine hood to remove compressor between the pulley and fan belt (3) during
belt guard (1) and fan belt guard (2). work.
2. Connect adapter U1 and ratchet handle U2.
3. Install connected adapter U1 and ratchet handle

U2 to (A) part (Width across flats: 12.7 mm) of
tensioner assembly (4).
4. Turn ratchet handle U2 in the direction (R)
opposite to the winding-up direction to loosen
the tension of fan belt (3), and remove fan belt
(3).
k When using ratchet handle U2, do not

attach a pipe to it. (The pipe may come off
when you turn it, and that is very
dangerous.)
k Before turning the handle, check that

adapter U1 and ratchet handle U2 are
connected securely and (a) part of
adapter U1 is set securely to (A) part of
tensioner (4). (If you install adapter U1
and ratchet handle U2 halfway and turn
them, they come off, and that is very
dangerous since the spring of tensioner
(4) is strong.)
k After removing fan belt (3), return

tensioner assembly (4) to its original
position slowly and carefully.
30-36 HB215LC-2
Hybrid system
Precautions related to hybrid equipment (HB380-PQG9-012-K-00-A)
k Before performing testing and adjusting

related to hybrid equipment, understand the
following items fully.
1. Only qualified person can perform removal of

hybrid equipment (motor-generator, capacitor,
inverter, electric swing motor) and high-voltage
wires.
2. Even qualified person must not disassemble the
equipment listed above for quality assurance
reasons.
3. Replace hybrid equipment and high-voltage
wires (orange conduit windings) as units.
4. Before removing hybrid equipment, be to
discharge the capacitors first.
(For the details, see "Discharge of capacitor
electric charge" in "Special functions of machine
monitor".)
The capacitor may not be discharged with
machine monitor depending on the error
occurred.
k The items with this mark relate to
handling of hybrid equipment. Before
performing work, understand "Foreword,
Safety, Basic information", "Handling Hybrid
Equipment and High-Voltage Wires".
HB215LC-2 30-37
Hybrid system
Bleeding air from hybrid cooling system (HB205-PQJA-231-K-00-A)
a Determine the ratio of water in the coolant by

checking the lowest ambient temperature in
the past and checking the mixing proportion
table below.
Actually, set a temperature approximately
10°C lower than the lowest temperature.
Mixing proportion of tap water and Super Coolant
(Exchange capacity in the hybrid system radiator:
6.0 l)
Min. temperature (°C)
Min.
(– (–
–10 –15 –20 –25 –30
35) 40)
Mixing ratio deg.
Amount of
SM: Electric swing motor super
HR: Hybrid radiator coolant 1.8 2.2 2.5 2.8 3.0 3.3 3.5
WP: Hybrid water pump (4) (liters)
HI: Inverter Water
quantity 4.2 3.8 3.5 3.2 3.0 2.7 2.5
HC: Capacitor (liters)
(1): Coolant filler port Volume ratio
(%) 30 36 41 46 50 54 58
(3): Water filler cap
(5): Drain valve
(6): Swing motor air bleeding plug
(7): Swing motor elbow plug (inlet)
(8): Swing motor elbow plug (outlet)
(9): Overflow hose
Bleeding air (HB205-PQJA-231-K-01-A)
k Undiluted super coolant is flammable. Be

careful of open flame.
1. Measure the coolant level in the hybrid radiator.

2. Pour coolant from water filler (1) of the hybrid
radiator slowly (taking approximately 5 minutes) 3. Close radiator cap (3), turn the starting switch to
up to upper side gauge (SG) (2) position. ON position, start the water pump (WP) (4), after
2 minutes, turn the starting switch to OFF
position to stop the water pump (WP) (4).
5 Hybrid radiator:
6.0 l
k Never start the engine.
a Be careful not to spill coolant out from the
a If the time from refilling with coolant to turning
water filler of the hybrid radiator when
on the starting switch is taken too long, air
pouring the water.
accumulates in the water pump suction side
a The mixing proportion of super coolant must causing the water pump defective suction.
be minimum of 30% in volume ratio. Turn on the starting switch promptly after
refilling.
a Use Komatsu genuine Super Coolant (AF-
NAC) as coolant. a To judge if hybrid system water pump (WP)
(4) is running, hear the pump driving sound
a Use tap water as dilution water.
or touch directly to water pump (WP) (4) by
hand. (Pump driving sound is low, so it may
be difficult to judge by driving sound.)
30-38 HB215LC-2
Hybrid system
4. The water level drops when the water pump

rotates. Supply coolant several times until it gets
to upper side gauge (SG) (2).
5. Loosen the radiator cap to complete air
bleeding.
6. Air may remain in the coolant circuit. Perform the
following work.
1) In approximately 8 hours after completing the
work, check the coolant level of the hybrid
radiator.
2) If the coolant level is low, supply coolant until
it gets to upper side gauge (SG) (2).
HB215LC-2 30-39
Hybrid system
Testing water pressure of hybrid coolant (HB380-PQJA-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
796-403-1100 Pressure checker
796-403-1110 • Pressure sensor
V 195-40-31670 • Plug
07002-11823 • O-ring
796-403-1120 • Tool box

3. Start the engine and check for coolant leakage
a Check this item under the following conditions. from the pressure sensor installation portion.
4. Display (15/17) or (17/17) of "Monitoring/Pre-
• Coolant temperature: 60 to 100°C defined" or monitoring code (01142) "Service
Testing (HB205-PQJA-216-K-01-A) Press Sensor (HYB W Pump)". For details, see
1. Remove coolant inlet elbow plug (1) of the swing
motor and install pressure sensor [1] of pressure • "Monitoring/Defined" screen
checker V.
• "Monitoring/Defined" screen
2. Open the side cover on the right side of machine

and install service connector (P49) (2) of main • "Monitoring" screen
harness to the sensor harness.
30-40 HB215LC-2
Hybrid system
5. Run the engine at low or high idle to measure

the water pressure of the hybrid coolant with the
monitor display screen.
a The water pressure (MPa) is converted from
value (A) displayed in monitoring code
(01142) "Service Press. Sensor (HYB W
Pump)" by the following calculation formula.
Water pressure (MPa) = A / 500
table for machine".
6. Disconnect connector (HK01) (4) of water pump
1 (3) and inspect (check) for pressure change.
a After finishing the inspection, connect
connector (HIK01) (4) of water pump 1 (3) to
restore it.

3 Plug (1):
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
HB215LC-2 30-41
Hybrid system
Testing swing parking brake (HB380-J6A0-360-K-00-A)
Testing (HB205-J6A0-360-K-00-A)
Swing parking brake disc is wear parts.

In case of abnormality in the hybrid system, the
swing parking brake stops the swing operation.
However, if abnormality is found in the swing
parking brake such as a wear of brake disc, the
swing operation cannot be stopped.
When the swing operation is stopped by pressing
the swing emergency stop switch, when an
abnormality is found in the swing parking brake
such as hydraulic drift of swing on slope, or when 4. Slowly move the left work equipment lever in left
other users pointed out an abnormality in the swing or right swing direction.
parking brake, inspect the swing parking brake 5. It is normal when upper structure does not move
according to the following procedure. in both directions of right and left.
If wear of the parking brake disc is found in the If upper structure moves, abnormality in
inspection result, replace the parking brake disc. electrical or hydraulic system such as swing lock
For other related abnormality, repair the machine solenoid valve improperly operating or
securely. abnormality in mechanical system such as wear
of parking brake disc is assumed.
1. Set the travel posture of the work equipment to
6. Stop the engine.
the posture for level ground
7. Check for abnormality in electrical or hydraulic
(Raising 40 to 50 cm from bucket ground with
system such as swing lock switch or swing
the arm vertical)
parking brake solenoid valve.
8. If an abnormality is not found in electrical or
hydraulic system as described above,
abnormality in mechanical system is assumed.
In this case, disassemble and investigate the
machine. For details, see Disassembly and
assembly, "Disassembly and assembly of swing
machinery assembly".
9. If the parking brake disc is worn, replace the disk
and reassemble it.
10.After reassembling, check whether the swing
parking brake operates correctly according to
above steps 3 to 5.
2. Move the machine to the level and firm ground
where the machine does not hit obstacles during
swing operation.
3. Set swing lock switch (1) to ON position while
keeping the posture as described in step 1.
30-42 HB215LC-2
Hybrid system
Cleaning and replacing oil filter of electric swing motor (HB380-PQHJ-250-K-00-A)
Cleaning and replacing (HB205-PQHJ-250-K-00-

A)
Electric swing motor filter (1) is installed in the

lubrication and cooling oil system circuit and
collects the dirt in the oil. Cleaning and change of oil
filter is performed every 2000 hours together with oil
change of the electric swing motor.
1. Remove the oil filter.
2. Clean or replace the filter as necessary.
a For Part No. of the filter or O-ring, see part
specifications.
3. Return the removed filter.

3 Filter: 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
HB215LC-2 30-43
Power train
Power train (ALL-C100-001-K-30-A)
Testing swing circle bearing clearance (ALL-J117-001-K-00-A)
a Testing tools 5. From this state, read the dial gauge K value.
Sym-
Part No. Part Name a The value indicated by dial gauge K is the
bol clearance of the bearing.
Commercially Dial gauge
K
available
k Be careful not to put a hand or foot under the

undercarriage, while taking measurement.
Testing (PC-J117-365-K-00-A)
1. Fasten dial gauge K to swing circle outer race

(1) or inner race (2), and touch the probe to the
end surface of inner race (2) or outer race (1) on
the opposite side.
a Set dial gauge K in the front side or rear side
of the machine.
6. Return the machine to the condition of step 2
and check that dial gauge K indicates 0 point.
a If 0 value is not indicated, repeat the steps 3
through 5.
2. Set the work equipment to the maximum reach

posture and set the bucket tip to the height of the
underside of the revolving frame.
a At this time, the front side of the upper
structure rises and the rear side lowers.
3. Set the reading of dial gauge K to the 0 point.
4. Set the arm almost perpendicular to the ground

and lower the boom until the front part of the
tracks float by 150 to 200 mm.
a At this time the front of the upper structure
rises and the rear lowers.
30-44 HB215LC-2
Undercarriage and frame
Testing and adjusting track tension (ALL-DTL0-001-K-00-A)
Testing (PC220-DTL0-285-K-00-A) a You can add grease until dimension (b)

between the idler guide and the track
1. Run the engine at low idle and move the
machine forward by the length of track on frame end becomes 0 mm. If the tension
is still low, the pins and bushings will
ground, and then stop slowly.
become excessively worn. In this case,
2. Place square bar [1] on the track shoes between
turn 180 deg. , or replace the pins and
the idler and the 1st carrier roller.
bushings.
a As the square bar [1], use an angle steel, etc.
which deflects less.
3. Measure maximum clearance (a) between steel
bar [1] and track shoe.
• Standard maximum clearance (a): 10 to 30
mm
2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten it.
k Do not loosen the valve more than 1

turn. Otherwise, the valve jumps out
Adjusting (PC220-DTL0-27C-K-00-A) because of the high-pressure grease
inside.
a If the track tension is improper, adjust it
according to the following procedure. 2) To check that the tension is proper, run the
1. Increasing tension engine at low idle and move the machine
forward by the length of track on ground,
1) Add grease through grease fitting (1) by
then stop slowly.
using a grease gun.
3) After adjusting, check the track tension again
2) To check that the tension is proper, run the
according to the above procedure.
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
HB215LC-2 30-45
Hydraulic system
Releasing remaining pressure from hydraulic circuit (ALL-C000-001-P-02-A)
Releasing remaining pressure (HB205- 3. Start the engine and run it at low idle for 5
C000-22A-K-01-A) seconds to accumulate the pressure in the
Releasing remaining pressure from hydraulic accumulator.
tank a The engine does not start unless the work
k The hydraulic tank is sealed and pressurized. equipment lock lever is set to LOCK
Therefore, when removing a hose or a plug position.
connected to the hydraulic tank, release the 4. Repeat above steps 2) and 3) 2 to 3 times,
remaining pressure in the hydraulic tank and all remaining pressure is released from
according to the following procedure. the piping completely.
• With anti-drop valve
1. Lower the work equipment to the ground in a Check function of PPC accumulator
stable posture and stop the engine.
a Place the machine on a firm, level ground.
2. Loosen oil filler cap (1) of the hydraulic tank
gradually to release the air in the tank. 1. Hold the work equipment in the maximum
reach posture (arm OUT, bucket DUMP
stroke end) at height (a) from the ground.
a: 1.5 m
Releasing remaining pressure in hydraulic

cylinder circuit
• Without anti-drop valve
2. Keep the work equipment at the maximum
reach, turn the starting switch to OFF
k When disconnecting a pipe between a position, and stop the engine.
hydraulic cylinder and the control valve, 3. Set the work equipment lock lever at FREE
release the remaining pressure from the position with starting switch at ON position,
piping according to the following operate the work equipment control levers
procedure. fully in boom LOWER direction, and check
1. Release the remaining pressure in the that the work equipment is lowered to the
hydraulic tank. For details, see preceding ground.
"Releasing remaining pressure in hydraulic a If the work equipment is lowered down
tank". under its weight to the ground, the
a Leave the oil filler cap of the hydraulic accumulator is normal.
tank removed. a Pressure of accumulator drops gradually
2. Turn the starting switch to ON position and after stopping the engine. Be sure to
set the work equipment lock lever to FREE perform this work (steps 2 and 3) in 15
position, operate the right and left work seconds after stopping the engine.
equipment control levers forward and
backward, and to the right and left. a If the work equipment is not lowered or
stops on the way lowering, pressure in
a The control valve is operated by the the accumulator may be dropped.
pressure in the accumulator. But the Pressure cannot be released with this
pressure in the accumulator is used up procedure if the function of accumulator
after the work equipment control levers is deteriorated.
are operated 2 to 3 times.
30-46 HB215LC-2
Hydraulic system
a Accumulator is a periodic inspection item 1) Turn the starting switch to ON position and
and an important periodic replacement set the work equipment lock lever to FREE
part. position, operate the right and left work
backward, and to the right and left.
a The control valve is operated by the
pressure in the accumulator. But the
pressure in the accumulator is used up
after the work equipment control levers
2) Start the engine, and run it at low idle for 5
seconds to accumulate the pressure in the
accumulator.
a The engine does not start unless the work
equipment lock lever is set to LOCK
Releasing remaining pressure from cylinder position once.
4. Repeat above steps 1) and 2) 4 to 5 times, and
1. Operate the arm to the maximum arm IN side all remaining pressure is released from the
and maximum arm OUT side, lower the work cylinders completely.
equipment to the ground, and stop the engine.
a When disassembling the anti-drop valve,
a Since anti-drop valve is attached to boom perform releasing remaining pressure in
cylinder bottom side, remaining pressure cylinders, loosen anti-drop valve assembly
drops due to less hydraulic oil on bottom side mounting bolts gradually. Check that
of boom cylinder when work equipment is hydraulic oil pressure is released, remove it
lowered to the ground. as an assembly, and disassemble it.
Releasing remaining pressure from cylinder
1. Lower the work equipment to the ground with
arm IN operation, and stop the engine.
a Since anti-drop valve is attached to arm
cylinder head side, remaining pressure drops
due to less hydraulic oil on head side of arm
cylinder when work equipment is lowered to
the ground. Also, Remaining oil on head side
is reduced.
2. Loosen oil filler cap of the hydraulic tank

gradually to release the air in the tank.
2. Loosen oil filler cap of the hydraulic tank
gradually to release the air in the tank. a Leave the oil filler cap of the hydraulic tank
removed.
a Leave the oil filler cap of the hydraulic tank
3. Releasing remaining pressure in hydraulic
removed.
cylinder circuit
cylinder circuit 1) Turn the starting switch to ON position and
set the work equipment lock lever to FREE
HB215LC-2 30-47
Hydraulic system
position, operate the right and left work a If the work equipment is lowered down under
equipment control levers forward and its weight to the ground, the accumulator is
backward, and to the right and left. normal.
a The control valve is operated by the a Pressure of accumulator drops gradually
pressure in the accumulator. But the after stopping the engine. Be sure to perform
pressure in the accumulator is used up this work (steps 2 and 3) in 15 seconds after
after the work equipment control levers stopping the engine.
a If the work equipment is not lowered or stops
on the way lowering, pressure in the
accumulator may be dropped. Pressure
accumulator.
cannot be released with this procedure if the
a The engine does not start unless the work function of accumulator is deteriorated.
equipment lock lever is set to LOCK position
a Accumulator is a periodic inspection item and
once.
an important periodic replacement part.
4. Repeat above steps 1) and 2) 4 to 5 times, and
all remaining pressure is released from the
cylinders completely.
perform releasing remaining pressure in
cylinders, loosen anti-drop valve assembly
mounting bolts gradually. Check that
hydraulic oil pressure is released, remove it
as an assembly, and disassemble it.
With anti-drop valve
(Releasing remaining pressure with maximum arm
OUT posture)
Check function of PPC circuit accumulator
Releasing remaining pressure from cylinder
a Place the machine on a firm, level ground.
1. Operate the arm to the maximum arm OUT side,
1. Hold the work equipment in the maximum reach lower the work equipment to the ground, and
posture (arm OUT, bucket DUMP stroke end) at stop the engine.
height (a) from the ground.
a: 1.5 m a Since anti-drop valve is attached to arm
cylinder head side, remaining pressure
increases due to more hydraulic oil applied to
head side when work equipment is lowered
to the ground. If it is the case, perform more
times of releasing of the remaining pressure
from hydraulic piping.
2. Keep the work equipment at the maximum reach,

turn the starting switch to OFF position, and stop
the engine.
3. Set the work equipment lock lever at FREE
position with starting switch at ON position, 2. Loosen oil filler cap of the hydraulic tank
operate the work equipment control levers fully gradually to release the air in the tank.
in boom LOWER direction, and check that the
work equipment is lowered to the ground. a Leave the oil filler cap of the hydraulic tank
removed.
cylinder circuit
30-48 HB215LC-2
Hydraulic system
1) Turn the starting switch to ON position and

set the work equipment lock lever to FREE
position, operate the right and left work
backward, and to the right and left.
a The control valve is operated by the
pressure in the accumulator. But the
pressure in the accumulator is used up
after the work equipment control levers
accumulator.
a The engine does not start unless the work
equipment lock lever is set to LOCK position
once.
4. Repeat above steps 1) and 2) 10 to 15 times,
and all remaining pressure is released from the
cylinders completely.
perform releasing remaining pressure in
cylinders, loosen anti-drop valve assembly
mounting bolts gradually. Check that
hydraulic oil pressure is released, remove it
as an assembly, and disassemble it.
a The control valve spool of the travel motor circuit
is an open type circuit, so the remaining
pressure in the circuit can be released by
performing the same operation as that described
in preceding "Releasing remaining pressure in
hydraulic tank".
HB215LC-2 30-49
Hydraulic system
Testing oil pressure of control circuit (HB380-C010-360-K-00-A)
a Testing tools 3. Start the engine to increase the hydraulic oil

Sym- temperature to 45 to 55°C.
Part No. Part name 4. Measure the hydraulic oil pressure, when the
bol
799-101-5002 Hydraulic tester engine is running at high idle and all the control
1 levers are set to NEUTRAL.
790-261-1204 Digital hydraulic tester
N 5. After finishing the test, remove the testing tools,
2 799-101-5220 Nipple (M10x1.25 mm)
3 07002-11023 O-ring
a Do not adjust the relief valve for the control
k Lower the work equipment to the ground and circuit pressure.
stop the engine. Operate the control levers
several times to release the remaining a The control circuit oil pressure may be tested
pressure in the piping, and then loosen the at EPC source pressure pickup port plug (2)
oil filler cap of the hydraulic tank slowly to (PEPB) (front side of machine) on the main
release the internal pressure. pump.

Testing (HB205-C010-362-K-00-A)
1. Remove oil pressure pickup plug (1) of the

control valve.
2. Install nipple N2 and connect hose [2] and oil

pressure gauge [3] of hydraulic tester N1.
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.
a When installing nipple N2, be sure to install
O-ring N3.
a The nipple and hose of the digital hydraulic
tester can also be used.
30-50 HB215LC-2
Hydraulic system
Testing and adjusting oil pressure in work equipment and travel

circuits (HB380-C000-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
M
2 799-101-5220 Nipple (M10x1.25 mm)
3 07002-11023 O-ring

Then, release the remaining pressure from
the hydraulic system. For details, see
"Releasing remaining pressure from
2. Increase the hydraulic oil temperature to 45 to
hydraulic system".
55°C and measure the pump discharged
a Check this item under the following conditions. pressure.
• Hydraulic oil temperature: 45 to 55°C Testing by using the testing tools
Testing (HB205-C000-362-K-01-A) 1. Open the side cover on the left side of machine,
and remove oil pressure pickup plugs (1) and (2)
a The oil pressures in the work equipment, swing, of main pump.
and travel circuits (pump discharged pressures)
• (1): Front pump discharged pressure pickup
can be checked from "Monitoring/Pre-defined" or
port (PFC) (rear side of machine)
"Monitoring / Custom" screen of the machine
• (2): Rear pump discharged pressure pickup
monitor.
port (PRC) (front side of machine)
Measuring method by using machine monitor
1. Start the engine and display "Monitoring/Pre-
defined" or "Monitoring/Custom" screen. For
details, see "Special functions of machine
monitor".
• Monitoring code: 01100 "F Pump Pressure"
• Monitoring code: 01101 "R Pump Pressure"
• "Monitoring/Pre-defined (08/17)" screen
• "Monitoring" screen
2. Install nipple M2 and connect it to hose [2] and

oil pressure gauge [3] of hydraulic tester M1.
a Use the oil pressure gauge of 60 MPa {600
kg/cm2}.
HB215LC-2 30-51
Hydraulic system
a When installing nipple M2, be sure to install a When the work equipment circuit is relieved
O-ring M3. singly, the oil flows from the pumps are merged.
When the travel circuit is relieved singly, the oil
a Joint and nipple of hydraulic tester M1 can
flows from the pumps are divided.
also be used instead of nipple M2.
a The actuators in the table are arranged in the
order that the control valves are viewed from the
front of the machine. (As for the service valve,
the table shows an example of 1 attachment
specification.)
Pump Actuator Valve to be relieved
(R unload valve) (R main relief valve)
Service Safety valve
Rear
pump Bucket R main relief valve
L.H. travel R main relief valve
Boom R main relief valve
(Merge-divider valve) (Travel junction valve)
(Self-pressure reducing valve)
Front R.H. travel F main relief valve
pump Arm Lo F main relief valve
(F unload valve) (F main relief valve)
(Centralized safety valve) (Back pressure valve)
Testing unload pressure

1. Start the engine, set the working mode to "P"
mode, and set the auto deceleration OFF.
2. Set all control levers and pedals to NEUTRAL
and measure the oil pressure while running the
engine at high idle.
3. Start the engine to increase the hydraulic oil a Hydraulic oil pressure when the unload valve
temperature to 45 to 55°C and measure oil unloads is displayed.
pressure gauge [3] values.
a For standard values, see "Standard value table for engine".
table for engine".
Testing work equipment relief pressure
1. Start the engine, and set the working mode to P
mode.
2. Operate the cylinder to be measured to the
stroke end with engine running at high idle.
3. Measure hydraulic oil pressure when the
cylinder is relieved.
a The pressure at the time when the main relief
valve is relieved is displayed.
a If the one-touch power maximizing switch is
not pressed, the low relief pressure is
obtained. If the former is pressed, the high
relief pressure is obtained.
Combination of pump, actuator, and valve a If the swing lock switch is set to ON position,
a When the oil flow is divided at pumps, front the 2-stage relief valve is kept ON and the
pump and rear pump act individually to each relief valve is relieved at high pressure.
actuator as following table. The valve to be Therefore, keep the swing lock switch at OFF
relieved differs depending on the actuator, so position during measurement.
take care. a For standard values, see "Standard value
table for engine".
30-52 HB215LC-2
Hydraulic system
Testing travel relief pressure a For the low-pressure relief pressure, the 2-stage
1. Run the engine, and lock the travel mechanism. relief solenoid valve is OFF. The pilot pressure is
not applied to the selector port.
k Insert pin [2] between the sprocket and
the track frame to securely lock the track.
1. Disconnect the pilot hose.

2. While fixing pressure adjustment screw (5),
2. Set the working mode to P mode. loosen lock nut (6).
3. Measure the pressure when the engine is 3. Turn pressure adjustment nut (5) to adjust the
running at high idle and the travel circuit is pressure.
relieved.
a When pressure adjustment screw (5) is
k Before operating the travel lever or pedal, • turned clockwise, the pressure is
check the pin position and locked increased.
direction of the travel again. • turned counterclockwise, the pressure is
decreased.
a The pressure at the time when the main relief
valve is relieved is displayed. The travel a Quantity of adjustment per turn of pressure
circuit is always relieved at high pressure. adjustment screw (5):
a For standard values, see "Standard value Approximately 20.5 MPa {Approximately 209
table for engine". kg/cm2}
4. While fixing pressure adjustment screw (5),
Work after finishing test tighten lock nut (6).
After finishing the test, remove the testing tools, and 3 Lock nut (6):
restore the machine.
49 to 58.8 Nm {5 to 6 kgm}
Adjusting (HB205-C000-270-K-00-A)
a The unload valve cannot be adjusted.
Adjustment of work equipment and travel relief

pressure
a If the work equipment and travel relief pressure
are not normal, adjust main relief valves (3) and
(4) according to the following procedure.
• (3): Main relief valve for front pump circuit
• (4): Main relief valve for rear pump circuit
a When adjusting the main relief valve on the front
pump side, remove the lower cover of the control
valve. 5. Connect the pilot hose.
6. After finishing the adjustment, recheck the oil
a When adjusting the main relief valve on the rear
pressure according to the testing procedure
pump side, remove the fuel tank cover.
described above.
a Adjust the low-pressure relief pressure only to
adjust the main relief valve. By adjusting the low-
pressure relief pressure, the high-pressure relief
pressure is also set automatically because of the
structure of the relief valve.
HB215LC-2 30-53
Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit (HB380-C2A3-360-K-

00-A)
a Testing tools 2. Install nipple P2 to the pickup ports of the front

Sym- and rear pumps.
Part No. Part name
bol a When installing nipple P2, be sure to install
799-101-5002 Hydraulic tester O-ring P3 to nipple P2.
1
790-261-1204 Digital hydraulic tester 3. Connect hose [2] and oil pressure gauge [3] of
P
2 799-101-5220 Nipple (M10x1.25 mm) hydraulic tester P1 to front pump control
3 07002-11023 O-ring pressure pickup port (Pen F).
k Lower the work equipment to the ground and a Use the oil pressure gauge of 60 MPa {600
stop the engine. Operate the control levers kg/cm2}.
several times to release the remaining a Joint and nipple of hydraulic tester P1 can
pressure in the piping, and then loosen the also be used instead of nipple P2.
oil filler cap of the hydraulic tank slowly to
release the internal pressure.
a Before testing the oil pressure in the pump PC

control circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
the oil pressure of the control circuit are proper.
a Measure the pump control pressure (servo
piston inlet pressure) under the following
condition.
Testing (HB205-C2A3-362-K-01-A)
Measurement of pump control pressure (servo
piston inlet pressure)
a To measure the pump control pressure (servo
piston inlet pressure), measure the front and
rear pump discharged pressures simultaneously
and compare the oil pressure ratio.
a Front pump discharge pressure and rear pump
discharge pressure can be checked on
"Monitoring/Pre-defined" or "Monitoring/Custom"
screen of the machine monitor.
1. Remove control pressure pickup plugs (1) and
(2) of the main pump.
4. Start the engine and display "Monitoring/Pre-
• (1): Front pump control pressure pickup port
defined" or "Monitoring/Custom" screen. For
(Pen F)
• (2): Rear pump control pressure pickup port
monitor".
(Pen R)
• Monitoring code: 01100 "F Pump Pressure"
30-54 HB215LC-2
Hydraulic system
5. Increase the hydraulic oil temperature to 45 to 9. Start the engine and display "Monitoring/Pre-
55°C. defined" or "Monitoring/Custom" screen. For
6. Measure the pump discharged pressure and details, see "Special functions of machine
pump control pressure (servo piston inlet monitor".
pressure) simultaneously after setting the • Monitoring code: 01101 "R Pump Pressure"
machine to the following conditions with the • "Monitoring/Pre-defined (10/17)" screen
engine running at high idle.
(The 2-stage relief solenoid valve is ON and
in high-pressure relief state.)
• Work equipment: Arm IN relief
table for machine".
a If the PC valve or the servo piston is
defective, the pump control pressure (servo
piston inlet pressure) comes to the "same
pressure as the pump discharged pressure",
or "almost 0".
10.Increase the hydraulic oil temperature to 45 to
55°C.
11.Measure the pump discharged pressure and
8. Connect hose [2] and oil pressure gauge [3] of
pump control pressure (servo piston inlet
hydraulic tester P1 to rear pump control pressure) simultaneously after setting the
pressure pickup port (Pen R) (2). machine to the following conditions with the
a Use the oil pressure gauge of 60 MPa {600 engine running at high idle.
kg/cm2}. • Working mode: P mode
a Joint and nipple of hydraulic tester P1 can • Swing lock switch: ON
also be used instead of nipple P2. (The 2-stage relief solenoid valve is ON and
in high-pressure relief state.)
• Work equipment: Arm IN relief
table for machine".
a If the PC valve or the servo piston is
defective, the pump control pressure (servo
piston inlet pressure) comes to the "same
pressure as the pump discharged pressure",
or "almost 0".
Measurement of PC mode selector pressure
1. Remove oil pressure pickup plugs (3) and (4) of
the main pump.
HB215LC-2 30-55
Hydraulic system
• (3): Front pump PC mode selector pressure 5. Measure the oil pressure with all the control
pickup port (PMF) levers in NEUTRAL and with the engine running
• (4): Rear pump PC mode selector pressure at low idle and at high idle.
pickup port (PMR) • Working mode: P mode
• Swing lock switch: OFF
table for machine".
hydraulic tester P1 to rear pump PC mode
selector pressure pickup port (PMR) (4).
a Use the oil pressure gauge of 6.0 MPa {60
kg/cm2}.
2. Install nipple P2 to the pickup ports of the front tester can also be used.
and rear pumps.
a When installing nipple P2, be sure to install
O-ring P3 to nipple P2.
hydraulic tester P1 to front pump PC mode
selector pressure pickup port (PMF) (3).
a Use the oil pressure gauge of 6.0 MPa {60
kg/cm2}.
a Joint and nipple of hydraulic tester P1 can
also be used instead of nipple P2.
8. Start the engine to increase the hydraulic oil

temperature to 45 to 55°C.
9. Measure the oil pressure with all the control
levers in NEUTRAL and with the engine running
at low idle and at high idle.
table for machine".
Adjusting (HB205-C2A3-270-K-00-A)
a When the following phenomena occur and the

PC valve seems to be defective, adjust PC
valves (5) and (6).
• When the working load increases, the engine
speed drops largely.
• The engine speed is normal but the work
equipment speed is low.

30-56 HB215LC-2
Hydraulic system
a The width across flats of the lock nut for PC

valve is 13 mm, and the width across flats
(inside) of the adjustment screw for PC valve is
4 mm. Do not turn the other lock nuts and
adjustment screws since it affects to the main
pump performance.
• (5): Front pump PC valve
• (6): Rear pump PC valve
4. After finishing the adjustment, check the pump

control pressure (servo piston inlet pressure)
1. Loosen lock nut (7).

a Before loosening lock nut (7), make a
matchmark on the end surface of adjustment
screw (8) so that you can see the position
before the adjustment (you can return to the
original position by rotating in reverse).
2. Adjust by rotating adjustment screw (8)
clockwise or counterclockwise.
a Rotate adjustment screw (8):
• Turn the screw clockwise when the work
equipment speed is low (to increase the
pump absorption torque)
• Turn the screw counterclockwise when
the engine speed is low (to decrease the
pump absorption torque).
a Adjustable range of adjustment screw is as
described below.
Counterclockwise: Within 1 turn
Clockwise: Within 1/2 turn (180 ° or less)
3. Tighten lock nut (7).
3 Lock nut (7):
27 to 34 Nm {2.8 to 3.5 kgm}
HB215LC-2 30-57
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit (HB380-C2A4-360-K-00-

A)
a Testing tools
Sym-
Part No. Part name
bol
1
Sensor adapter (pressure
2 796T-440-1101 range: 50 MPa {500 kg/
Q cm2})
3 799-101-5220 Nipple (10 x 1.25 mm)
4 07002-11023 O-ring
Differential pressure
5 799-401-2701 gauge
k Lower the work equipment to the ground and a To obtain the LS pressure (actuator load
stop the engine. Operate the control levers pressure), measure the front and rear pump
several times to release the remaining discharge pressures simultaneously, and
pressure in the piping, and then loosen the calculate the difference pressure.
oil filler cap of the hydraulic tank slowly to 1. Remove LS oil pressure pickup plugs (1) and (2)
release the internal pressure. of the main pump.
• (1): Front pump LS pressure pickup port
a Before measuring the oil pressure in the pump (PLSFC)
LS control circuit, check that the oil pressure in • (2): Rear pump LS pressure pickup port
the work equipment and travel circuits and the (PLSRC)
oil pressure of the control circuit are normal.
a Measure the LS valve output pressure (servo
piston inlet pressure) under the following
condition.
Testing (HB205-C2A4-362-K-01-A)
Measuring LS differential pressure with the
machine monitor
screen of the machine monitor. 2. Install nipple Q3 to the pickup ports of the front
a LS pressure (actuator load pressure) can be and rear pumps.
checked on "Monitoring/Pre-defined" or a When installing nipple Q3, be sure to install
"Monitoring/Custom" screen of the machine O-ring Q4.
monitor by using service oil pressure connector 3. Connect sensor adapter Q2 to front pump LS
(CN-P49) (11) (in the revolving frame on the left pressure pickup ports (PLSFC)(1).
side of the machine).
30-58 HB215LC-2
Hydraulic system
4. Connect sensor adapter Q2 to service oil discharge pressure and LS pressure (actuator
pressure connector (CN-P49) (11) (in the load pressure) simultaneously.
revolving frame on the left side of the machine). • Working mode: P mode
• Travel speed: Hi
• All control levers are at NEUTRAL and travel
control lever is at half stroke (to run a track
idle off ground).
k Run the raised track idle, paying enough

attention to the surroundings for safety.
table for machine".
9. Connect sensor adapter Q2 to rear pump LS
5. Start the engine and display "Monitoring/Pre- pressure pickup port (2).
defined" (09/17) screen. For details, see
• Monitoring code: 01141 "Service Pressure"
10.Connect sensor adapter Q2 to service oil

pressure connector (CN-P49) (11) (in the
revolving frame on the left side of the machine).

55°C ,and raise the track of the side to be tested
off the ground.
• When measuring front circuit: R.H. track
k Provide a enough work space to run the

track idle off the ground.
11.Start the engine and display "Monitoring/Pre-

defined" (09/16) screen. For details, see
• Monitoring code: 01141 "Service Pressure"
• "Monitoring / Pre-defined (10/17)" screen
7. While running the engine at high idle under the

following condition, measure the pump
HB215LC-2 30-59
Hydraulic system

discharge pressure can be checked on the
the main pump.
• (1): Front pump LS pressure pickup port
(PLSFC)
• (2): Rear pump LS pressure pickup port
(PLSRC)
12.Increase the hydraulic oil temperature to 45 to

off the ground.
• When measuring rear circuit: L.H. track

2. Install nipple Q3 to the pickup ports of the front

and rear pumps.
a When installing nipple Q3, be sure to install
O-ring Q4.
hydraulic tester Q1 or differential pressure
gauge Q5 to front pump LS pressure pickup port
(1).
13.While running the engine at high idle under the kg/cm2}.
following condition, measure the pump a Since the differential pressure is 3.9 MPa {40
discharge pressure and LS pressure (actuator kg/cm2} at maximum, use the same gauge
load pressure) simultaneously. throughout the measurement, reconnecting it
• Working mode: P mode properly.
a Joint and nipple of hydraulic tester Q1 can
also be used instead of nipple Q3.
idle off ground).

table for machine".
Measuring LS differential pressure with oil
pressure gauge
a To obtain the LS pressure (actuator load
pressure), measure the front and rear pump
discharge pressures simultaneously, and
calculate the difference pressure.
30-60 HB215LC-2
Hydraulic system
discharge pressure and LS pressure (actuator

load pressure) simultaneously.
idle off ground).

table for machine".
a When using differential pressure gauge Q5:
Connect the pump discharge pressure to the 7. Connect hose [2] and oil pressure gauge [3] of
high-pressure side (reverse side), and hydraulic tester Q4 to rear pump LS pressure
connect the LS pressures to the low- pickup port (2).
pressure side (lower side).
a The differential pressure gauge needs 12 V kg/cm2}.
DC power, so connect it to a battery.
a Joint and nipple of hydraulic tester Q1 can
also be used instead of nipple Q3.

off the ground.

a When using differential pressure gauge Q5:

Connect the pump discharge pressure to the
high-pressure side (reverse side), and
connect the LS pressures to the low-
pressure side (lower side).
5. While running the engine at high idle under the a The differential pressure gauge needs 12 V
following condition, measure the pump DC power, so connect it to a battery.
HB215LC-2 30-61
Hydraulic system

the main pump.
• (3): Front pump control pressure pickup port
(Pen F)
• (4): Rear pump control pressure pickup port
(Pen R)
8. Start the engine. Increase the hydraulic oil

temperature to 45 to 55°C and raise the track of
the side to be tested off the ground.

2. Install nipple Q3 to the pickup ports of the front

and rear pumps.
a When installing nipple Q3, be sure to install
O-ring Q4.
hydraulic tester Q1 to front control pressure
pickup port (3).
kg/cm2}.
9. While running the engine at high idle under the a Joint and nipple of hydraulic tester Q1 can
following condition, measure the pump also be used instead of nipple Q3.
discharge pressure and LS pressure (actuator
load pressure) simultaneously.
idle off ground).

table for machine".
Measuring LS valve output pressure (servo
piston inlet pressure)
a To measure the LS valve output pressure (servo
piston inlet pressure), measure the front and
rear pump discharge pressures simultaneously
and compare them.
30-62 HB215LC-2
Hydraulic system

off the ground.


off the ground.

5. While running the engine at high idle under the
following condition, measure the pump
discharge pressure and LS valve output
pressure (servo piston inlet pressure)
simultaneously.
idle off ground).

a For standard values, see "Standard value 9. While running the engine at high idle under the
table for machine". following condition, measure the pump
6. After finishing the test, remove the testing tools, discharge pressure and LS valve output
and restore the machine. pressure (servo piston inlet pressure)
7. Connect hose [2] and oil pressure gauge [3] of simultaneously.
hydraulic tester Q1 to rear control pressure • Working mode: P mode
pickup port (4). • All control levers are at NEUTRAL and travel
a Use the oil pressure gauge of 60 MPa {600 control lever is at half stroke (to run a track
kg/cm2}. idle off ground).
a The nipple and hose of the digital hydraulic k Run the raised track idle, paying enough
tester can also be used. attention to the surroundings for safety.
HB215LC-2 30-63
Hydraulic system

table for machine".
Measuring LS-EPC valve output pressure
1. Remove oil pressure pickup plug (7) of the main
pump.
• (7): LS set selector pressure pickup port
(Psig)

5. Measure the oil pressure while the engine is
running at high idle and the travel speed switch
and travel control lever are operated.
table for machine".
Note: Operate the travel control lever to a
degree that the PPC oil pressure switch is just
turned on (position just before the machine
2. Install nipple Q3 to the pickup port.
starts moving).
a When installing nipple Q3, be sure to install 6. After finishing the test, remove the testing tools,
O-ring Q4. and restore the machine.
Adjusting (HB205-C2A4-270-K-00-A)
hydraulic tester Q1 to LS set selector pressure
pickup port (7). a If the LS differential pressure is abnormal, adjust
LS valves (8) and (9) according to the following
a Use the oil pressure gauge of 6.0 MPa {60 procedure.
kg/cm2}.
• (8): Front pump LS valve
a The nipple and hose of the digital hydraulic • (9): Rear pump LS valve
1. While fixing adjustment screw (10), loosen lock

nut (11).
2. Turn adjustment screw (10) to adjust the
pressure.
a Rotate the adjustment screw:
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure is
decreased.
30-64 HB215LC-2
Hydraulic system
a Quantity of pressure adjustment (LS

differential pressure) per turn of adjustment
screw (10):
Approximately 1.3 MPa {Approximately 13.3
kg/cm2}
3. While fixing adjustment screw (10), tighten lock
nut (11).
3 Lock nut (11):
49 to 68.6 Nm {5 to 7 kgm}
4. After finishing the adjustment, check the LS

differential pressure according to the above
procedure.
HB215LC-2 30-65
Hydraulic system
Testing outlet pressure of solenoid valve (HB380-PQPT-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
799-401-3100 Adapter (size: 02)
R 2
02896-11008 O-ring
799-401-3200 Adapter (size: 03)
3
02896-11009 O-ring
k Lower the work equipment to the ground and

several times to release the remaining
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
a Before testing the solenoid valve outlet pressure,

check that the control circuit oil pressure is
normal.
Testing (HB205-PQPT-362-K-01-A)
Testing with machine monitor a For the conditions for turning the solenoid
valve ON/OFF, see the operation table of
a The solenoid valve outlet pressure can be
each solenoid valve.
checked with "Monitoring" screen of machine
monitor. a When the solenoid valve displayed on the
1. Start the engine and display "Monitoring/ "Monitoring" screen is "ON", the pressure is
Custom" screen. For details, see "Special normal.
functions of machine monitor". Measuring with oil pressure gauge
• Monitoring code: 02300 "Solenoid 1" 1. Disconnect one of outlet hose (1) to (7) of the
• Monitoring code: 02301 "Solenoid 2" solenoid valve to be measured.
• "Monitoring/Custom" No. Solenoid valve to be tested
1 PPC lock solenoid valve
2 2-stage relief solenoid valve
3 Swing parking brake solenoid valve
4 Travel speed solenoid valve
5 Travel junction solenoid valve
Attachment selector solenoid valve (for the
6 attachment installed specification)

55°C.
3. Run the engine at high idle, operate each control
lever and switch, turn the solenoid valve ON or
OFF, and check "Monitoring/Custom" screen.
30-66 HB215LC-2
Hydraulic system
a When checking PPC lock solenoid outlet 5. Run the engine at high idle, operate each control
pressure at the place beneath the cab, lever and switch, turn the solenoid valve ON or
remove the cover at bottom of the cab and OFF, and then measure the oil pressure.
remove hose (7).
a For the conditions for turning the solenoid
valve ON/OFF, see the operation table of
each solenoid valve.
table for machine".
2. Install adapter R2 or R3 and connect the

disconnected hose again.
3. Install nipple [1], hose [2], and oil pressure
gauge [3] of hydraulic tester R1.
cm2}.
a The figure shows the installation to outlet
hose (3) of the solenoid valve.

HB215LC-2 30-67
Hydraulic system
Operating condition (HB205-PQPT-04C-K-01-A)
(1) PPC lock solenoid valve operation table

Solenoid
No. Operating condition energized
(operation) status
Locked OFF
1 PPC lock lever
Canceled ON
(2) 2-stage relief solenoid valve operation table
Solenoid
(operation) status
1 Overheat 1st setting signal ON
2 Overheat 2nd setting signal ON OFF
3 All signals of work equipment, swing, and travel OFF
4 Swing lock switch: ON
5 Travel operation signal ON
6 Working mode: L
ON
7 Operation signal of Boom LOWER ON
Other than signals below
8 One-touch power
Working mode: P, E ON
maximizing switch ON
9 Signal of sole swing ON
OFF
10 Other than the above conditions
(3) Travel junction solenoid valve operation table
Solenoid
(operation) status
1 Operation signal of travel steering ON
Operation signal of When F or R pump pressure is 24.5 MPa ON
Operation signal of {250 kg/cm2} or higher
2 sole travel ON
travel steering OFF
Other than the above conditions OFF
(4) Swing parking brake solenoid valve operation table
Solenoid
(operation) status
1 Operation signal of work equipment and All signals OFF OFF
swing
2 (work equipment including services) Either of signals ON ON
(5) Travel speed solenoid valve operation table

Solenoid
(operation) status
1 Overheat 2nd setting signal ON
2 Fuel dial 1,200 ppm or lower
3 Travel speed switch: Lo, Mi (HB205-2)
OFF
Travel operation signal OFF
Travel speed F or R pump pressure 24.5 MPa {250 kg/
4 switch: Hi (HB205- Travel operation cm2} or higher
2) signal ON F or R pump pressure 14.7 MPa {150 kg/
cm2} or lower ON
5 Conditions other than above 1 to 4
(6) Attachment selector solenoid valve operation table
30-68 HB215LC-2
Hydraulic system
Solenoid
(operation) status
1 When working mode is other than B OFF
2 When working mode is B ON
HB215LC-2 30-69
Hydraulic system
Testing PPC valve outlet pressure (HB380-PW11-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
799-401-3100 Adapter (size: 02)
S 2
02896-11008 O-ring
799-401-3200 Adapter (size: 03)
3
02896-11009 O-ring
k Lower the work equipment to the ground and

several times to release the remaining 2. Increase the hydraulic oil temperature to 45 to
pressure in the piping, and then loosen the 55°C.
oil filler cap of the hydraulic tank slowly to 3. Run the engine at high idle, set the control
release the internal pressure. levers of the tested circuit to NEUTRAL position,
and then measure the oil pressure at full stroke.
a Before testing PPC valve outlet pressure, check
that the control circuit oil pressure is normal. a For standard values, see "Standard value
table for machine".
• Hydraulic oil temperature: 45 to 55°C Testing by using the testing tools
1. Disconnect hydraulic hoses (1) to (10) of PPC
Testing (HB205-PW11-362-K-01-A) circuit to be tested.
Testing with machine monitor Circuit to be Circuit to be
1. Start the engine and display the "Monitoring/Pre- No. No.
measured measured
defined" or "Monitoring/Custom" screen. For Bucket CURL Boom RAISE
1 (White) 6 (Green)
monitor". Bucket DUMP Travel R.H.
2 (Black) 7 FORWARD (Green)
• Monitoring code: 07200 "Arm Curl (IN) PPC
Pressure" Travel L.H. Travel R.H.
3 FORWARD (Red) 8 REVERSE (Blue)
• Monitoring code: 07600 "Arm Dump (OUT)
PPC Pressure" Travel L.H.
4 REVERSE (None) 9 Arm IN (Blue)
• Monitoring code: 07300 "Bucket Curl PPC
Pressure" Boom LOWER
5 (Brown) 10 Arm OUT (Yellow)
• Monitoring code: 07301 "Bucket Dump PPC
Pressure" • The colors in ( ) are the colors of the bands
• Monitoring code: 07400 "Boom Raise PPC installed for piping identification.
Pressure"
• Monitoring code: 07500 "Boom Lower PPC
Pressure"
• Monitoring code: 09001 "Swing Left PPC
Pressure"
• Monitoring code: 09002 "Swing Right PPC
Pressure"
• Monitoring code: 07102 "Travel Fwd L.H.
PPC Pressure"
• Monitoring code: 07103 "Travel Fwd R.H.
PPC Pressure"
• Monitoring code: 07104 "Travel Rev L.H.
PPC Pressure"
• Monitoring code: 07105 "Travel Rev R.H.
PPC Pressure" 2. Install nipple [2] of hydraulic tester S1 and
• "Monitoring/Pre-defined (11/17)" screen connect oil pressure gauge [1] to it.
30-70 HB215LC-2
Hydraulic system

cm2}.
3. Start the engine, and set the working mode to P

mode.
4. Run the engine at high idle, set the control
levers of the tested circuit to NEUTRAL position,
and then measure the oil pressure at full stroke.
table for machine".
HB215LC-2 30-71
Hydraulic system
Adjusting play of work equipment and swing PPC valves (ALL-PL28-001-K-00-A)
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 measured at a position of
200 mm from the pivot must be 0.5 to 3 mm.
Adjusting (PC400-PL28-270-K-00-A)
1. Remove boot (1).

2. Loosen locknut (2) and tighten disc (3) until it
touches the heads of 4 pistons (4).
a Do not move the piston at this time.
3. Fix the position of disc (3) and tighten locknut (2)
to the specified torque.
3 Locknut:
69 to 88 Nm {7 to 9 kgm}
4. Install boot (1).
30-72 HB215LC-2
Hydraulic system
Testing pump swash plate sensor (PC200_10-C3WG-360-K-01-A)
Testing (PC220-C3WG-36J-K-00-A)
1. Start the engine and raise the track on the side

to be tested, by using the work equipment, and
prepare for running the track idle.
• When testing front pump: right track
• When testing rear pump: left track
k Provide an enough work space to run the

2. Set the working mode to the Power Mode (P)
and set the travel speed to the High.
3. Set the swing lock switch to ON position.
4. While running the engine at high idle, set all the
levers and pedals for work equipment, swing,
and travel to the neutral, and then set the travel
lever to stroke end in order to run a track idle,
and measure the voltage during each operation.
k While taking care of safety around the
machine, run the raised track idle.
a Testing condition and judgment: If the voltage is

as shown in the standard value, the pump
swash plate sensor is normal. For standard
values, see "Standard value table for machine".
HB215LC-2 30-73
Hydraulic system
Isolating the parts causing hydraulic drift in work equipment (ALL-L410-001-K-00-A)
a If the work equipment (cylinder) drifts

hydraulically, perform check to see if the
problem is in the cylinder seal or control valve
Testing (PC-L410-360-K-00-A)
1. Testing boom cylinder and bucket cylinder

1) Stop the engine with the same posture as the
hydraulic drift measurement.
a Apply rated load to the bucket inside or fill
the bucket with soil or sand.
2) Operate the arm control lever to IN again to

determine the test results.　
• When the lowering speed is increased at
this time, the cylinder packing is
defective.
• If the lowering speed does not change at
this time, the control valve is defective.
a The control lever can be operated when
the starting switch is set to ON position.
a If the accumulator pressure is reduced,
run the engine for approximately 10
2) For boom, move the boom control lever to seconds to accumulate the pressure.
"RAISE" side. For bucket, move the bucket [Reference] Reasons why the lowering speed is
control lever to "CURL" side. increased by the above operation when the
• When the lowering speed is increased at cylinder packing causes the hydraulic drift:
this time, the cylinder packing is 1) When the machine is set in the above
defective. posture (where the holding pressure is
• If the lowering speed does not change at applied to the bottom side), the oil leaks from
this time, the control valve is defective. the bottom side to the head side. Since the
Determine the test results as described volume on the head side is less than that on
above. the bottom side by the volume of the rod, the
pressure in the head side is increased by the
a The control lever can be operated when
oil flowing in from the bottom side.
the starting switch is set to ON position.
2) As the internal pressure on the head side
a If the accumulator pressure is reduced, increases, both pressures come to balance
run the engine for approximately 10 at a certain level of pressure (depending on
seconds to accumulate the pressure. leakage), and the lowering speed becomes
2. Testing arm cylinder slower.
1) Operate the arm control lever to IN, and stop 3) If the circuit on the head side is opened to
the engine at the time when the arm cylinder the drain circuit by the above operation of the
extends to approximately 100 mm front of the lever (the bottom side is closed by the check
stroke end. valve at this time), the oil in the head side
flows in the drain circuit. As a result, the
pressure is imbalanced and the lowering
speed is increased.
3. Testing PPC valve
Test the lowering volume of the work equipment
when the work equipment lock lever is set to the
LOCK position and FREE position with the
pressure accumulated in the accumulator.
a The control lever can be operated when the
starting switch is set to ON position.
30-74 HB215LC-2
Hydraulic system
a If the accumulator pressure is reduced, run

the engine for approximately 10 seconds to
accumulate the pressure.
a In case of a difference of lowering volume
between the LOCK and FREE positions, the
PPC valve is defective (internal defect).
HB215LC-2 30-75
Hydraulic system
Testing oil leakage (ALL-C000-001-P-03-A)
a Component to be checked adjusting, "Bleeding air from hydraulic

Sym- circuit".
Part No Part Name 2. Testing oil leakage of arm cylinder
bol
Available on Measuring cylinder 1) Set the arm cylinder at its extension stroke
T
the market end, and stop the engine.
a Measure the oil leakage under the following
k Release the remaining pressure in the
condition.
piping on the arm cylinder head side
• Hydraulic oil temperature: 45 to 55 °C (however, operate the lever only in the
Testing (HB205-C000-364-K-00-A) arm IN direction). For details, see
"Releasing remaining pressure in
1. Testing oil leakage of boom cylinder hydraulic circuit".
1) Set the boom cylinder at RAISE stroke end,
and stop the engine. 2) Disconnect hose (2) on the cylinder head
side, and block the hose side by using a
flange.
piping on the boom cylinder head side
k Take care not to disconnect the hose
(however, operate the lever only in the
boom RAISE direction). For details, on the cylinder bottom side.
see "Releasing remaining pressure in a Use the following parts to block the hose.
hydraulic circuit". 07379-00640 (flange #06)
2) Disconnect hose (1) on the cylinder head
flange.

on the cylinder bottom side.
a Use the following parts to block the hose.
07379-00640 (flange #06)
3) Start the engine, run it at high idle, and

perform the arm digging relief.
k Be careful not to operate the lever to

"Arm OUT" side.
4) 30 seconds after starting relief, measure the
amount of oil leakage for 1 minute.
3) Start the engine, run it at high idle, and table", "Standard value table for engine".
relieve the circuit by raising the boom. 5) After finishing the test, restore the machine.
Bleed air. For details, see Testing and
k Be careful not to operate the lever to adjusting, "Bleeding air from hydraulic
"Boom LOWER" side. circuit".
3. Testing oil leakage of bucket cylinder
4) 30 seconds after starting relief, measure the
amount of oil leakage for 1 minute. 1) Set the bucket cylinder at the digging stroke
end, and stop the engine.
5) After finishing the test, restore the machine.
30-76 HB215LC-2
Hydraulic system

piping on the bucket cylinder head
side (however, operate the lever only
in the bucket CURL direction). For
details, see "Releasing remaining
pressure in hydraulic circuit".
2) Disconnect hose (3) on the cylinder head
flange.

on the cylinder bottom side.
3) Disconnect drain hose (5) of the travel motor
a Use the following parts to block the hose. and block the hose side by using a plug.
07379-00640 (flange #06)
a Use the following parts to block the hose.
07376-70422 (Plug #04)
3) Start the engine, run it at high idle, and

relieve the circuit by moving the bucket in
CURL direction. 4) Start the engine, run it at high idle, relieve the
travel circuit, and measure the leakage at
k Be careful not to operate the lever to this time.
"Bucket DUMP" side.
k Before operating the travel lever,
4) 30 seconds after starting relief, measure the check the pin position and locked
amount of oil leakage for 1 minute. direction of the travel again.
table", "Standard value table for engine". k Make signs and perform checks
5) After finishing the test, restore the machine. securely, since a mistake in lever
Bleed air. For details, see Testing and operation can cause an accident.
adjusting, "Bleeding air from hydraulic
a 30 seconds after starting relief, measure
circuit".
the amount of leakage for 1 minute.
4. Testing oil leakage of travel motor
1) Remove travel motor cover. a Measure several times, moving the motor
2) Start the engine, lock the travel mechanism, a little each time (changing the relative
and stop the engine. position between the valve plate and
cylinder and that between the cylinder
k Insert pin [1] between the sprocket and piston).
and the track frame to securely lock a For standard values, see "Standard value
the track. table", "Standard value table for engine".
5) After finishing the test, restore the machine.
adjusting, "Bleeding air from hydraulic
circuit".
HB215LC-2 30-77
Hydraulic system
Bleeding air from hydraulic circuit (HB380-C000-360-P-00-A)
q: Starts the work.

o: Moves to the next work.
Air bleeding procedure and items
1 2 3 4 5
Bleeding air
Bleeding air Bleeding air Check of oil
from Starting
from from level and
hydraulic engine
cylinder travel motor operation
pump
• Hydraulic oil change q
• Strainer cleaning q q q q
(Note)
• Replacement of return filter o o
q q
element
• Replacement and repair of
hydraulic pump q q q o q
Contents of operation
• Removal of suction piping

control valve q q o q
• Removal of control valve piping
cylinder q q o q
• Removal of cylinder piping
travel motor q o q q
• Removal of travel motor piping
swivel joint q o o q
• Removal of swivel joint piping
Note: Bleed air from the travel motor only when draining the oil from the motor case.
Bleeding air (HB205-C000-231-P-02-A)
1. Bleeding air from main pump When starting the engine after performing step 1,
keep it at low idle for 10 minutes.
a Keep the oil filler cap of the hydraulic tank
loosened during air bleeding work of the a When performing the automatic warm-up
main pump. operation while engine coolant temperature
1) Loosen air bleeder (1), and check that oil is low, stop the engine once and cancel the
oozes out from the air bleeder. automatic warm-up function with fuel control
2) When oil without air starts to flow out, tighten dial. (Turn the starting switch to ON position
air bleeder (1). and keep the fuel control dial at MAX position
for 3 seconds or more, and automatic warm-
3 Air bleeder: up function will be canceled.)
7.8 to 9.8 Nm {0.8 to 1.0 kgm} 3. Bleeding air from cylinders
a When the cylinder has been replaced, bleed
air from the cylinder before connecting the
work equipment. Especially, the LOWER
side of the boom cylinder does not operate to
the stroke end with the work equipment
installed.
1) Start the engine and run it at low idle for
approximately 5 minutes.
2) While running the engine at low idle, raise
and lower the boom 4 to 5 times.
a Stop the piston rod at approximately 100
mm before stroke end to avoid relieving.
2. Starting the engine 3) While running the engine at high idle,
perform the operation in step 2).
30-78 HB215LC-2
Hydraulic system
4) While running the engine at low idle, move

the piston rod to the stroke end to relieve the
circuit.
5) Bleed air from the arm and bucket cylinders
according to steps 2) to 4).
4. Bleeding air from travel motor
1) Start the engine and run it at low idle.
2) Loosen air bleeder (2), and check that oil
oozes out from the air bleeder.
3) When oil without air starts to flow out, tighten
air bleeder (2).
3 Air bleeder:
27.5 to 35.3 Nm {2.8 to 3.6 kgm}
4) Raise the one side of track off ground by

using the work equipment.
5) Slowly run the raised one side track off the
ground for 2 minutes.
6) Raise the opposite side of track off ground by
using the work equipment and slowly run it
off the ground for 2 minutes in the same way.
5. Check of oil level and operation
1) Start the engine, retract the arm and bucket
cylinders fully, lower the work equipment to
the ground, and stop the engine.
2) Check the oil level by sight gauge (3) at the

rear of the hydraulic tank.
a When the oil level is between the lines H
and L, it is appropriate.
a If the oil level is below line L, add new oil.
HB215LC-2 30-79
Cab and its attachments
Testing cab tipping stopper (ALL-K138-001-K-00-A)
a Check the cab tipping stopper according to the following procedure.

Testing (PC-K138-280-K-00-A)
1. Check the tightening torque of the mounting bolt

(2) of the lock plate (1).
3 Bolt (2):
98 to 123 Nm {10 to 12.5kgm}
[Reference]
• Note that the tightening torque for mounting bolt
(4) of cab tipping stopper (3) is different from that
of a common bolt 30 mm in diameter.
3 Bolt (4):
245 to 309 Nm {25 to 31.5kgm}
30-80 HB215LC-2
Adjusting mirrors (HB205-K810-001-K-00-A)
k When adjusting the mirror, prepare a

scaffold first in order to provide a safe
working platform.
If you try to work by standing on the
counterweight, there is always a danger of
serious injury or death due to falling off from
the machine.
1. Mirror installing positions
2. Adjusting mirror (a) a Tighten the right and left bolts of each
Adjust mirror (a) so that the operator can see bracket alternately so that their right and left
people in the rear left end of the machine. clearance (R) and (L) become equal.
• Adjust the mirror so that the side of the
machine is reflected in it as shown in the a If the mirror and stay mounting bolts are
figure. tightened excessively, the bracket may be
damaged. Tighten them to the specified
torque.
3. Adjusting mirror (b)

a Install the mirror and stay according to the Adjust mirror (b) so that the operator can see
following dimension. people at the right rear end of the machine.
• Stay (1) • Adjust the mirror so that the side of the
Mounting position (2): 77 mm machine is reflected in it as shown in the
Mounting angle (3): 81 deg. figure.
Mounting angle (4): 99 deg.
3 Mounting bolt (5):
15.0 to 19.6 Nm {1.52 to 2.0 kgm}
• Mirror (6)
6.0 to 7.0 Nm {0.61 to 0.71 kgm}
Mounting position (8): 74 mm
HB215LC-2 30-81
4. Adjusting mirror (c)

Adjust mirror (c) so that the operator can see
a Install the mirror and stay according to the people standing on the ground around the
following dimension. machine (W).
(W): 1 m
• Stay (9)
15.0 to 19.6 Nm {1.52 to 2.0 kgm}
• Mirror (14)
6.0 to 7.0 Nm {0.61 to 0.71 kgm}
a Install the mirror according to the following
dimension.
• Mirror (17)
6.0 to 7.0 Nm {0.61 to 0.71 kgm}
a Tighten the right and left bolts of each

bracket alternately so that their right and left
clearance (R) and (L) become equal.
a If the mirror and stay mounting bolts are
tightened excessively, the bracket may be
damaged. Tighten them to the specified
torque.
30-82 HB215LC-2
HB215LC-2 30-83
Electrical system
Special functions of machine monitor (PC220-Q170-042-K-01-A)
30-84 HB215LC-2
Electrical system
Upper part of machine monitor (display portion)

(a): Multi-information display
a When the engine is started, the battery voltage
may drop suddenly, depending on the ambient
temperature and the condition of the battery.
In this case, the screen display of the machine
monitor may go off for a moment. This
phenomenon is not a failure, however.
Upper part of machine monitor (switch portion)

[F1]: F1 Function switch
a The function of each function switch is indicated
by the icon which is displayed just above the
function switch on the screen of the multi-
information display panel (a).
a If the icon for a function switch is not displayed,
that function switch is not working.
Lower part of machine monitor (switch portion)

[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 stop
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Window washer switch
[7]: Numeral 7 input switch/Air conditioner switch
Switch having no numerals : Air conditioner switch
a Each switch has the function indicated by the
icon on it and the function of inputting a numeral.
a The machine monitor automatically judges which
function of each switch is currently enabled
according to the screen display of the multi-
information display panel (a).
HB215LC-2 30-85
Electrical system
Ordinary functions and special functions of machine monitor (HB205-Q170-042-K-02-A)
The machine monitor has the ordinary functions and special functions to display the various types of
information on the multi-display.
Some items 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 function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially.
This function is used for special setting, testing, adjusting, or troubleshooting.
Operator mode (outline) Service mode

A Display of KOMATSU logo(PAGE 30-88) Monitoring/ Pre-defined(PAGE 30-104)
A Password input(PAGE 30-89) Monitoring(PAGE 30-109)
Abnormality record (mechanical systems)(PAGE
A Display of check of breaker mode(PAGE 30-89) 30-118)
Abnormality record (electrical systems)(PAGE
A Display of "Check before starting"(PAGE 30-89) 30-118)
Display of warning after "Check before
A starting"(PAGE 30-90) Maintenance Record(PAGE 30-120)
Display of maintenance due time over(PAGE 30-
A 90) Maintenance mode setting(PAGE 30-121)
Display of working mode and checking travel
A speed(PAGE 30-90) Phone number entry(PAGE 30-124)
A Display of standard screen(PAGE 30-90) Default (Key-on Mode)(PAGE 30-124)
A Display of end screen(PAGE 30-91) Default value setting (Unit)(PAGE 30-125)
Display of operation screen for engine shutdown Default (With/Without Attachment)(PAGE 30-
A secondary switch(PAGE 30-91) 126)
B Selection of auto-deceleration(PAGE 30-91) Default (Camera)(PAGE 30-127)
(Special operation)
Default (Auto Idle Stop Timer Setting)(PAGE 30-

B Selection of working mode(PAGE 30-91)
128)
B Selecting travel speed(PAGE 30-92) Default (Auto Idle Stop Setting)(PAGE 30-129)
Testing (Cylinder Cut-out operation)(PAGE 30-
B Operation to cancel alarm buzzer(PAGE 30-93)
130)
Testing (Reset Number of Abrupt Engine Stop by
B Operation of windshield wiper(PAGE 30-93)
AIS)(PAGE 30-131)
Testing (discharge of capacitor electric charge)
B Operation of window washer(PAGE 30-93)
o (PAGE 30-131)
Operation to display air conditioner settings Adjustment (Pump Absorption Torque (F))(PAGE
B (PAGE 30-93) 30-134)
Adjustment (Pump Absorption Torque (R))(PAGE
B Operation to display camera mode(PAGE 30-93)
30-135)
Operation to display clock and service meter Adjustment (travel low speed setting)(PAGE 30-
B (PAGE 30-94) 136)
Adjustment (Attachment Flow Adjustment)(PAGE

B Display of energy monitor(PAGE 30-94) 30-136)
Setting and display of user mode (including Adjustment (F pump swash plate sensor
B KOMTRAX messages for user)(PAGE 30-94) calibration)(PAGE 30-138)
Adjustment (R pump swash plate sensor
B Display of ECO guidance(PAGE 30-95) calibration)(PAGE 30-143)
Adjustment (Pump calibration: Matching speed
C Display of machine setting(PAGE 30-97) check)(PAGE 30-144)
30-86 HB215LC-2
Electrical system

C Check of maintenance information(PAGE 30-97) calibration)(PAGE 30-149)
Adjustment (Pump calibration: Restore default
C Display of monitor settings(PAGE 30-97) value)(PAGE 30-149)
Adjustment (Swing Motor Starting Torque)(PAGE

C Display of message(PAGE 30-97) 30-150)
Adjustment (Hoist Swing Adjustment)(PAGE

C Display function of alarm monitor(PAGE 30-98)
30-151)
Display of action level and failure code(PAGE Adjustment (Setting of swing derate
C 30-99)
adjustment mode)(PAGE 30-151-1)
No-Injection(PAGE 30-152)
O (Special operation) KOMTRAX Settings (Terminal Status)(PAGE 30-

153)
Function of checking display of LCD (Liquid KOMTRAX Settings (GPS and Communication
D Crystal Display)(PAGE 30-100) Status)(PAGE 30-153)
Function of checking service meter(PAGE 30- KOMTRAX Settings screen (Modem Status)
D 100) (PAGE 30-154)
Function of Usage Limitation Setting/ Change
D Password(PAGE 30-100) Service Message(PAGE 30-155)
a Classification of operator mode

A: Display or function that is indicated or enabled from the time when the starting switch is turned to ON
position to the time when display changes to the standard screen, and display after starting switch is
turned to OFF position
B: Display/Function when machine monitor switch is operated
C: Display/Function when certain condition is satisfied
D: Display/Function that require special operations of switches
• The values in the table show the displaying order in each pattern.
HB215LC-2 30-87
Electrical system
Operator mode (outline) (HB205-Q193-042-K-03-A) Function of checking display of LCD (Liquid

Crystal Display)(PAGE 30-100)
a Only outline of the operator mode is described in Function of checking service meter(PAGE 30-100)
this section. Function of Usage Limitation Setting/ Change
For details of each function and display, and Password(PAGE 30-100)
their operation, see "Structure and function ", or
the "Operation and Maintenance Manual". a Display pattern of operator mode
The contents of display from when the starting
a In this section, the following displays or functions
switch is turned to ON position to when the
of the operator mode are explained (including
standard screen appears depend on the settings
some items which need special operations).
and conditions of the machine.
A: When engine start lock is enabled
Display B: When engine start lock is disabled
pattern
C: When working mode at start is set to breaker
A B C D E
mode (B)
Display of KOMATSU logo(PAGE
30-88) 1 1 1 1 1 D: When there is abnormal item in "Check
Password input(PAGE 30-89) 2 before starting" items
Display of check of breaker mode E: When there is maintenance item which
(PAGE 30-89) 2
exceeded due time
Display of "Check before • The values in the table show the displaying
starting"(PAGE 30-89) 3 2 3 2 2
order in each pattern.
Display of warning after "Check
before starting"(PAGE 30-90) 3
Display of KOMATSU logo (HB205-Q180-044-K-04-A)
Display of maintenance due time
over(PAGE 30-90) 3 When starting switch is turned to ON position,
Display of working mode and KOMATSU logo is displayed for 2 seconds.
checking travel speed(PAGE 30- 4 3 4 4 4 a After the KOMATSU logo is displayed for 2
90) seconds, the screen changes to "Password
Display of standard screen(PAGE input (if password is set)" screen, or "Check
30-90) 5 4 5 5 5
before starting" screen.
Display of end screen(PAGE 30-91)
Display of operation screen for engine shutdown
secondary switch(PAGE 30-91)
Selection of auto-deceleration(PAGE 30-91)
Selection of working mode(PAGE 30-91)
Selecting travel speed(PAGE 30-92)
Operation to cancel alarm buzzer(PAGE 30-93)
Operation of windshield wiper(PAGE 30-93)
Operation of window washer(PAGE 30-93)
Operation to display air conditioner settings(PAGE
30-93)
Operation to display camera mode(PAGE 30-93)
Operation to display clock and service meter
(PAGE 30-94) a The following screen may sometimes be
Display of energy monitor(PAGE 30-94) displayed instead of the above "Password input"
Setting and display of user mode (including screen.
KOMTRAX messages for user)(PAGE 30-94)
Display of ECO guidance(PAGE 30-95)
Display of machine setting(PAGE 30-97)
Check of maintenance information(PAGE 30-97)
Display of monitor settings(PAGE 30-97)
Display of message(PAGE 30-97)
Display function of alarm monitor(PAGE 30-98)
Display of action level and failure code(PAGE 30-
99)
O (Special operation)
30-88 HB215LC-2
Electrical system
a If this screen is displayed, call the person

responsible for the operation of KOMTRAX in
your Komatsu distributor and ask for remedy.
Display of check of breaker mode (PC220-Q180-

044-K-03-A)
When the starting switch is turned ON, if the
Password input (HB205-Q180-044-K-06-A) working mode is set to the breaker mode [B], a
After KOMATSU logo is displayed, display the message to inform the operator of starting in the
screen to input the "Engine Start Lock" password. breaker mode is displayed on the screen.
a This screen is displayed only when the engine k If an attachment other than the breaker is
start lock function is enabled. used while the working mode is set to the
breaker mode [B], the machine may move
a When correct password is input, the screen unexpectedly or may not operate normally or
changes to "Check before starting" screen. the hydraulic components may be damaged.
a The machine monitor has some password
functions other than the "Engine Start Lock". a After operation to check of the breaker mode is
Those passwords are individually set. finished, the screen changes to "Display of
check before starting".
If [No] is selected: Working mode is set to
economy mode [E]
If [Yes] is selected: Working mode is set to
breaker mode [B]
a The following screen may sometimes be

displayed instead of the above "Password input"
screen.
a If this screen is displayed, call the person
responsible for the operation of KOMTRAX in
your Komatsu distributor and ask for remedy. Display of "Check before starting" (HB380-Q180-
044-K-02-A)
When the screen changes to "Check before
starting" screen, the check before starting is
performed for 2 seconds.
a If any abnormalities are detected by the check
before starting, the screen changes to "Display
of warning after Check before starting" or
"Display of maintenance due time over".
HB215LC-2 30-89
Electrical system
a If no abnormalities are detected by the check a This screen is displayed only when the
before starting, the screen changes to "Display maintenance function is enabled.
of working mode and travel speed check". If the remaining time of any item is 30 hours or
a The monitors (6 monitors) on the screen shows less, the yellow icon is displayed. If the
the items currently subjected to the check before remaining time of any item is 0 hour or less, the
starting. red icon is displayed.
a Perform setting and change of the maintenance
function in the service mode.
Display of warning after "Check before

starting" (HB380-Q180-044-K-03-A)
If any abnormalities are detected in "Check before Display of working mode and checking travel
starting", the alarm monitor is displayed on the speed (HB380-Q180-044-K-05-A)
screen. If the check before starting is finished normally, the
a The following figure shows that low radiator screen to check the working mode and travel mode
coolant level monitor (a) is warning of low settings is displayed for 2 seconds.
radiator coolant level. a After the display of the working mode and travel
mode settings is finished, the screen changes to
the display of standard screen.
Display of maintenance due time over (HB380-

Q180-044-K-04-A)
If you find a maintenance item at check before Display of standard screen (HB205-Q180-044-K-07-A)
starting that it is near or overdue the set interval, If the machine monitor starts normally, the standard
maintenance monitor (a) is displayed for 30 screen is displayed.
seconds to urge the operator to perform a Service meter (a) or the clock is displayed at the
maintenance. center top of the screen (Switch between the
Press [F6] to check the necessary maintenance service meter and clock with [F4]).
items on the maintenance screen.
a ECO gauge (b) is displayed at the right end of
the screen. (Switch the Display/Non display in
the operator mode.)
30-90 HB215LC-2
Electrical system
If you turn the engine shutdown secondary switch to

OFF position, the KOMATSU logo appears once,
and then the display changes to the standard
screen.
Selection of auto-deceleration (HB380-AF6C-100-K-

00-A)
Press the acceleration switch while the standard
screen is displayed to display large monitor (a) of
the auto-deceleration for 2 seconds and then the
auto-deceleration setting is switched.
a Auto-deceleration setting switches [ON] o [OFF]
o [ON] in order by pressing switch.
Display of end screen (PC220-Q180-044-K-09-A) a When the auto-deceleration is set to ON, auto-
When starting switch is turned to OFF position, the deceleration monitor (b) is also displayed as
end screen is displayed for 5 seconds. soon as large monitor (a) is displayed.
a Other messages may appear on the end screen a When the auto-deceleration is set to OFF, auto-
due to KOMTRAX message display function. deceleration monitor (b) is disappears.
Display of operation screen for engine Selection of working mode (HB380-PT5W-100-K-00-A)

shutdown secondary switch (PC220-AKHL-100-K-00-A) Select the working mode according to the following
When you turn the engine shutdown secondary procedure.
switch to ON position, the "Engine Shutdown 1. When the working mode selector switch is
Secondary Switch Activated" screen is displayed on pressed while the standard screen is displayed,
every screen except the end screen. "Working mode selection" screen is displayed.
a The engine shutdown secondary switch is a The following figure shows the working mode
provided on the lower left side of the operator's selection screen with the attachment
seat. It is used to stop the engine when you available (if not setting as service mode
cannot stop the engine by turning the starting available, the attachment mode "ATT/P" or
switch to OFF position. "ATT/E" does not appear).
HB215LC-2 30-91
Electrical system
2. Operate the function switch or working mode • If an attachment other than the breaker is
selector switch to select and enter the working used, the machine may operate
mode to be used. unexpectedly and may be not operated
Function switch correctly. In addition, the hydraulic
• [F3]: Moves selection downward. components may be damaged.
• [F4]: Moves selection upward • The screen to make an operator check
• [F5]: Cancels the selection and returns the whether the working mode is selected the
display to the standard screen. breaker mode securely appears after the
• [F6]: Enters the selection and returns to the mode is selected (buzzer sounds
standard screen. intermittently during the display).
Working mode selector switch • When the setting is entered in this screen,
• Pressing: Moves selection downward. the display returns to the standard screen.
• Holding down: Enters the selection and When selecting [No]: Returns to working
returns to the standard screen. mode selection screen.
When selecting [Yes]: Specifies breaker
a If not operating both of the function switch
mode [B].
and working mode selector switch for 5
seconds or longer, the selection is entered
and the standard screen appears again.
Selecting travel speed (HB380-C6T7-100-K-00-A)

Press the travel speed selector switch while the
standard screen is displayed to display large
3. After returning to the standard screen, display
monitor (a) of the travel speed for 2 seconds and
large motor (a) of the selected working mode for
then the travel speed setting is switched.
2 seconds to switch the working mode setting.
a In setting of the travel speed, each time the
a As soon as large monitor (a) appears, the
switch is pressed, sequential switching among
display of working mode monitor (b) is also
[Lo] o [Mi] o [Hi] o [Lo] takes place in this
changed.
order.
a As soon as large monitor (a) appears, the
display of travel speed monitor (b) is also
changed.
<Caution for selecting breaker mode [B]>

• When breaker mode [B] is selected, the
hydraulic circuit setting is also changed as
soon as the hydraulic pump control is
changed.
30-92 HB215LC-2
Electrical system
Operation to cancel alarm buzzer (PC220-Q576-100-

K-00-A)
Press the buzzer cancel switch while the alarm
buzzer is sounding, then the alarm buzzer stops.
a Even if the buzzer cancel switch is pressed, the
display on the screen does not change.
Operation of windshield wiper (HB380-K751-100-K-00-

A)
Press the wiper switch while the standard screen is
displayed to display large monitor (a) of the wiper
for 2 seconds and then the wiper operates/stops.
a Wiper does not move while the window limit
switch is [ON]. Operation to display camera mode (HB205-Q16A-
100-K-03-A)
a In setting of the monitoring, each time the switch
When [F3] is pressed with the standard screen
is pressed, sequential switching among [INT] o
displayed, the multi-display changes to the camera
[ON] o [OFF] o [INT] takes place in this order.
image (set the connection of the camera in the
a As soon as large monitor (a) appears, display of service mode).
wiper monitor (b) is also changed and hidden.
a When the wiper is set to OFF, large monitor (a)
does not appear.
a Up to 3 cameras can be connected. However, if

the camera image display mode is selected, only
the image of camera 1 is always displayed.
Operation of window washer (PC220-K7DA-100-K-00-

A)
While the ordinary screen is displayed, if the
window washer switch is pressed, the washer fluid
is splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen display does not change.
Operation to display air conditioner

settings (PC220-K500-100-K-00-A)
Operate the air conditioner switch while the
standard screen is displayed, and the air
conditioner setting screen will appear.
a If the caution is issued during the camera mode
a If the switch is not operated for 5 seconds or (camera image is displayed), the related error
longer while the air conditioner setting screen is monitor or warning monitor appears and flashes
displayed, the screen changes to the standard at the upper left of the screen (excepting the
screen. caution for low hydraulic oil temperature).
HB215LC-2 30-93
Electrical system
a When selecting the clock display, perform the

time adjustment, 12-hour or 24-hour display
setting, and daylight saving setting by using the
user mode functions.
a If no control lever is operated for 10 seconds or

more while a failure enough to display action
level "L02" is occurring in the camera mode
(while camera image is displayed on the screen),
the screen returns to the standard screen and
displays information about that failure.
Display of energy monitor (HB380-PQJT-100-K-00-A)
a When two or more cameras are connected, the
image for display can be selected, or two
images can be displayed at the same time.
a Press [F2] in the standard screen to switch to
a As 2-camera image display [F4] is selected, the "Energy Monitor" screen.
images of cameras 1 and 2 are displayed on the
left and right sides of the screen. You can
change displaying which image of camera 1 or 2
on either right or left side of the screen with
"Default" ("Camera") of the service mode.
The image of camera 3 is displayed only singly.
Setting and display of user mode (including

KOMTRAX messages for user) (HB380-Q1C3-100-K-
00-A)
To enter and display the user mode, press [F6] to
display "User Menu" screen while the standard
screen is displayed.
a On the camera screen, there is no switching
function between "load ratio, actual load, rated
load" and "load ratio, working radius, lifting
height".
Operation to display clock and service

meter (HB380-Q1MA-100-K-00-A)
When [F4] is pressed while the standard screen is
displayed, the display at section (a) is alternately
switched between service meter display and clock
display.
30-94 HB215LC-2
Electrical system
a There are following items in user menu. [F5]: Returns to "ECO Guidance" menu screen
• "ECO Guidance" (a)
• "Machine setting" (b)
• "Maintenance" (c)
• "Monitor setting" (d)
• "Check mail" (e)
Display of ECO guidance (HB380-Q1L3-100-K-00-A)

1. Press [F6] in the normal screen. Select fuel
consumption logs (3) in "ECO Guidance" menu
screen and press [F6]. When the machine remains in a certain operating
condition, "ECO Guidance" screen is displayed
automatically to urge the operator to perform
energy-saving operation.
a The ECO Guidance screen is displayed when
the following conditions are met while this
display function is set to be enabled in operator
mode.
a Conditions for display:
• Idle stop guidance
When no lever is operated for a period of at least
5 minutes and the engine keeps running at idle
during this period, the guidance on idle stop is
displayed on the monitor. This function helps
2. By using "Fuel Consumption Logs" menu,
reduce unnecessary fuel consumption by
display the graph of average fuel consumption
alerting the operator to stop the engine while
during the last 12 hours or the graph of daily fuel
waiting for the next operation, or during a break.
consumption during the last one week.
a The lamp for the idle stop guidance goes out
automatically when the lever operation is
resumed, or if the function switch [F5] is
pressed.
3. You can perform the following operations in the

fuel consumption logs screen.
[F1]: Clears the graph data
[F2]: Switches graphical displays of the average
fuel consumption
HB215LC-2 30-95
Electrical system
• Deterrence guidance of hydraulic relief • Reduce engine speed (recommended) guidance

If relieving lasts for 3 or more seconds during If travel condition continues for 2 or more
operation, deterrence guidance of hydraulic minutes when travel mode is Hi and fuel control
relief is displayed on the monitor. dial is at MAX position, the reduce engine speed
(recommended) guidance is displayed. Throttle
a The lamp for the guidance on deterrence of
the fuel control dial to reduce necessary fuel
hydraulic relief goes out automatically after
consumption during travel for long time.
10 seconds has passed since it appeared, or
if the function switch [F5] is pressed. a The lamp for the E-reduce engine speed
(recommended) guidance goes out
automatically after 10 seconds has passed
since it appeared, or if the function switch
[F5] is pressed.
• E-mode (recommended) guidance

When light-load work continues for 10 minutes
or more in P mode or ATT/P mode, E-mode
recommendation guidance is displayed. This
function helps reduce unnecessary fuel • Low fuel level guidance
consumption in light-load work by alerting the If the operable time estimated from the current
operator to switch to E-mode. fuel level and the latest average fuel
consumption is shorter than 8 hours, the low fuel
a The lamp for the E-mode recommendation
level guidance is displayed.
guidance goes out automatically after 10
seconds has passed since it appeared, or if a The low fuel level guidance goes out
the function switch [F5] is pressed. automatically after 10 seconds has passed
since it appeared, or if the function switch
[F5] is pressed.
30-96 HB215LC-2
Electrical system
a To reset the remaining time after finishing the

maintenance, further operations are required.
Display of machine setting (HB380-Q1C9-100-K-00-A) Display of monitor settings (HB380-Q193-110-K-01-A)

In each item of this menu, check or change the In each item of this menu, check or change the
setting and information on the machine. setting of the monitor.
a There are following items in the machine setting a There are following items in the monitoring
(information). setting.
• "Economy Mode Adjustment" • "Screen Adjustment"
• "Auto Decel Setting" • "Screen adjustment (camera)"
• "Clock Adjustment"
• "Language setting"
• "ID Key Information"
Check of maintenance information (HB205-Q1C2-

100-K-03-A)
You can check the maintenance information on
"Maintenance" screen by pressing [F6] while the Display of message (HB380-Q235-110-K-00-A)
maintenance time notice and alarm monitor (a) are On machines equipped with KOMTRAX, you can
displayed. When the maintenance time notice and see the messages from your Komatsu distributor on
alarm monitor (a) are not displayed, press [F6] and this menu.
then press [F1] or [F2] to switch to "Maintenance"
When any massage is available, the message
screen.
monitor at the left end of the standard screen lights
up.
HB215LC-2 30-97
Electrical system
• There are 2 types of KOMTRAX message; one

is for the user and the other is for the technician.
• For user:
It denotes the messages transmitted from the
KOMTRAX base station to users. Upon
receiving a message, the message monitor
is displayed on the standard screen. Operate
this "Check mail" when viewing contents of a
message.
• For technician:
It denotes the messages transmitted from the
KOMTRAX base station to users. Upon
receiving a message, nothing is displayed on
the standard screen. Operate "Service
message display" of the service mode when
viewing contents of a message.
Display function of alarm monitor (HB205-Q1FC-

044-K-02-A)
If an abnormality that displays the alarm monitor of
action level "L01" occurs on the standard screen or
camera mode screen, the alarm monitor is
displayed in a large size for a while and then kept
displayed at (a) inside the screen.
a When a caution occurs while the camera mode
is displayed, the alarm monitor flashes at the
upper left of the screen.
If an abnormality that displays an alarm monitor of

action level "L02", "L03", or "L04" occurs, the alarm
monitor is displayed at the center of the monitor until
the abnormality is eliminated.
30-98 HB215LC-2
Electrical system
Display of action level and failure code (HB380-

Q1FC-100-K-00-A)
If an abnormality that displays an action level and a
failure code occurs on the standard screen or
camera mode screen, the alarm monitor lights up.
a Remedies that displayed action levels require

operator to do (The following table is an excerpt
from the Operation and Maintenance Manual)
De-
gree Alarm
If the alarm monitor lights up, press function switch of Action Buz- moni- Remedy
[F5] to display "Error List". urgen- level zer tor
• [F1]: Moves to next page (screen) (- When not cy
being displayed on the screen) Stop immediately and
• [F2]: Returns to previous page (screen) (- When High Q perform checking and
not being displayed on the screen) (Con- maintenance.
L04 Q
• [F5]: Returns to the standard screen tinu- Ask your Komatsu
ous) distributor for testing
On "Error List" screen, the following information is
and repair services.
displayed.
Stop the work, move
(a): Alarm monitor machine to safe
(b): Action level (3 digits) Q place, stop it, and
(Inter- perform checking and
(c): Failure code (5 or 6 digits) I L03 Q maintenance.
mit-
(d): Failure code name tent) Ask your Komatsu
(e): Message distributor for testing
(f): Telephone No. (if registered) and repair services.
Stop the work once,
a This screen appears when trouble (failure code) and run the engine at
occurs only if its action level is set. medium speed with
Q no load or stop the
a The telephone number is displayed only when
(Inter- engine. If no
the telephone number is registered in Service O L02 Q
mit- improvement is seen,
Mode. tent) ask your Komatsu
a If multiple troubles occur simultaneously, all the distributor for
codes are displayed repeatedly in order. checking and repair
services.
a Since the information of the displayed failure Some functions may
code is recorded in "Abnormality Record" in the be limited. However,
service mode, check the details in the service you can perform the
mode. work. Perform the
L01
inspection and
a "Error List" is replaced with the standard screen (For 2 maintenance after
automatically after 30 seconds. sec- ― Q completion of the
onds work.
a Since "Error List" cannot be displayed from the only)
Ask your Komatsu
screen on which the camera mode is displayed,
distributor to perform
move to "Error List" from the standard screen testing or repairs as
side. Low
necessary.
HB215LC-2 30-99
Electrical system
Function of checking display of LCD (Liquid

Crystal Display) (PC-Q1LE-100-K-00-A)
While the standard screen is displayed, if the
numeral input switches or function switches are
operated in the following manner, the entire LCD
screen turns white.
• Switch operations (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 To return to the former screen, press any one of
the function switches. Function of Usage Limitation Setting/ Change
Reference: An LCD panel, as one of its
Password (HB380-Q19X-100-K-00-A)
Selecting the Usage Limitation Setting displays the
characteristics, sometimes shows black spots
password input screen when you proceed to
(spots that remain unlit) and bright spots (spots that
breaker setting, attachment setting and
do not go off).
maintenance resetting. Observe the following
If the number of the bright points and black points procedure when using the Usage Limitation Setting.
does not exceed 10, the LCD panel is not faulty or
1. While the standard screen is displayed, perform
defective.
the following operation by using the numeral
input switches.
• Switch operation (Press the switches in order
while pressing [4])
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes elapse after the
starting switch is turned to ON position.
Function of checking service meter (PC-Q1MB-

100-K-00-A)
When checking the service meter with the starting
switch in OFF position, operate the numeral input
switches as follows to display only the service meter
section.
• Switch operations (simultaneous): [4] + [1]
a There is some time lag in start of the LCD, so 2. After "Usage Limitation Password" screen is
hold down the switches until the service meter is displayed, input the current password by using
displayed. the numeral input switches and confirm it by
a If you release one of the switches, the monitor using the function switch.
goes off. • [F5]: Deletes input numbers/ Returns to
Reference: After the machine monitor is used standard screen
continuously over a long period of time, blue points • [F6]: Enters input password
(points that remain lit) may appear on this screen. It a Default password: [000000]
does not indicate that the LCD panel is faulty or
defective. a When the input password is correct, the
screen changes to the next screen.
a When the input password is incorrect, the
screen displays message to request inputting
the password again.
30-100 HB215LC-2
Electrical system
3. After "Usage Limitation Setting" screen is

a The password for the Usage Limitation and
displayed, select a setting by using the function
the engine start lock password are not
switch.
identical.
• [F3]: Moves selection downward 4. Changing a password
• [F4]: Moves selection upward After "Usage Limitation New Password Input"
• [F5]: Cancels the selection and returns the screen is displayed, input the new password by
display to the previous screen using the numeral input switches and confirm it
• [F6]: Enters selection by using the function switch.
• [F5]: Deletes input numbers/ Returns the
display to the preceding screen
• [F6]: Enters input password
a Default password: [000000]
a When the input password is correct, the
screen changes to the next screen.
a When the input password is incorrect, the
screen displays message to request inputting
the password again.
a Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it
Selection of use/ non-use of Usage Limitation is not accepted).
After "Usage Limitation ON/OFF" screen is
switch.
• Non-use: Password input screen is not
displayed
• ON: The password input screen for setting of
the circuit breaker or attachment, or
maintenance resetting appears.
• [F3]: Moves selection downward
• [F4]: Moves selection upward
• [F5]: Cancels the selection and returns the
display to the previous screen
• [F6]: Enters selection
After "Usage Limitation New Password Input"
screen is displayed once more, input the new
password for the second time by using the
numeral input switches and confirm it by using
the function switch.
• [F5]: Deletes input numbers/ Returns to
standard screen
• [F6]: Enters input password
HB215LC-2 30-101
Electrical system
a If the input password is different from the one

input before, the message to request
inputting again is displayed.
If the standard screen is displayed after the

screen to notify completion of setting is
displayed, the password is changed successfully.
30-102 HB215LC-2
Electrical system
Service mode (HB205-Q194-100-K-01-A) a The following shows the items selectable

To change the operator mode to the service mode, with "service menu" (including some items
perform the following operation. which need special operations).
This operation is always required when you use the 01 Monitoring/ Pre-defined(PAGE 30-104)
service mode. 02 Monitoring(PAGE 30-109)
1. Checking of display of screen, and switch Abnormality record (mechanical systems)
operation (PAGE 30-118)
03 Abnormality record (electrical systems)(PAGE
While the standard screen is displayed, perform
the following operation with the numeral input 30-118)
switches. 04 Maintenance Record(PAGE 30-120)
• Switch operation (Press the switches in order 05 Maintenance mode setting(PAGE 30-121)
while pressing [4]) 06 Phone number entry(PAGE 30-124)
[4] + [1] o [2] o [3]
Default (Key-on Mode)(PAGE 30-124)
a This switch operation is accepted only while Default value setting (Unit)(PAGE 30-125)
the standard screen is displayed. Default (With/Without Attachment)(PAGE 30-
126)
07
Default (Camera)(PAGE 30-127)
Default (Auto Idle Stop Timer Setting)(PAGE
30-128)
Default (Auto Idle Stop Setting)(PAGE 30-129)
Testing (Cylinder Cut-out operation)(PAGE 30-
130)
Testing (Reset Number of Abrupt Engine Stop
08 by AIS)(PAGE 30-131)
Testing (discharge of capacitor electric charge)
(PAGE 30-131)
Adjustment (Pump Absorption Torque (F))
(PAGE 30-134)
Adjustment (Pump Absorption Torque (R))
2. Selecting the service menu (PAGE 30-135)
When the "Service Menu" screen is displayed, Adjustment (travel low speed setting)(PAGE
the service mode is selected. Select a service 30-136)
menu you use by using the function switches or Adjustment (Attachment Flow Adjustment)
numeral input switches. (PAGE 30-136)
• [F3]: Moves selection downward. Adjustment (F pump swash plate sensor
• [F4]: Moves selection upward. calibration)(PAGE 30-138)
• [F5]: Returns the display to the standard Adjustment (R pump swash plate sensor
09 calibration)(PAGE 30-143)
screen (operator mode).
• [F6]: Enters selection. check)(PAGE 30-144)
a When you input a 2-digit code by using the Adjustment (Pump calibration: Matching speed
numeral input switches, the corresponding calibration)(PAGE 30-149)
menu is directly selected. Accordingly, you Adjustment (Pump calibration: Restore default
may enter the selection by using [F6]. value)(PAGE 30-149)
Adjustment (Swing Motor Starting Torque)
(PAGE 30-150)
Adjustment (Hoist Swing Adjustment)(PAGE
30-151)
Adjustment (Setting of swing derate
adjustment mode)(PAGE 30-151-1)
10 No-Injection(PAGE 30-152)
KOMTRAX Settings (Terminal Status)(PAGE
30-153)
KOMTRAX Settings (GPS and Communication
11 Status)(PAGE 30-153)
KOMTRAX Settings screen (Modem Status)
(PAGE 30-154)
12 Service Message(PAGE 30-155)
HB215LC-2 30-103
Electrical system
Monitoring/ Pre-defined (HB205-Q1S1-100-K-01-A)

The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
various parts of the machine and the information
from the controllers which is controlling switches,
etc. The monitoring items are pre-selected which
are often used.
1. Selecting menu
Select "Monitoring / Pre-defined" on "Service
Menu" screen.
2. Checking Monitoring/Pre-defined information

After ""Monitoring/ Pre-defined"" screen is
displayed, you can check the items displayed in
"Monitoring/ Pre-defined" by using the function
switches.
• [F1]: Moves to next page (screen)
• [F2]: Returns to previous page (screen)
• [F4]: Selects hold or releasing hold (If the
Hold is selected, HOLD part is hatched.)
• [F5]: Returns the display to "Service Menu"
screen
a For the items not displayed in "Pre-defined
Monitoring", you can freely select and check
from "Monitoring / Custom" items.
a When the working mode is changed to

breaker mode [B], the screen to confirm the
change of the setting is displayed as in
changing the working mode on the standard
screen.
30-104 HB215LC-2
Electrical system
List of "Monitoring/ Pre-defined" items (SI unit is the default value)

"Monitoring/ Pre-defined" screen (1/17) Machine basics 1
Applicable
No. ID Item name Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 04107 Coolant Temperature °C ENG
3 37212 Engine Oil Switch ENG
4 18400 Intake Temperature °C ENG
5 04401 Hydr. Oil Temperature °C PUMP
6 03203 Battery Power Supply V ENG
"Monitoring/ Pre-defined" screen (2/17) Fuel injection system
Applicable
component
2 18600 Inject Fueling Command mg/st ENG
3 36400 Rail Pressure MPa ENG
4 36200 Rail Pressure Command MPa ENG
5 48000 IMV Current A ENG
6 48001 IMV Current Command A ENG
Monitoring/ Pre-defined screen (3/17) EGR, KVGT actuator
Applicable
component
2 18105 EGR Opening % ENG
3 36500 Charge Pressure-A kPa ENG
4 19000 VFT Opening % ENG
5 48200 Mass Air Flow kg/min ENG
Monitoring / Pre-defined screen (4/17) Engine temperature system
Applicable
component
2 04107 Coolant Temperature °C ENG
3 18400 Intake Temperature °C ENG
4 18500 Charge Temperature °C ENG
5 48500 EGR Orifice Temperature °C ENG
"Monitoring/ Pre-defined" screen (5/17) Intake and exhaust pressure system
Applicable
component
2 37400 Ambient Pressure kPa ENG
4 48300 Exhaust Manifold Pressure kPa ENG
5 48200 Mass Air Flow kg/min ENG
"Monitoring / Pre-defined" screen (6/17) Engine
Applicable
component
2 37212 Engine Oil Switch ENG
3 48400 Crankcase Pressure kPa ENG
HB215LC-2 30-105
Electrical system
"Monitoring/ Pre-defined" screen (7/17) F&R pump basic

Applicable
component
2 01100 F Pump Pressure MPa PUMP
3 01101 R Pump Pressure MPa PUMP
4 01300 PC-EPC Sol Current (F) mA PUMP
5 01302 PC-EPC Sol Current (R) mA PUMP
"Monitoring/ Pre-defined" screen (8/17) F&R pump application
Applicable
component
4 01137 F pump Displacement cc/rev PUMP
5 01139 R Pump Displacement cc/rev PUMP
"Monitoring/ Pre-defined" screen (9/17) F pump application
Applicable
component
3 01141 Service Pressure Sensor MPa PUMP
4 01300 PC-EPC Sol Current (F) mA PUMP
5 01137 F pump Displacement cc/rev PUMP
6 01500 LS-EPC Sol Current mA PUMP
"Monitoring/ Pre-defined" screen (10/17) R pump application
Applicable
component
3 01141 Service Pressure Sensor MPa PUMP
4 01302 PC-EPC Sol Current (R) mA PUMP
5 01139 R Pump Displacement cc/rev PUMP
6 01500 LS-EPC Sol Current mA PUMP
"Monitoring /Pre-defined" screen (11/17) PPC pressure
Applicable
component
2 07400 Boom Raise PPC Pressure MPa PUMP
3 07500 Boom Lower PPC Pressure MPa PUMP
4 07200 Arm Curl PPC Pressure MPa PUMP
5 07600 Arm Dump PPC Pressure MPa PUMP
6 04401 Hydr.Oil Temperature °C PUMP
30-106 HB215LC-2
Electrical system

Applicable
component
2 09002 Swing Right PPC Pressure MPa PUMP
3 09001 Swing Left PPC Pressure MPa PUMP
4 07300 Bucket CURL PPC Pressure MPa PUMP
5 07301 Bucket DUMP PPC Pressure MPa PUMP
Applicable
component
2 07102 Travel Fwd LH PPC Pressure MPa PUMP
3 07103 Travel Fwd RH PPC Pressure MPa PUMP
4 07104 Travel Rev LH PPC Pressure MPa PUMP
5 07105 Travel Rev RH PPC Pressure MPa PUMP
Monitoring/ Pre-defined screen (14/17) Hybrid system

Applicable
component
2 09200 DC Current, High-Voltage Side °C HYB
3 09300 Capacitor Voltage °C HYB
4 09603 Generator Motor Torque °C HYB
5 09102 Swing Motor Rev. Speed r/min HYB
6 09103 Swing Motor Torque Nm HYB
Monitoring/ Pre-defined screen (15/17) Hybrid system temperature (1)

Applicable
component
2 09306 Capacitor Cell Temperature °C HYB
3 09402 Booster Inductor Temperature °C HYB
4 09403 Booster IGBT Base Temperature °C HYB
5 09404 Booster IGBT Junc. Temperature °C HYB
6 01142 Service Press. Sensor (HYB W Pump) MPa PUMP
Monitoring/ Pre-defined screen (16/17) Hybrid system temperature (2)

Applicable
component
2 09101 Swing Motor Coil Temperature °C HYB
3 09507 Swing Motor IGBT Junc. Temp. °C HYB
4 09600 Generator Motor Temperature °C HYB
5 09607 Gen. Motor IGBT Base Temp. #0 °C HYB
6 09608 Gen. Motor IGBT Base Temp. #1 °C HYB
HB215LC-2 30-107
Electrical system
Monitoring/ Pre-defined screen (17/17) Hybrid system temperature

Applicable
component
2 01142 Service Press. Sensor (HYB W Pump) MPa PUMP
3 03203 Battery Power Supply V ENG
4 04300 Battery Charge Volt V HYB
5 09300 Capacitor Voltage V HYB
6 09400 Booster Volt., Low-Volt. Side V HYB
30-108 HB215LC-2
Electrical system
Monitoring (HB380-Q19L-100-K-00-A)
The machine monitor can monitor the condition of a 6 monitoring items at maximum can be
the machine in real time by receiving signals from selected at the same time. However, it may
various switches, sensors, and actuators installed to not be possible to set up to 6 items
various parts of the machine and the information depending on the display pattern of the
from the controllers which is controlling switches, selected items.
etc. The monitoring item can be selected freely in
the monitoring.
1. Selecting menu
Select "Monitoring/Custom" on "Service Menu"
screen.
3. Deciding monitoring items

After selecting monitoring items, execute
monitoring with the function switch or numeral
input switch.
a Execution with function switch: Double click
2. Selecting monitoring item or keep pressing [F6] (for approximately 2
After "Monitoring Selection Menu" screen is seconds).
displayed, select items to be monitored by using
the function switches or numeral input switches. a Execution with numeral input switch: Input
• [F1]: Moves selection leftward [99999] and press [F6].
• [F2]: Moves selection rightward a When monitoring only 2 items, for example,
• [F3]: Moves selection downward select them and confirm with [F6]. If [F6] is
• [F4]: Moves selection upward pressed once more at this time, monitoring is
• [F5]: Clears input numbers/ Returns the executed.
display to the service menu screen
• [F6]: Enters selection a If monitoring items are selected up to the limit
number, monitoring is executed
a In setting of the monitoring, each time automatically.
function switch [F2] is pressed, sequential
switching among [ENG]o[PUMP]o[HYB]o
[MON]o[ENG] takes place in this order.
a Selection with function switches: Select an
applicable equipment by using [F1] or [F2],
select an item by using [F3] or [F4], and then
enter it by using [F6].
a Selection with 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, the selection of the item of that 4. Executing monitoring
box is entered. After "Monitoring" screen is displayed, perform
the necessary operation of the machine and
check the monitoring information.
a Monitoring information is indicated by value,
ON/OFF, or special display.
HB215LC-2 30-109
Electrical system
a The unit of display can be selected in SI unit,

metric unit, or inch unit with the Default
function in the service mode.
a When the working mode is changed to

breaker mode [B], the screen to confirm the
change of the setting is displayed as in
5. Holding monitoring information changing the working mode on the standard
You can hold and release holding of the screen.
monitoring information by using the function
switches.
• [F4]: Selects hold or releasing hold
(If the Hold is selected, a diagonal line is
drawn on HOLD part.)
• [F5]: Returns the display to monitoring
selection menu screen
7. Saving and deleting of monitoring item

Selected monitoring item can be saved and
deleted by using function switch
• [F1]: MEMORY
• [F2]: CLEAR
6. Changing machine setting mode

To change the setting of the working mode,
travel speed, or auto-deceleration during
monitoring, operate the corresponding switch
under the current condition, and the
corresponding mode is selected.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after
monitoring is finished.
a When a monitoring item is saved, a

confirmation screen appears asking whether
the saved item should be displayed or not
when "Monitoring" is selected again.
30-110 HB215LC-2
Electrical system
a When an item is saved, it can be displayed

as many times as required unless it is
cleared.
a If another item is saved while having the
previous item saved, the previously saved
item is overwritten by the latest one.
a The saved monitoring item is cleared by
using [F2]. It is also cleared when the
selection is entered by using [F6] in the
following screen.
• KOMTRAX terminal screen
• "With/Without Attachment" screen
• Functional specification screen
• Air conditioner setting screen
HB215LC-2 30-111
Electrical system
Table of monitoring items (HB205-Q19L-208-K-01-A)
Unit (Default: SI) Applic-

Code Monitoring item (Display on screen) able
Remarks
No. SI Metric Imperial compo-
nent
01002 Engine Speed r/min rpm rpm ENG
04107 Coolant Temperature °C °C °F ENG
48000 IMV Current A A A ENG
48001 IMV Current Command A A A ENG
03203 Battery Power Supply V V V ENG
37212 Engine Oil Switch ON, OFF ENG
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18400 Intake Temperature °C °C °F ENG
18500 Charge Temperature °C °C °F ENG
Absolute value
indication
36500 Charge Pressure-A kPa kg/cm2 psi ENG (including
Ambient
Pressure)
48200 Mass Air Flow kg/min kg/min lb/min ENG
48300 Exhaust Manifold Pressure kPa kg/cm2 psi ENG
48400 Crankcase Pressure kPa mmAg psi ENG
48500 EGR Orifice Temperature °C °C °F ENG
36700 Engine Torque Ratio ％％％ ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Throttle Position Sensor Volt V V V ENG
04105 Coolant Temp Sensor Volt V V V ENG
37401 Ambient Pressure Sensor Volt V V V ENG
18401 Intake Temp Sensor Volt V V V ENG
18501 Charge Temp Sensor Volt V V V ENG
36501 Charge Pressure Sensor Volt V V V ENG
36401 Rail Pressure Sensor Volt V V V ENG
48301 Exhaust Manifold Press. Sens Volt V V V ENG
48401 Crankcase Pressure Sens Volt V V V ENG
48501 EGR Orifice Temp Sens Volt V V V ENG
17500 Engine Power Mode - ENG
48900 Engine Operation Mode - ENG
08402 Droop switch - ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Pressure Command MPa kg/cm2 psi ENG
37300 Fuel Rate l/h l/h gal/h ENG
ON, OFF WIF: Water In
18800 Water In Fuel ENG
Fuel
18105 EGR Opening % % % ENG
19000 VFT Opening % % % ENG
20216 ECM Build Version - ENG
20217 Calibration Data Version - ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM S/N - ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F Pump Pressure MPa kg/cm2 psi PUMP
30-112 HB215LC-2
Electrical system

Remarks
nent
01101 R Pump Pressure MPa kg/cm2 psi PUMP
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07500 Boom Lower PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
07600 Arm Dump 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
07102 Travel Fwd LH PPC Pressure MPa kg/cm2 psi PUMP
07103 Travel Fwd RH PPC Pressure MPa kg/cm2 psi PUMP
07104 Travel Rev LH PPC Pressure MPa kg/cm2 psi PUMP
07105 Travel Rev RH PPC Pressure MPa kg/cm2 psi PUMP
01137 F Pump displacement cc/rev cc/rev cc/rev PUMP
01138 F pump sw plate sensor volt V V V PUMP
01139 R Pump displacement cc/rev cc/rev cc/rev PUMP
01140 R pump sw plate sensor volt V V V PUMP
04401 Hydr. Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol Current (F) mA mA mA PUMP
01302 PC-EPC Sol Current (R) mA mA mA PUMP
01500 LS-EPC Sol Current mA mA mA PUMP
08000 Merge-divide Sol Current Main mA mA mA PUMP
08001 Merge-divide Sol Current LS mA mA mA PUMP
01700 Attachment Sol Current mA mA mA PUMP
03200 Battery Voltage V V V PUMP
04402 Hydr. Temp. Sensor Volt V V V PUMP
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP
01141 Service Pressure Sensor MPa kg/cm2 psi PUMP
Service Pressure Sensor (HYB W
01142 MPa kg/cm2 psi PUMP
Pump)
01337 PC-EPC Cal Torque1 (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
01345 PC-EPC Calibration Torque 1 Nm kgm lbft PUMP
01349 PC-EPC Calibration Current 1 mA mA mA PUMP

Bucket_Proh_Sol ON, OFF PUMP
16100 Crane_Out
Revol_Lamp_Relay ON, OFF PUMP
Pressure Swing ON, OFF PUMP
01900
Switch 1 Travel ON, OFF PUMP
HB215LC-2 30-113
Electrical system

Remarks
nent
Boom Lower ON, OFF PUMP
Boom Raise ON, OFF PUMP
Arm Curl ON, OFF PUMP
Arm Dump ON, OFF PUMP
Bucket Curl ON, OFF PUMP
Pressure Bucket Dump ON, OFF PUMP
01901
Switch 2 Service ON, OFF PUMP
Travel Steering ON, OFF PUMP
Travel Junction ON, OFF PUMP
Swing Brake ON, OFF PUMP
Solenoid Valve Merge-divider ON, OFF
02300 PUMP
1
2-Stage Relief ON, OFF PUMP
Travel Speed ON, OFF PUMP
Solenoid Valve Service Return ON, OFF PUMP
02301
2 Variable Back Press ON, OFF PUMP
02200 Switch Input 1 Lever Sw. ON, OFF PUMP
Model Select 1 ON, OFF PUMP
02201 Switch Input 2
Overload Alarm ON, OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON, OFF PUMP
02203 Switch Input 4 Lock Lever Sw 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
20229 Pump Controller Ass'y P/N - PUMP
20403 Pump Controller Serial No - PUMP
20230 Pump Controller Prog. P/N - PUMP
20212 Pump Controller Prog. Version - PUMP
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 Voltage mV V V HYB
09007 Swing-Right PPC Sensor2 Volt. mV V V 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
30-114 HB215LC-2
Electrical system

Remarks
nent
09608 Gen. Motor IGBT Base Temp. #1 °C °C °F HYB
09507 Swing Motor IGBT Junc. Temp. °C °C °F HYB
Booster Is Not ON, OFF HYB
HYB Controller Started
09703 Emergency Stop
Caution ON, OFF
Input HYB
HYB Controller HYB Swing Brake ON, OFF
09700 HYB
Solenoid
HYB Controller Battery Relay Drive
09705 Output ON, OFF HYB
(HYB)
09602 Generator Motor Rev. Speed rpm rpm rpm HYB
09603 Generator Motor Torque Nm kgm lbft HYB
09604 Gen. Motor Axial Outpu kW kW kW HYB
09605 Gen. Motor Target Rev. Speed rpm 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
Gen. Speed Control ON, OFF HYB
Gen. Torque Control ON, OFF HYB
HYB Controller Gen. Servo ON ON, OFF HYB
09701 Control Output Swing Motor Servo
ON, OFF HYB
ON
Low-Speed
ON, OFF HYB
Matching ON
Key SW (HYB Cont.) ON, OFF HYB
Emergency Stop
ON, OFF HYB
HYB Controller Input
09702 SW Input Swing Lock Lever ON, OFF HYB
Swing Release Sw ON, OFF HYB
Swing Brake Sw ON, OFF PUMP
09102 Swing Motor Rev. Speed rpm rpm rpm PUMP
09103 Swing Motor Torque Nm kgm lbft HYB
09104 Swing Motor Axial Output kW kW kW HYB
09105 Swing Motor Target Rev. Speed rpm rpm rpm HYB
09106 Swing Motor Torque Limit Value Nm kgm lbft HYB
09900 Bad Insulating Sensor Voltage V V V 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
04300 Battery Charge Volt V V V MON
04200 Fuel Level Sensor Volt V V V MON
04500 Monitor Input 1 Key Switch ON, OFF MON
HB215LC-2 30-115
Electrical system

Remarks
nent
Start ON, OFF MON
Preheat ON, OFF MON
Light ON, OFF MON
Radiator Coolant ON, OFF MON
Level
Aircleaner ON, OFF MON
04501 Monitor Input 2 Eng. Oil Level ON, OFF MON
Battery Charge Volt ON, OFF MON
Swing Brake Sw. ON, OFF MON
ENG Shutdown
04502 Monitor Input 3 ON, OFF MON
Secondary
Seat Belt Sw. ON, OFF MON
F1 ON, OFF MON
F2 ON, OFF MON
Monitor F3 ON, OFF MON
04503 Function
F4 ON, OFF MON
Switches
F5 ON, OFF MON
F6 ON, OFF MON
SW1 ON, OFF MON
SW2 ON, OFF MON
Monitor 1st & SW3 ON, OFF MON
04504 2nd Row
SW4 ON, OFF MON
Switches
SW5 ON, OFF MON
SW6 ON, OFF MON
SW7 ON, OFF MON
SW8 ON, OFF MON
Monitor 3rd & SW9 ON, OFF MON
04505 4th Row
SW10 ON, OFF MON
Switches
SW11 ON, OFF MON
SW12 ON, OFF MON
SW13 ON, OFF MON
Monitor 5th ON, OFF
04506 SW14 MON
Row Switches
SW15 ON, OFF MON
20227 Monitor Ass'y P/N - MON
20402 Monitor Serial No - MON
20228 Monitor Prog. P/N - MON
20200 Monitor Prog. Version - MON
55300 Aircon Compressor Status ON, OFF MON
55000 Aircon Outside Temp. Code - MON
55100 Aircon Inside Temp. Code - MON
55200 Aircon Mode Data(Mon) - MON
55201 Aircon Mode Data(Aircon ECU) - MON
Only when
20260 KOMTRAX Ass'y P/N - MON KOMTRAX is
used
Only when
20418 KOMTRAX Serial No - MON KOMTRAX is
used
Only when
20261 KOMTRAX Prog. P/N - MON KOMTRAX is
used
30-116 HB215LC-2
Electrical system

Remarks
nent
Only when
20273 KOMTRAX Prog. Version - MON KOMTRAX is
used
Only when ID key
20262 ID Key Controller Ass'y P/N - MON
is used
Only when ID key
20419 ID Key Controller Serial No - MON
is used
Only when ID key
20263 ID Key Controller Prog. P/N - MON
is used
a Listing order in table

The monitoring items are listed in the order of the display on the monitoring item selection menu screen.
a Unit
The display unit can be set to SI, Metric, or Imperial as required (select a desired unit from "Unit" of
"Default").
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Applicable component
ENG: The engine controller is in charge of detecting the monitoring information.
PUMP: The pump controller is in charge of detecting the monitoring information.
HYB: The hybrid controller (inverter) is in charge of detecting the monitoring information.
MON: The machine monitor detects monitoring information.
Note 1: Instantaneous fuel consumption (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it
is a theoretical value, it is slightly different from the actual fuel consumption ratio.)
HB215LC-2 30-117
Electrical system
Abnormality record (mechanical (a): Occurrence order from latest one/Total

systems) (PC220-Q1S2-100-K-00-A) number of records
The machine monitor logs the past and currently (b): Failure code
occurring failures classifying them into the (c): Detail of failure
mechanical system abnormality and electrical (d): Number of occurrences (displayable range:
system abnormality. 0 to 65,535 times)
To check the mechanical system abnormality record, (e): Service meter reading at the first occurrence
perform the following procedures. (f): Service meter reading at the last occurrence
• [F1]: Moves to next page (screen) (This
a For the failure code list, see "(Chapter 40) function key is available when more than 1
Failure code list for troubleshooting". page is needed for display.)
1. Selecting a menu • [F2]: Returns to previous page (screen) (This
Select "Abnormality Record" on "Service Menu" function key is available when more than 1
screen. page is needed for display.)
• [F5]: Returns to the "Abnormality Record"
screen.
a If no abnormality is recorded, "No Error" is
displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
a If the number of occurrence is 1 (first
occurrence), the service meter reading at the
first occurrence and that at the last
occurrence are the same.
2. Selecting a sub menu When the latest service meter reading is
After the "Abnormality Record" screen is recovered, the value at the recovery time is
displayed, select "Mechanical Systems" by displayed, thus the above readings may not
using the function switch or numeral input be the same.
switches. a If [E] is displayed on the left of a failure code,
• [F3]: Moves selection downward. the abnormality is still occurring or correction
• [F4]: Moves selection upward. of it is not confirmed.
• [F5]: Returns to "Service Menu" screen.
• [F6]: Enters selection. a For all of the failure codes that the machine
monitor can record, see the failure code list.
a When you input a 2-digit code by using the
numeral input switches, the corresponding
item is directly selected. Accordingly, you
may enter the selection by using [F6].
4. Clearing abnormality record

The contents of an abnormality record of the
mechanical system cannot be deleted.
3. Information displayed on "Abnormality Record" Abnormality record (electrical

screen systems) (HB380-Q1S3-100-K-00-A)
On the "Mechanical Systems" screen, the The machine monitor logs the past and currently
following information is displayed. occurring failures classifying them into the
30-118 HB215LC-2
Electrical system
mechanical system abnormality and electrical (d): Number of occurrences (displayable range:
system abnormality. 0 to 65,535 times)
To check the electrical system abnormality record, (e): Service meter reading at the first occurrence
perform the following procedures. (f): Service meter reading at the last occurrence
• [F1]: Moves to next page (screen) (This
a For the failure code list, see "(Chapter 40) function key is available when more than 1
Failure code list for troubleshooting". page is needed for display.)
1. Selecting menu • [F2]: Returns to previous page (screen) (This
Select "Abnormality Record" on "Service Menu" function key is available when more than 1
screen. page is needed for display.)
• [F5]: Returns to "Abnormality Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a On the electrical systems abnormality record
screen, up to 20 cases currently stored are
displayed.
If the number of abnormality records
increases to 21 or beyond, the latest
occurrence code is displayed and the oldest
one is deleted.
2. Selecting sub menu
a If the number of occurrence is 1 (first
After "Abnormality Record" screen is displayed,
occurrence), the service meter reading at the
select "Electrical Systems" by using the function
first occurrence and that at the last
switch or numeral input switches.
occurrence are the same.
• [F4]: Moves selection upward a If [E] is displayed on the left of a failure code,
• [F5]: Returns to "Service Menu" screen. the abnormality is still occurring or correction
• [F6]: Enters selection of it is not confirmed.
a When you input a 2-digit code by using the a For all of the failure codes that the machine
numeral input switches, the corresponding monitor can record, see the failure code list.
item is directly selected. Accordingly, you
4. Clearing abnormality record

1) While "Electrical Systems" screen is
3. Information displayed on "Abnormality Record" displayed, perform the following operation by
screen using the numeral input switches.
On "Electrical Systems" abnormality record
• Switch operation (Press the switches in
screen, the following information is displayed.
order while pressing [4])
(a): Occurrence order from latest one/ Total
[4] + [1] o [2] o [3]
number of records
(b): Failure code
(c): Detail of failure
HB215LC-2 30-119
Electrical system
a The following figure shows the screen

when an individual item is cleared (it is
slightly different from the screen when all
the item are cleared at once).
2) Check that the display on the screen

becomes the clear mode, then clear the
individual information one by one or all
together by using the function switches.
a If the screen is set in the clear mode, 4) If the screen to notify completion of clearing
graphic mark [CLEAR] is indicated above is displayed and then the "Electrical System
[F2]. Abnormality Record" (mode) screen is
• [F2]: Clears all items displayed, the clearing of the abnormality
• [F3]: Moves selection downward. record is complete.
• [F4]: Moves selection upward a After a while, the screen returns to
• [F5]: Returns to "Abnormality Record" "Electrical Systems" abnormality record
screen screen.
• [F6]: Clears items one by one
a To clear items one by one: Select the item
to be cleared with [F3] or [F4] and press
[F6].
a To clear all items together: Press [F2],
and all the items are cleared, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the item is not cleared.
Maintenance Record (HB205-Q19Z-100-K-01-A)

The machine monitor records the maintenance
information of the filters, oils, etc., which are
displayed and checked by the following operations.
When the maintenance is performed, if the data are
reset in the operator mode, the number of the times
of maintenance is recorded in this section.
1. Selecting menu
Select "Maintenance Record" on "Service Menu"
screen.
3) After "Electrical Sys. Error Reset" screen is
displayed, operate the function switches.
• [F5]: Returns to the Electrical System
Abnormality Record screen (clear mode).
• [F6]: Executes clearing
30-120 HB215LC-2
Electrical system
(a): Maintenance items

(b): Number of replacements up to now
(c): Service meter reading (SMR) at the last
replacement
2. Selecting maintenance record item

After the "Maintenance Record" screen is
displayed, select an item of which the setting is
to be checked by using the function switches or
numeral input switches.
• [F1]: Moves to next page (screen) Maintenance mode setting (HB205-Q1F1-100-K-01-A)
• [F2]: Returns to previous page (screen) The actuating condition of the maintenance
• [F3]: Moves selection downward reminder function in the operator mode can be set
• [F4]: Moves selection upward and changed by using this menu.
• [F5]: Returns to "Service Menu" screen. • To enable or disable the function
a You may enter a 2-digit code by using the • Change replacement interval setting (by item)
numeral input switches to select the item of • To initialize all of replacement interval setting
that code. 1. Selecting menu
Select "Maintenance Mode Setting" on "Service
Menu" screen.
a The following items can be selected in the

maintenance record.
49 Air Cleaner Cleaning / Change
After the "Maintenance Mode Setting" screen is
01 Engine Oil Change displayed, select an item of which the setting is
02 Engine Oil Filter Change to be changed by using the function switches or
03 Fuel Main Filter Change numeral input switches.
41 Fuel Pre Filter Change • [F1]: Moves to next page (screen).
04 Hyd Oil Filter Change • [F2]: Returns to previous page (screen).
05 H/Tank Breather Change • [F3]: Moves selection downward.
08 Final Drive Oil Change • [F4]: Moves selection upward.
09 S/Machinery Oil Change • [F5]: Returns to "Service Menu" screen.
• [F6]: Enters selection
10 Hydraulic Oil Change
45 Gen. Oil Change, Filter Clean a When you input a 2-digit code by using the
46 Swing Motor Oil Change numeral input switches, the corresponding
47 KCCV Filter Change item is directly selected. Accordingly, you
3. Items displayed on Maintenance Record screen
The following information is displayed.
HB215LC-2 30-121
Electrical system
4. Setting of Maintenance Notice Time Setting

a The following items can be selected on the
After selecting "Maintenance Notice Time
"Maintenance Mode Setting" screen.
Setting", if the screen is displayed, set with the
00 Maintenance Mode Change function switches.
49 Air Cleaner Cleaning / Change Interval
01 Engine Oil Change Interval
02 Eng Oil Filter Change Interval
03 Fuel Main Filter Change Interval
41 Fuel Pre Filter Change Interval
04 Hyd Oil Filter Change Interval
05 H/Tank Breather Change Interval
08 Final Drive Oil Change Interval
09 S/Machinery Oil Change Interval
10 Hydraulic Oil Change Interval
45 Gen. Oil Change, Filter Clean Interval
46 Swing Motor Oil Change Interval
99 All Default Value • Default value: Maintenance notice time set
3. Setting of maintenance mode change on the machine monitor (Recommended by
After selecting "Maintenance Mode Change" the manufacturer and not changeable).
and the screen is displayed, select the desired • Set value: Maintenance interval that can be
setting by using the function switches. freely set. Maintenance reminder function
• ON: All of functions of maintenance items works according to this set time in operator
become effective in operator mode. mode (the time increases or decreases in
• OFF: All of functions of maintenance items multiples of 10 hours).
becomes ineffective in operator mode. • [F3]: Decreases set value.
• [F3]: Moves selection downward. • [F4]: Increases set value.
• [F4]: Moves selection upward. • [F5]: Cancels contents of setting not yet
• [F5]: Cancels selection and returns to the entered and returns the screen to
"Maintenance Mode Change" screen. "Maintenance Mode Change" screen
• [F6]: Enters selection and returns to • [F6]: Enters setting and returns the screen to
"Maintenance Mode Change" screen. "Maintenance 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.
30-122 HB215LC-2
Electrical system
5. Setting of each maintenance item • [F5]: Cancels contents of setting not yet
Select each maintenance item. After the screen entered and returns the screen to
is displayed, set the item by using the function "Maintenance Mode Change" screen
switches. • [F6]: Enters setting and returns the screen to
• ON: Function of the selected individual "Maintenance Mode Change" screen
maintenance item becomes effective in
a When you enter by using [F6] and return to
operator mode.
the "Maintenance Mode Setting" screen by
• OFF: Function of the selected individual
using [F5] , your setting is validated.
maintenance item becomes ineffective in
operator mode. a If the set value of an item of which
• [F3]: Moves selection downward. maintenance reminder function is set to "ON"
• [F4]: Moves selection upward. is changed after 1 operating hour or more
• [F5]: Cancels the selection and returns the from the setup, the change is recognized as
screen to "Maintenance Mode Change" a reset of the remaining time.
screen
• [F6]: Enters selection and returns the screen
to "Maintenance Mode Change" screen
7. Function to return all of the values to default

values
After selecting "All Default Value" and the screen
6. Setting of set value of each maintenance item is displayed, select the desired setting by using
Select the set value of each maintenance item. the function switches.
After the screen is displayed, set the value by
using the function switches.
• If the operation for this function is executed,

the set values of all the maintenance items
• Default value: Maintenance notice time set are returned to the default values.
on the machine monitor (Recommended by • [F5]: Returns the display to "Maintenance
the manufacturer and not changeable). Mode Setting" screen.
• Set value: Maintenance interval that can be • [F6]: Executes initialization
freely set. Maintenance reminder function a A while after [F6] is pressed, the initialization
works according to this set time in operator completion screen is displayed. When the
mode (the time increases or decreases in "Maintenance Mode Setting" screen is
multiples of 25 hours). displayed, initialization is complete.
• [F3]: Decreases set value.
• [F4]: Increases set value.
HB215LC-2 30-123
Electrical system
Phone number entry (PC220-Q19A-110-K-00-A) a Up to 14 digits can be input from the left.
The telephone number displayed together with the Leave the surplus places without inputting.
"Error List" in operator mode can be input and a If an input numeral is wrong, move the cursor
changed according to the following procedure. (orange background) to that digit and
If no telephone number is inputted with this function, overwrite it with the correct numeral.
no telephone number is displayed in operator mode.
a If [F6] is pressed without inputting a digit,
1. Selecting a menu there is no information of telephone number
Select "Phone Number Entry" on "Service for display in operator mode.
Menu" screen.
2. Registering and changing phone number Default (Key-on Mode) (HB205-Q1F2-100-K-01-A)

After the "Phone Number Entry" screen is Use the menu of "Default" to check or change
displayed, register or change the phone number various settings of the machine monitor and
by using the function switch or numeral input machine.
switches.
Use the sub menu of "Key-on Mode" to set the
• [F2]: Deletes all input digits
working mode selected and displayed on the
• [F3]: Moves the input position to the next left
machine monitor when the starting switch is turned
place (if not blank)
to ON position.
• [F4]: Moves the input position to the next
right place (if not blank) 1. Selecting a menu
• [F5]: Deletes input numbers or returns the Select "Default" on "Service Menu" screen.
screen to the "Service Menu" screen
• [F6]: Validates the entry
30-124 HB215LC-2
Electrical system

to the "Default "screen
a Factory default is, "Mode at Previous Key-
off".
a If "With Attachment" is not selected, selection
of the Attachment/P-Mode and Attachment/
E-mode is disabled.
a If you change the setting to "Without
attachment" when Attachment/P-mode [ATT/
P] or Attachment/E-mode [ATT/E] is selected,
Power mode [P] is displayed when [ATT/P]is
2. Selecting a sub menu selected, and Economy [E] is displayed
After "Default" screen is displayed, select "Key- when [ATT/E] is selected respectively when
on Mode" by using the function switch or the starting switch is turned to ON position.
numeral input switches. a If the engine is stopped with the working
a Selecting method is the same as on "Service mode set to breaker mode [B] in the operator
Menu" screen. mode, breaker mode [B] is always displayed
when the starting switch is turned to ON
position, regardless of the above setting.
3. Selecting a mode
After "Key-on Mode" screen is displayed, select
the mode to be set by using the function
Default value setting (Unit) (HB205-Q1F3-100-K-01-A)
switches.
Use the menu of "Default" to check or change
• Power mode: [P] is displayed when the
various settings of the machine monitor and
starting switch is set to ON position
machine.
• Economy mode: [E] is displayed when the
starting switch is set to ON position The unit selecting function is used to select the unit
• Lifting Operation Mode: [L] is displayed when of the data to be displayed in monitoring, etc.
the starting switch is turned to ON position. 1. Selecting a menu
• Breaker Mode: [B] is displayed when the Select "Default" on "Service Menu" screen.
• Attachment/P-mode: [ATT/P] is displayed
when the starting switch is set to ON
position.
• Attachment/E-mode: [ATT/E] is displayed
when the starting switch is set to ON
position.
• Mode at Previous Key-off: Final mode in
previous operation is displayed when the
• [F5]: Cancels selection and returns the
display to "Default" screen 2. Selecting a sub menu
HB215LC-2 30-125
Electrical system
After "Default" screen is displayed, select "Unit"

by using the function switches or numeral input
switches.
a Selecting method is the same as on "Service
Menu" screen.
2. Selecting a sub menu

After "Default" screen is displayed, select "With/
Without Attachment" by using the function
3. Selecting an unit Menu" screen.
After "Unit" screen is displayed, select the unit to
be set by using the function switches.
• [F5]: Cancels selection and returns the
display to "Default" screen
• [F6]: Enters selection and returns the display
to "Default" screen
a Factory default is SI Unit.
3. Selecting With/Without
After "With/Without Attachment" screen is
displayed, select the setting by using the
function switch.
• Without attachment: When attachment is not
installed
• With attachment: When attachment is
installed
• [F5]: Cancels the selection and returns the
Default (With/Without Attachment) (HB205-Q1F4- screen to "Default" screen
100-K-01-A)
to "Default "screen
machine. a The attachment setting in the operator
Use the sub menu of "With/Without Attachment" to mode cannot be performed without
configure attachment setting when the attachment performing this setting correctly when
is installed or removed. attachment is installed. As a result, the
attachment may not work normally or the
1. Selecting a menu
hydraulic components may be damaged.
Select "Default" on "Service Menu" screen.
30-126 HB215LC-2
Electrical system
• "Use": Images from connected camera are

displayed as a normal image.
• [Я]: Reverse images (mirror images if it is
used for rear view monitor) are displayed.
• [R]: Normal images (visual images if it is
used for front or side monitor) are displayed.
• [F4]: Moves selection upward.
• [F5]: Cancels contents of setting before entry
and returns to "Default" screen
• [F6]: Enters selection in each line
a You cannot switch camera 1 between [Я] and
[R].
Default (Camera) (HB205-Q1F6-100-K-01-A) a Enter selection in each line with [F6], and
Use the menu of "Default" to check or change return to "Default" screen with [F5], and then
various settings of the machine monitor and your setting is validated.
machine.
Camera setting is for setting of camera when the a Unless setting is normally set with this
camera is installed or removed. function when the camera is connected, the
graphic mark of camera is not displayed at
1. Selecting a menu [F3] in the operator mode. Accordingly, the
Select "Default" on "Service Menu" screen. image of the camera cannot be used.
a When the camera is installed, check that the
right and left portions of the displayed image
are correct.

After "Default" screen is displayed, select
"Camera" by using the function switch or
numeral input switches.
Menu" screen.
3. Selecting camera setting

After "Camera" screen is displayed, select a
setting by using the function switch.
• "Not Use": Camera is not used
HB215LC-2 30-127
Electrical system

a If 2 or more cameras are connected, be sure
After "Default" screen is displayed, select "Auto
to set the use of them from camera 1 in
Idle Stop Time Fixing" by using the function
order.
a The simultaneous display function of 2
images becomes effective when camera 1
Menu" screen.
and camera 2 are set for use.
3. Setting selectable time

• "2-camera display setting" After "Auto Idle Stop Time Fixing" screen is
switch.
• Variable: Selection from OFF to 60 minutes
is allowed.
• OFF: Auto idle stop function is not used.
• X-minute fixing: OFF setting and setting the
time longer than the selected time are
unselectable.
• [F5] Cancels contents of setting before entry
and returns to "Default" screen
to Default screen
Default (Auto Idle Stop Timer Setting) (HB205-
Q1GE-100-K-01-A) a When this setting is "OFF", the auto idle stop
Use the menu of "Default" to check or change does not operate. Accordingly, the auto idle
various settings of the machine monitor and stop time setting in the operator mode is
machine. disabled.
Use the auto idle stop time fixing setting function to
set the time selectable by using the auto idle stop
time setting in the operator mode.
1. Selecting menu
Select "Default" on "Service Menu" screen.
30-128 HB215LC-2
Electrical system
3. Setting of shortest time or OFF

Default (Auto Idle Stop Setting) (HB205-Q1C9-110-K- After "Auto Idle Stop Setting" screen is displayed,
02-A)
select a setting by using the function switch.
• OFF: Auto idle stop function is not used.
• 1 minute: When selection from "1-minute fix"
machine.
to "60-minute fix" is allowed or when
Use the auto idle stop setting function to set the "Variable" is selected in "Auto Idle Stop Time
shortest time selectable at auto idle stop time fixed. Fixing", selection from "1 minutes" to "60
1. Selecting menu minutes" is allowed in "Auto Idle Stop
Select "Default" on "Service Menu" screen. Setting".
• 3 minute: When selection from "3-minute fix"
to "60-minute fix" is allowed or when
"Variable" is selected in "Auto Idle Stop Time
Fixing", selection from "3 minutes" to "60
minutes" is allowed in "Auto Idle Stop
Setting".
• 5 minutes: When selection from "5-minute
fix" to "60-minute fix" is allowed or when
"Variable" is selected in "Auto Idle Stop Time
Fixing", selection from "5 minutes" to "60
minutes" is allowed in "Auto Idle Stop
Setting".
2. Selecting a sub menu • [F4]: Moves selection upward
After "Default" screen is displayed, input "50" by • [F5] Cancels contents of setting before entry
using the numeral input switches and press "F6". and returns to "Default" screen
a This function is required if the setup time to Default screen
needs to be shorter than the initial setting "5
minutes" by laws and regulations or if the a When this setting is "OFF", the auto idle stop
auto idle stop setting by the specifications is does not operate. Accordingly, the auto idle
not allowed to operate. Accordingly, this stop time setting in the operator mode is
function is not displayed in the menu list. disabled.
a This function allows you to set the time

shorter than the initial setting "5 minutes".
However, setting the shorter time may result
in lower durability of the starting motor due to
increase in frequency of engine start.
HB215LC-2 30-129
Electrical system
Testing (Cylinder Cut-out operation) (HB205- • [F6]: Enters selection

AD00-34F-K-01-A)
On the machine monitor, the cylinder cutout mode a This operation may be performed while the
operation, reset of auto-idle stop sudden stop engine is running.
numbers, and capacitor discharge operation can be a When [F6] is pressed, if background (a) of
executed. the selected cylinder No. becomes white, the
Cylinder cutout mode operation means to run the cylinder is cut out.
engine with one or more fuel injectors disabled
a If the machine monitor cuts out a cylinder but
electrically to reduce the number of effective
the engine controller cannot cutout that
cylinders. This operation is used to identify a
cylinder, the background (a) of the cylinder
cylinder that does not output power normally
number becomes yellow.
(combustion in it is abnormal).
1. Selecting menu a One or more cylinders can be cut out.
Select "Diagnostic Tests" on "Service Menu" a Auto-deceleration function can be selected in
screen. the cylinder cutout mode operation. When
turning auto-deceleration ON, auto-
deceleration monitor (b) is displayed.

After "Diagnostic Tests" screen is displayed,
select "Cylinder Cut-out" by using the function
4. Releasing cut out cylinder
When changing a cylinder to be cut out or when
a Selecting method is the same as on "Service cylinder cutout operation is finished, select a cut
Menu" screen. out cylinder to be reset with 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 No. becomes blue, the
cylinder is reset.
a If the machine monitor releases a cut-out
cylinder but the engine controller cannot
release the cut-out cylinder, the background
(a) of the cylinder number becomes red.
a The cut-out cylinder mode operation is not
3. Selecting cylinder to be cut-out automatically released after the screen
After "Cylinder Cut-out" screen is displayed, returns to the operator mode. Accordingly, be
select a cylinder to be cut out by using the sure to perform the releasing operation after
function switches. the cylinder cut-out mode operation is
• [F1]: Moves selection leftward finished.
• [F2]: Moves selection rightward 5. Holding displayed data
• [F4]: Selects hold or releasing hold Each time [F4] is pressed during the Cylinder
(If the Hold is selected, a diagonal line is Cut-Out operation, the displayed data is newly
drawn on the HOLD portion.) held (c) (the real-time data is kept displayed on
• [F5] Returns to "Diagnostic Tests" screen the left side).
30-130 HB215LC-2
Electrical system
While the data is held, if [F4] is pressed, the data 2. Selecting a sub menu
holding function is reset. After "Diagnostic Tests" screen is displayed,
select "Reset Number of Abrupt Engine Stop by
a The holding function is available for a
AIS" by using the function switch or numeral
cylinder, regardless of whether it is cut out or
input switches.
not.
Menu" screen.
[Reference]
• If a normally operating cylinder is cut out, the
following phenomena occur. 3. Performing reset
1) Lowering of engine speed After "Reset Number of Abrupt Engine Stop by
2) Fuel Inject Command (quantity) increases. AIS" screen is displayed, select the item to be
• If the engine is running at near high idle, reset by using the function switch.
however, the engine speed may not lower for • [F5]: Returns to "Diagnostic Tests" screen
the reason of engine control. • [F6]: Executes reset
• In this case, lower the engine speed with the
a Perform the sudden stop number reset after
fuel control dial and judge by increase of the
replacing the turbocharger.
injection rate command.
Testing (Reset Number of Abrupt Engine Stop

by AIS) (HB205-AF87-360-K-01-A)
On the machine monitor, the cylinder cutout mode
operation, reset of auto-idle stop sudden stop
numbers, and capacitor discharge operation can be
executed.
Reset of auto-idle stop sudden stop numbers by
auto idle stop is used to reset the counter that
counts the high engine speed state when stopping
the engine by the auto idle stop function saved in
the machine. The reset is performed after replacing
the turbocharger.
1. Selecting a menu Testing (discharge of capacitor electric
Select "Diagnostic Tests" on "Service Menu" charge) (HB205-PQJW-360-K-01-A)
screen.
When the hybrid system is normal, discharging of

capacitor can be done by operating the machine
monitor. This is done by consuming the electric
charge of the capacitor by using motor-generator.
Therefore, discharging of capacitor with the
machine monitor cannot be done for some errors
(see following table) when the hybrid system is
stopped. In this case, discharge by using the
dedicated capacitor discharge device.
HB215LC-2 30-131
Electrical system
a Even if an error that does not allow you to generator. Accordingly, the engine speed
discharge the capacitor with the machine becomes higher temporarily. However, this is
monitor occurs, it is possible to "shift to the normal status.
discharge screen and operate the screen" on
the monitor screen. However, never perform
this.
a You cannot perform the swing operation when
discharging the capacitor. However, you can
operate the work equipment. Be careful of it.
a "Disables Auto Idle"
1. Start the engine, and run it at low idle.
2. Selecting a menu
Select "Diagnostic Tests" on "Service Menu"
screen.

After the "Diagnostic Tests" screen is displayed, 5. Completion of discharging
select "Discharge Capacitor" using the function 1) After 20 minutes or so, when "Capacitor
switch or numeral input switches. Charge Ratio 0%" is displayed and
a Selecting method is the same as on the "COMPLETED" is displayed, turn the starting
"Service Menu" screen. switch to OFF position to finish the procedure
(discharge completed).
4. Discharging capacitor
After the "Discharge Capacitor" screen is
a After completion of discharge and turning
displayed, select the item to be performed by
the starting switch to OFF position, when
using the function switches.
turning the starting switch to ON position
• [F1]: Discharge the capacitor
(do not start the engine) and displaying
• [F5]: Returns to "Service Menu" screen
the "Discharge Capacitor" screen,
a Press function switch F1 (START) and "Capacitor Charge Ratio 60%" appears.
discharge the capacitor. This is not abnormal.
This operation allows the electric charge in the
capacitor to be consumed via the motor-
30-132 HB215LC-2
Electrical system
a Between the dummy charge ratio and

charge ratio based on the actual voltage,
larger value appears on the machine
monitor.
• Dummy charge ratio: Charge ratio that
drops from "60%" to "0%" for
approximately 20 minutes from the
discharge start time independently
from the capacitor actual voltage
a The capacitor actual voltage suddenly
drops after approximately 30 seconds of
discharge start, and the charge ratio
drops to "0%" after approximately 20 2) Turn the starting switch to OFF position,
minutes. However, the capacitor actual completely stop the engine, and remove the
voltage is hardly changed after a lapse of key.
30 seconds from discharge start by
a After completion of discharge, the
displaying the charge ratio based on the
capacitor is charged again when the
actual voltage, and whether the capacitor
engine runs. Therefore, do not operate
is correctly discharged or not is unclear.
the starting switch as described below.
This is why the dummy charge ratio is
used. • After turning the starting switch to OFF,
turning the starting switch to ON
a The dummy charge ratio is reset and position again (before completely
returns to "60%" by turning the starting stopping the engine)
switch to OFF position. • Turn the starting switch to ON position
a If the message "NOT COMPLETED" after turning the starting switch to OFF
appears, if the capacitor charge ratio position and completely stopping the
does not drop after a lapse of 5 minutes engine
or more from discharge start, if LED is not a Even if the capacitor charge ratio is [0%],
displayed as "Not charged" despite the the capacitor voltage is not necessarily to
"0%" of capacitor charge ratio, if the be completely 0 V. With the nature of a
message "COMPLETED" does not capacitor, the voltage tends to recover
appear even after a lapse of 30 minutes after discharging. Accordingly, take care
from discharge start, and if the upper- at the maintenance such as
capacitor LED that indicates the capacitor disconnecting the connector.
charge status is not displayed as "Not
charged", the capacitor is not discharged Failure code that does not allow the discharge
(discharge not completed) for some with the machine monitor
reason. In this case, immediately stop the The failure code listed below do not allow the
capacitor discharge with the machine capacitor to be discharged with the machine monitor.
monitor and use the dedicated capacitor Even if you cannot discharge the capacitor, it is
discharge device to discharge the possible to "shift to the discharge screen and
capacitor. operate the screen" on the monitor screen. However,
never perform this.
HB215LC-2 30-133
Electrical system
• Failure code and phenomenon related to high- The sub menu of Pump Absorption Torque is used
pressure circuit to finely adjust the absorption torque of the
Failure hydraulic pump.
Failure
code 1. Selecting a menu
GA00NS HYB Equipment Overheat Select "Adjustment" on "Service Menu" screen.
GA01KA Power Cable Interlock Open Circuit
GA02KZ DC Electric Leakage Error
GA04KG Abnormal DC HW Volt. Before Booster
GA05KG Abnormal DC SW Volt. Before Booster
GA05KP Low DC SW Output Volt. Bef. Booster
GA06KZ DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster
GA08KG Abnorm. DC HW Volt. After Booster
GA09KG Abnorm. DC SW Volt. After Booster
GA09KP Low DC SW Output Volt. After Booster
GA0AKZ DC Vlt. Sen. Op./Shrt Cir. Aft. Booster
GA10MC HYB Controller Error
GA12NK HYB Cont. Pow. Suppl. Not Turn. ON
GA12NL HYB Cont. Pow. Suppl. Not Turn. OFF 2. Selecting a sub menu
GA18MC Gen. Mo.Dr. Excite. Pow. Sup. Failure After the "Adjustment" screen is displayed,
GA1SFS Contactor Locked select "Pump Absorption Torque (F)" by using
GA1SMC Contactor Failure the function switch or numeral input switches.
GA1VMC Capacitor Contactor Failure a Selecting method is the same as on the
GA21KB Booster IGBT Open Circuit "Service Menu" screen.
• Failure code and phenomenon related to motor-
generator
Failure
Failure
code
GA13MC HYB Contror. Sen. Power Sup. Failure
GA17KR Gen. Mot. Drv. Communication Failure
GA17KY Gen. Mot Dr. Power Line Short Circuit
Gen. Motor Driver Sub-CPU Comm.
GA19KR
Failure
Int. Abnorm. Gen. Mot. Drv. Sub-CPU
GA19KT
Con.
GA19MA Gen. Mot. Drv. Sub-CPU Malfunction
GA1BMA Gen. Mot. Dr. DC Vlt. Sens. Malfunction
GA25MA Gen. Motor Driver IGBT 0 Abnormality 3. Selecting a pump absorption torque setting
GA26MA Gen. Motor Driver IGBT 1 Abnormality After the "Pump Absorption Torque (F)" screen
GA60MC Generator Motor Failure is displayed, select the desired value at the right
side by using the function switches.
GA60N1 Generator Motor Overrun
• Set value: For actual torque adjustment
Gen. Mot. Ph-A Cur. Sen. Power Short
GA62KY value, see table
Cir
Gen. Mot. Ph-A Current Sen. • [F3]: Increases set value
GA62MA • [F4]: Decreases set value
Malfunction
Gen. Mot. Ph-B Cur. Sen. Power Short • [F6]: Checks and enters setting. Returns the
GA63KY screen to "Adjustment" screen
Cir
Gen. Mot. Ph-B Current Sen.
GA63MA
Malfunction
Gen. Mot. Ph-C Cur. Sen. Power Short
GA64KY
Cir
Gen. Mot. Ph-C Current Sen.
GA64MA
Malfunction
Adjustment (Pump Absorption Torque

(F)) (PC220-C201-27E-K-00-A)
You can perform various adjustments related to the
machine with the machine monitor.
30-134 HB215LC-2
Electrical system
a The 3-digit number in the left column does a Selecting method is the same as on the
not change since it is the code of this "Service Menu" screen.
function.
3. Selecting a pump absorption torque setting

After the "Pump Absorption Torque (R)" screen
a Relationship between set value and torque
is displayed, select the desired value at the right
adjustment value
Torque adjustment • Set value: For actual torque adjustment
Code Set Value
value value, see table
000 +39.2 Nm {+4 kgm} • [F3]: Increases set value
001 +29.4 Nm {+3 kgm} • [F4]: Decreases set value
002 +19.6 Nm {+2 kgm} • [F6]: Checks and enters setting. Returns to
003 +9.8 Nm {+1 kgm} "Adjustment" screen.
021 004 0 Nm {0 kgm} a The 3-digit number in the left column does
005 -9.8 Nm {-1 kgm} not change since it is the code of this
006 -19.6 N {-2 kgm} function.
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
Adjustment (Pump Absorption Torque

(R)) (PC220-C202-27E-K-00-A)
The sub menu of Pump Absorption Torque (R) is
used to finely adjust the absorption torque of the
rear hydraulic pump.
1. Selecting a menu
Select "Adjustment" on "Service Menu" screen.
a Relationship between set value and torque

adjustment value
Torque adjustment
Code Set Value
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}
2. Selecting a sub menu 007 -29.4 Nm {-3 kgm}
After the "Adjustment" screen is displayed, 008 -39.2 Nm {-4 kgm}
select "Pump Absorption Torque (R)" by using
the function switch or numeral input switches.
HB215LC-2 30-135
Electrical system
Adjustment (travel low speed setting) (PC220-

Q1F8-100-K-00-A)
The sub menu of Low Speed is used to finely adjust
the travel speed at Low setting.
1. Selecting a menu
a Relationship between set value and travel

Low speed value
Travel speed at
Code Set Value
Low
000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h
After the "Adjustment" screen is displayed, Adjustment (Attachment Flow
select "Low Speed" by using the function switch Adjustment) (PC220-Q1F9-100-K-00-A)
or numeral input switches. You can perform various adjustments related to the
a Selecting method is the same as on the
"Service Menu" screen. The sub menu of "Attachment Flow Adjustment" is
used to finely adjust the oil flow rate to the
attachment in combined operations.
1. Selecting a menu
3. Selecting a travel Low Speed

After the "Low Speed" screen is displayed,
select the desired value at the right side by using
the function switches.
• Set value: For actual travel Low speed value, 2. Selecting a sub menu
see table After the "Adjustment" screen is displayed,
• [F3]: Increases set value select "Attachment Flow Adjustment" by using
• [F4]: Decreases set value the function switch or numeral input switches.
• [F6]: Checks and enters setting. Returns
screen to the "Adjustment" screen a Selecting method is the same as on the
"Service Menu" screen.
a The 3-digit number in the left column does
not change since it is the code of this
function.
30-136 HB215LC-2
Electrical system
3. Selecting a distribution of oil flow

After the "Attachment Flow Adjustment" screen
is displayed, select the desired value at the right
• Set value: For actual distribution of oil flow,
see table
• [F3]: Increases set value
• [F4]: Decreases set value
• [F6]: Checks and enters setting. Returns
screen to the "Adjustment" screen
function.
a Relationship between set value and

distribution of oil flow to attachment
Distribution of flow to
Code Set Value
attachment
000 50%
001 70%
044
002 100%
003 40%
HB215LC-2 30-137
Electrical system
Adjustment (F pump swash plate sensor calibration) (HB205-C3W9-273-K-01-A)

You can perform various adjustments related to the machine with the machine monitor.
The F pump swash plate sensor calibration is used to calibrate the sensor installed on the actual machine to
eliminate deviation of the sensor signal made when the front pump swash plate sensor is removed/installed or
replaced with new one.
a The pump swash plate sensor needs to be calibrated in the following cases.
Necessity of front pump Necessity of rear pump
Contents of operation swash plate sensor swash plate sensor
calibration calibration
Removal and installation or replacement of front
Necessary Unnecessary
pump swash plate sensor
Removal and installation or replacement of rear pump
Unnecessary Necessary
swash plate sensor
Replacement of main pump assembly Necessary Necessary
Replacement of pump controller Necessary Necessary
Adjustment and disassembly of front pump PC valve Necessary Unnecessary
Adjustment and disassembly of rear pump PC valve Unnecessary Necessary
a Before performing calibration of pump swash • Travel speed: Hi

plate sensor, check that the pump swash plate 2. Selecting a menu
sensor is normal. Select "Adjustment" on "Service Menu" screen.
a A rough flow of calibration of the pump swash
plate sensor is as follows.
• Perform calibration on "Adjustment screen"
of "Service Menu".

After "Adjustment" screen is displayed, select
"Cal F pump swash plate sensor" by using the
function switch or numeral input switches.
Menu" screen.
1. Preparation for calibration

Before starting calibration, set the machine 4. Cal F pump swash plate sensor max
under the following condition 1) After "Cal F pump swash plate sensor max"
• Hydraulic oil temperature: 45 to 55°C is displayed, calibrate the front pump swash
30-138 HB215LC-2
Electrical system
plate sensor for the maximum angle by

running track idle off the ground and
operating the function switches.
[F1]: START
[F2]: CLEAR
[F5]: Returns to the adjustment screen
[F6]: Enters setting
4) Calibration is finished successfully, "OK" is

displayed for the State of Adjustment to show
that calibration for the maximum angle is
complete.
Press [F6] to go to calibration for the
minimum angle.
2) Raise the right track off ground by using the

work equipment and move the right travel
lever to the stroke end to run the right track
idle off the ground.
• Fuel control dial: MAX
• R.H. travel lever: Full stroke
Travel direction may be set in either of
forward and reverse.
• Swing lock switch may be set in either
ON or OFF.
k Provide an enough work space to run

the track idle off the ground. If calibration is finished unsuccessfully, "NG"
is displayed for the State of Adjustment and
the failure cause code is displayed. Referring
k Be careful about safety around the
to the failure cause codes in Table 1, find out
machine while running the track idle
and remove the cause and repeat calibration.
off the ground.
3) When running speed of the track idle off the a The calibration value can be initialized by
ground becomes steady, hold down button holding down CLEAR button [F2].
[F1] of machine monitor to start the If the calibration value is initialized,
calibration. The state of process is displayed ""READY"" is displayed for the State of
as a bar on the screen during calibration, so Adjustment on the screen.
keep running the track idle off the ground 5. Calibration of front pump swash plate sensor for
until the end of calibration. the minimum angle
HB215LC-2 30-139
Electrical system
1) After "Cal F pump swash plate sensor min"

screen is displayed, calibrate the front pump
swash plate sensor for the minimum angle by
running track idle off the ground and
operating the function switches.
[F1]: START
[F2]: CLEAR
[F5]: Returns to the adjustment screen
[F6]: Enters setting
If calibration is finished unsuccessfully, "NG"

is displayed for the State of Adjustment and
the failure cause code is displayed. Referring
to the failure cause codes in Table 1, find out
and remove the cause and press [F6] to
repeat the calibration for the minimum angle.
2) Wait under the following conditions.

• All control levers: NEUTRAL
Fuel control dial may be at any position.
3) Hold down [F1] of the machine monitor to
start calibration.
The state of process is displayed as a bar on
the screen during calibration. Keep all control
levers in NEUTRAL position until the
calibration is finished.
a The calibration value can be initialized by

holding down CLEAR button [F2].
If the calibration value is initialized,
""READY"" is displayed for the State of
Adjustment on the screen.
4) When calibration is finished successfully,

"OK" is displayed for the State of Adjustment
to show that calibration for the minimum
angle is complete.
Press [F6] and return the display to
"Adjustment" screen.
30-140 HB215LC-2
Electrical system
Table 1. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
MIN MAX
Cause swash swash Pump
plate plate cali- Content Remedies
code
cali- cali- bra-
bra- bra- tion
tion tion
A-1 q q q Engine speed signal is 0 rpm Check that engine is started
Check hydraulic oil temperature
A-2 q q q Hydraulic oil temperature is low.
(Min. 45°C)
Check hydraulic oil temperature.
(Calibration of swash plate: Max.
A-3 q q q Hydraulic oil temperature is high
85°C, Calibration of pump: Max.
55°C)
A-4 q q q Overheating Check for overheating.
Pump pressure sensor (F, R) is Perform troubleshooting for pump
A-6 q q q pressure sensor
defective
Pump swash plate (F, R) sensor is Perform troubleshooting for pump
A-7 q q -
swash plate sensor
defective
Arm IN PPC pressure sensor is Perform troubleshooting for arm IN
A-8 - - q PPC pressure sensor
defective.
Perform troubleshooting for PC-
A-9 - - q PC-EPC abnormality
EPC
CAN communication is defective
A-A - - q (engine, monitor, pump)
Perform troubleshooting for CAN
Bucket CURL PPC pressure sensor is Perform troubleshooting for bucket
A-B - - q CURL PPC pressure sensor
defective
Pump pressure of calibrated pump is Perform troubleshooting for relief
B-1 q ― -
valve and pump
above standard value
B-3 q ― ― Lever is not in NEUTRAL Set lever in NEUTRAL
C-1 - q ―
valve and pump.
below standard value
C-2 - q ― Travel speed setting is not Hi Set travel speed to Hi on monitor.
Fuel control dial is not set to Max. Set fuel control dial to Max.
C-3 - q q position. position.
Set travel lever to full stroke and
C-4 - q ― Both tracks are running
work equipment lever to neutral.
Check adjustment of service (Oil
C-5 - q ― Oil flow from 2 pumps are not divided flow is normally divided during
travel single operation)
Travel PPC pressure sensor Perform troubleshooting for travel
C-6 - q ―
abnormality PPC
Travel PPC pressure is below
C-7 - q ― Set travel lever to full stroke.
standard value
When arm IN is relieved, arm IN PPC
pressure is below specified value or
E-1 - - q arm IN PPC pressure sensor is out of Set arm control lever to full stroke.
the normal range (*1)
Pump pressure (F, R) is out of Perform troubleshooting for relief
E-2 - - q standard range valve and pump.
E-3 - - q Engine speed is out of standard range Set the engine to Hi idle speed.
Engine torque is out of standard Perform troubleshooting for engine
E-4 - - q range and pump
PC-EPC current is out of standard Perform troubleshooting for PC-
E-5 - - q range EPC current
HB215LC-2 30-141
Electrical system
Object
MIN MAX
Cause swash swash Pump
plate plate cali- Content Remedies
code
cali- cali- bra-
bra- bra- tion
tion tion
When bucket digging is relieved,
bucket digging PPC pressure is below
Set bucket CURL lever to full
E-6 - - q specified value or bucket digging PPC
pressure sensor is out of the normal stroke.
range (*1)
Working mode is not set to [P] or Set working mode to [P] or [ATT/
E-7 - - q [ATT/P] P].
Hybrid system stop switch is not set to Set hybrid system stop switch to
E-8 - - q ON position ON position
Swing lock switch is not set to ON Set swing lock switch to ON
E-9 - - q position position.
E-A - - q Air conditioner is ON Set air conditioner to OFF position.
Output voltage of pump swash plate Perform troubleshooting for swash
FF q q ―
sensor is out of calibration range. plate sensor
(*1) When the sensor voltage is out of the normal range (0.5 to 4.5 V), the pump controller recognizes the
relief pressure to be 0 MPa {0 kg/cm2}. Accordingly, perform troubleshooting, referring to Troubleshooting
(Failure codes "DHPAMA" and "DHPBMA").
30-142 HB215LC-2
Electrical system
Adjustment (R pump swash plate sensor

calibration) (PC220-C3WB-273-K-00-A)
Before starting calibration, set the machine
under the following condition
2. Selecting a menu

After the "Adjustment" screen is displayed,
select "Cal R pump swash plate sensor" by
using the function switch or numeral input
switches.
a Select this item similarly to an item on the
4. Perform the subsequent calibration procedure

according to "Cal F pump swash plate sensor".
HB215LC-2 30-143
Electrical system
Adjustment (Pump calibration: Matching speed check) (HB205-C200-280-K-01-A)

The pump calibration function is used to check the
matching speed for arm IN relief and bucket CURL
relief and to set the matching speed to the engine
properly when the pump or pump controller is
replaced.
a The pump calibration (matching speed check
and calibration) is required in the following
cases.
Necessity of
Contents of operation pump
calibration
Replacement of engine Unnecessary
Replacement of main pump
Necessary
assembly
Replacement of pump controller Necessary
Adjustment and disassembly of
Necessary
front pump PC valve
Adjustment and disassembly of
Necessary
rear pump PC valve
Control valve replacement Unnecessary
Adjustment or replacement of main Unnecessary
relief valve
a A rough flow of calibration of the pump is as

follows. 1. Preparation for calibration
Repeat "Matching Speed Check" and "Matching Before starting calibration, set the machine
Speed Calibration" 3 times. under the following condition
• Perform calibration on "Adjustment" menu of • Perform warm-up operation for at least 30
"Service Menu". minutes
• Hybrid system stop switch: ON
• Air conditioner: OFF (stopped)
2. Selecting menu

After "Adjustment" screen is displayed, input
"40" by using the numeral input switches and
press "F6".
30-144 HB215LC-2
Electrical system
a Accordingly, the alarm buzzer of the swing

emergency stop switch stops.
a Since this function is required only when the
pump is replaced, the PC valve is adjusted or
disassembled, or the pump controller is
replaced, it is not displayed in the menu list.
2) Operate the arm control lever or bucket

control lever under the following condition to
check the relief matching.
(Operation)
Operate according to the arm IN relief and
bucket CURL relief screen.
a Set bucket CURL relief matching after
4. Selection of matching speed check menu
completing arm IN relief matching.
After "Pump Calibration" screen is displayed,
select "Matching Speed Check" by using the Arm lever: IN stroke end (Operate during
function switch or numeral input switches. arm IN relief matching)
Bucket lever: CURL stroke end (Operate
a Select this when it is required to check
during bucket CURL relief matching)
abnormality or current condition of the
(Condition)
machine.
Selecting method is the same as on "Service • Hybrid system stop switch: ON
Menu" screen. • Working mode: P mode
• Air conditioner: OFF
k Secure sufficient area for operation of

the work equipment during testing.
k When operating the work equipment,

secure full safety around the machine.
[Reference]
• The alphabet letter at the right top of the
screen indicates the following condition.
D: Default
F: Adjustment value at shipment from factory
(Factory shipment state (Normal))
U: User calibration value
5. Matching speed check (arm IN relief)
1) When "Matching Speed Check" screen is
displayed, check the matching speed by arm 3) Keep arm IN relief state. When the engine
IN relief and function switch. speed is stabilized, hold down [F1] on the
[F1]: START machine monitor to start checking.
[F5]: Returns to pump calibration screen During matching speed check, a bar is
displayed on the screen. Keep relief
operation until the check is finished.
HB215LC-2 30-145
Electrical system
• It takes approximately 10 seconds to start

the bar graph operation.
2) Wait under the following conditions.

4) If the check is normally completed, the result • Working mode: P mode
is displayed. • Hybrid system stop switch: ON
Press [F6] to move to the next • Fuel control dial: MAX
3) Keep bucket CURL relief state. When the
engine speed is stabilized, hold down [F1] on
the machine monitor to start checking.
During matching speed check, a bar is
displayed on the screen. Keep relief
operation until the check is finished.
• It takes approximately 10 seconds to start
the bar graph operation.
If check is finished unsuccessfully, "NG" is

displayed for the State of check and the
failure cause code is displayed. Referring to
the failure cause codes in Table 2, find out
and remove the cause and repeat matching
speed check.
4) If the check is normally completed, the result

is displayed.
Press [F6] to move to the next
6. Matching speed check (Bucket CURL relief)

1) When "Matching Speed Check" screen is
displayed, check the matching speed by the
bucket CURL relief and the function switch.
[F1]: START
[F5]: Returns to arm IN relief screen
30-146 HB215LC-2
Electrical system
If check is finished unsuccessfully, "NG" is

displayed for the State of check and the failure
cause code is displayed. Referring to the failure
cause codes in Table 1, find out and remove the
cause and repeat matching speed check.
Table 1. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
MIN MAX
Cause swash swash Pump Content Remedies
code plate plate calibra-
calibra- calibra- tion
tion tion
A-1 q q q Engine speed signal is 0 rpm Check that engine is started
Check hydraulic oil temperature
A-2 q q q Hydraulic oil temperature is low
(Min. 45°C)
Check hydraulic oil temperature.
(Calibration of swash plate: Max.
A-3 q q q Hydraulic oil temperature is high
85°C, Calibration of pump: Max.
55°C)
A-4 q q q Overheating Check for overheating.
Pump pressure sensor (F, R) is Perform troubleshooting for pump
A-6 q q q pressure sensor
defective
Pump swash plate (F, R) sensor is Perform troubleshooting for pump
A-7 q q -
swash plate sensor
defective.
Arm IN PPC pressure sensor is Perform troubleshooting for arm
A-8 - - q IN PPC pressure sensor
defective.
Perform troubleshooting for PC-
A-9 - - q PC-EPC abnormality
EPC
CAN communication is defective
A-A - - q (engine, monitor, pump)
Perform troubleshooting for CAN
Perform troubleshooting for
Bucket CURL PPC pressure sensor
A-B - - q bucket CURL PPC pressure
is defective.
sensor
B-1 q ― -
valve and pump
above standard value
B-3 q q ― Lever is not in NEUTRAL Set lever in NEUTRAL
C-1 - q ―
valve and pump.
below standard value
C-2 - q ― Travel speed setting is not Hi Set travel speed to Hi on monitor.
Fuel control dial is not set to Max. Set fuel control dial to Max.
C-3 - q q position. position.
Set travel lever to full stroke and
C-4 - q ― Both tracks are running work equipment lever to
NEUTRAL.
HB215LC-2 30-147
Electrical system
Object
MIN MAX
Cause swash swash Pump Content Remedies
code plate plate calibra-
calibra- calibra- tion
tion tion
Check adjustment of service (Oil
Oil flow from 2 pumps are not
C-5 - q ― flow is normally divided during
divided travel single operation)
Travel PPC pressure sensor Perform troubleshooting for travel
C-6 - q ―
abnormality PPC
Travel PPC pressure is below
C-7 - q ― Set travel lever to full stroke.
standard value
When arm IN is relieved, arm IN
PPC pressure is below specified
Set L.H. work equipment control
E-1 - - q value or arm IN PPC pressure
sensor is out of the normal range lever to arm IN stroke end.
(*1)
Pump pressure (F, R) is out of Perform troubleshooting for relief
E-2 - - q standard range valve and pump.
Engine speed is out of standard
E-3 - - q range
Set the engine to Hi idle speed.
Engine torque is out of standard Perform troubleshooting for
E-4 - - q range engine and pump
PC-EPC current is out of standard Perform troubleshooting for PC-
E-5 - - q range EPC current
When bucket CURL is relieved,
bucket CURL PPC pressure is below
Set R.H. work equipment control
E-6 - - q specified value or bucket CURL PPC
pressure sensor is out of the normal lever to bucket CURL stroke end.
range (*1)
Working mode is not set to [P] or Set working mode to [P] or [ATT/
E-7 - - q [ATT/P] P].
Hybrid system stop switch is not setSet hybrid system stop switch to
E-8 - - q to ON position ON position
Swing lock switch is not set to ON Set swing lock switch to ON
E-9 - - q position position.
Set air conditioner to OFF
E-A - - q Air conditioner is ON position.
Output voltage of pump swash plate Perform troubleshooting for
FF q q ―
sensor is out of calibration range. swash plate sensor
(*1) When the sensor voltage is out of the normal range (0.5 to 4.5 V), the pump controller recognizes the
relief pressure to be 0 MPa {0 kg/cm 2}. Accordingly, perform troubleshooting, referring to Troubleshooting
(Failure codes "DHPAMA" and "DHPBMA").
30-148 HB215LC-2
Electrical system
Adjustment (Pump calibration: Matching

speed calibration) (HB205-C200-270-K-01-A)
Before starting calibration, set the machine
under the following condition
• Perform warm-up operation for at least 30
minutes
• Hybrid system stop switch: ON
• Fuel control dial: MAX position
2. Selecting menu 5. Perform the subsequent calibration procedure
Select "Adjustment" on "Service Menu" screen. according to "Matching Speed Calibration".
Adjustment (Pump calibration: Restore

default value) (PC200_10-C200-270-K-01-A)
1. Selecting menu

After "Adjustment" screen is displayed, input
"40" by using the numeral input switches and
press "F6".
a Since this function is required only when the 2. Selecting sub menu
pump is replaced, the PC valve is adjusted or After "Adjustment" screen is displayed, input
disassembled, or the pump controller is "40" by using the numeral input switches and
replaced, it is not displayed in the menu list. press "F6".
a Since this function is required only when the
pump is replaced, the PC valve is adjusted or
disassembled, or the pump controller is
replaced, it is not displayed in "Adjustment"
menu list.
4. Selecting matching speed calibration menu

After the "Pump Calibration" screen is displayed,
select "Matching Speed Calibration" by using
the function switches or numeral input switches.
3. Return to the default value.
HB215LC-2 30-149
Electrical system
4. After "Pump Calibration" screen is displayed, Swing starting torque setting function is to finely
select "Restore to Default Setting" by using the adjust the maximum value of swing motor torque
function switch or numeral input switches. when starting the swing operation.
a Selecting method is the same as on the This adjustment enables you to finely adjust the
"Service Menu" screen. acceleration time when starting the swing operation.
1. Selecting a menu
• [F5]: Returns to "Pump Calibration"

• [F6]: Performs initialization
"Swing Motor Starting Torque" by using the
Menu" screen.
• When [F6] is pressed, if "Pump Calibration"

screen is displayed and alphabet letter "D" is
indicated at the right top of the screen,
initialization is complete.
3. After "Swing Motor Starting Torque" screen is

displayed, select the desired value at the right
• Set value: For actual swing motor torque,
see table
• [F4]: Decreases set value
• [F6]: Checks and enters setting. Returns the
screen to "Adjustment" screen
Adjustment (Swing Motor Starting function.
Torque) (HB205-PQJX-270-K-01-A)

30-150 HB215LC-2
Electrical system

Menu" screen.
a Relation between set values and swing

starting torque value
3. After "Hoist Swing Adjustment" screen is
Adjustment value of
Code Set Value displayed, select the desired value at the right
swing starting torque
000 0 Nm {0 kgm}
–8 Nm {–0.8 kgm} • Set value: For actual swing motor torque,
001
158 see table
002 –18 Nm {–1.8 kgm}
003 –28 Nm {–2.9 kgm} • [F4]: Decreases set value
• The default value is set to the maximum value of • [F6]: Checks and enters setting. Returns the
starting torque "000". screen to "Adjustment" screen
• Since the maximum value of the swing motor
torque is finely adjusted, the swing acceleration
by the fine swing operation is not changed.
function.
Adjustment (Hoist Swing Adjustment) (HB205-
PQJY-270-K-01-A)

Hoist swing adjustment function is to finely adjust
the swing acceleration performance during hoist
swing operation by adjusting the maximum value of
swing motor torque during combined operation of
swing and boom.
1. Selecting a menu
a Relation between set value and hoist swing

torque value
Swing torque adjustment
Code Set Value value during hoist swing
000 100%
001 90%
159
002 80%
003 70%
• The default value is set to "001".
• This adjusts the swing acceleration performance
during hoist swing operation.

"Hoist Swing Adjustment" by using the function
HB215LC-2 30-151
Electrical system
Adjustment (Setting of swing derate 3. Setting swing derate adjustment mode

adjustment mode) After the "Setting of swing derate adjustment
You can perform various adjustments related to the mode" screen is displayed, select the desired
machine with the machine monitor. value at the right side by using the function
a If capacitor voltage decreases due to continuous switches.
swing operations and the temperature of the • Set value: For actual value, see the table
booster inductor increases, overheating may below that shows the relation between the
frequently occur. This setting is a function set value and setting of swing derate
used to relieve overheating that occurs for this adjustment mode
reason, and does not appear in the adjustment • [F3]: Increases set value
menu. • [F4]: Decreases set value
• [F6]: Checks and enters setting. Returns to
a With this setting enabled, when the booster "Adjustment" screen.
inductor reaches high temperature, swing output
is limited to increase an engine speed. This will a The 3-digit number in the left column does
reduce load of hybrid equipment to prevent not change since it is the code of this
overheating. However, fuel consumption may function.
increase.
1. Selecting a menu S胃lni lni
84P40078
a Relation between set value and setting

of swing derate adjustment mode
Code Set Value Setting state

2. Selecting a sub menu 000 Normal
When the "Adjustment" screen is displayed, use 162 Relieve function
the numeral input switches to enter "31", and 001
enabled
press "F6".

B4P40077
30-151-1 HB215LC-2
Electrical system
HB215LC-2 30-151-2
Electrical system
No-Injection (PC220-AD00-25L-K-00-A) a Do not crank the engine for 20 seconds or

If the engine is operated after long storage of the longer to protect the starting motor.
machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this, the
machine monitor has a function to crank the engine
without injecting fuel to lubricate the engine before
starting it.
Set no-injection cranking while the engine is
stopped.
1. Selecting a menu
Select "No Injection" on "Service Menu" screen.
4. Finishing no-injection cranking

After the cranking is over, turn the starting switch
to OFF position.
a You cannot change the screen described
above to another screen.
5. Prohibiting no-injection cranking
Even if the operator tries to perform the no-
injection cranking while the engine is running,
the message "The engine is operating" is
2. Displaying check screen displayed and the no-injection cranking does not
When the "No Injection" screen is displayed, the become effective.
message to ask if "Begin Injectionless
a This function can be selected even when the
Cranking?" appears. Select the answer by using
engine is running. However, if you execute
the function switch.
no-injection cranking, a message "The
• [F5]: Does not implement (returns the screen
engine is operating. Please turn the key off
to "Service Menu")
once." is displayed on the screen.
• [F6]: Executes
Also, if no-injection cranking is operated when

3. Starting no-injection cranking
"Check" screen is displayed, the function does
If no-injection cranking (no fuel injection to every
not become effective in the following case.
cylinder) is enabled, a message "No-injection is
• The communication between the monitor and
possible" is displayed on the screen. Under this
engine controller is not normal.
condition, crank the engine with the starting
• Perform an engine start operation before the
motor.
message "No injection is possible" is
a While the screen is changing to the following displayed.
screen, the screen of "Getting Ready" is
displayed.
30-152 HB215LC-2
Electrical system
On "Terminal Status" screen, the following items

of information are displayed.
• "Terminal Type": Model name of the
KOMTRAX communication modem
• "KOMTRAX Communication": Status of radio
station establishment underway
• "GMT Time": Greenwich Mean Time (add 9
hours to it for Japan time)
• [F5]: Returns the screen to "KOMTRAX
Settings" screen
KOMTRAX Settings (Terminal Status) (PC220-

Q210-110-K-00-A)
The setting and operating conditions of KOMTRAX
can be checked on the display of KOMTRAX
Settings.
Terminal setting status is used for checking the
setting condition of the KOMTRAX terminal.
1. Selecting a menu
Select "KOMTRAX Settings" on "Service Menu"
screen.
KOMTRAX Settings (GPS and Communication
Status) (PC220-Q210-110-K-01-A)
Settings.
GPS & Communication Status is for checking the
positioning and communication condition of the
KOMTRAX terminal.
1. Selecting a menu
screen.

After the "KOMTRAX Settings" screen is
displayed, select "Terminal Status" by using the
a Selecting method is the same as ot on the

After the "KOMTRAX Settings" screen is
displayed, select "GPS & Communication
Status" by using the function switch or numeral
input switches.
a Selecting method is the same as it on the
3. Contents displayed on Terminal Status screen
HB215LC-2 30-153
Electrical system
3. Contents of display of GPS & Communication 2. Selecting a sub menu

Status After the "KOMTRAX Settings" screen is
On "GPS & Communication Status" screen, the displayed, select "Modem Status" by using the
following items of information are displayed. function switch or numeral input switches.
• "Positioning": GPS positioning status
• "Communication": Communication
environment and connecting condition of the
communication modem
• "Number of message not yet sent": Number
of message(s) not yet sent: Number of
unsent mails existing in the machine monitor
Settings" screen
3. Details displayed on Modem Status screen

IP addresses (2 systems) of the modem are
displayed.
Settings" screen
a IP address is a unique number assigned to
each modem that is used when
KOMTRAX Settings screen (Modem communication between the modem and
Status) (PC220-Q210-110-K-02-A) server is established.
Settings.
Modem information is used to check the IP address
of the KOMTRAX communication modem.
1. Selecting a menu
screen.
30-154 HB215LC-2
Electrical system
Service Message (PC220-Q210-100-K-00-A) a This message is different from that sent to

Special messages for the technician sent from the operator in the operator mode.
KOMTRAX base station (a distributor, etc.) can be
a Since this message is special for the
checked with this function.
technician, the message monitor is not
If a received message includes a setting operation, displayed when it is received with the
a return mail can be sent by using the numeral input machine monitor in the operator mode.
switches as well.
1. Selecting a menu
Select "Service Message" on "Service Menu"
screen.
2. Displaying message (read only)

If there is a message, the contents are displayed.
If there is no message, "No message." is
displayed.
• [F5]: Returns to "Service Menu" screen
a This message is different from that sent to
the operator in the operator mode.
a Since this message is special for the
technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
3. Display of message (with return mail function)

If Numeric Input is displayed under the message,
input a proper number by using the numeral
input switches and enter it by using the function
switch, and the information is returned to the
KOMTRAX base station.
• [F5]: Returns to "KOMTRAX Settings" screen
• [F6]: Enters input value and sends it back
HB215LC-2 30-155
Electrical system
KOMTRAX terminal start-up procedure (HB380-Q210-110-K-00-A)
Observe the following procedure when using a KOMTRAX-Keyperson is a specially educated

KOMTRAX. administrator who performs operation and
• Inside Japan: setting for KOMTRAX in the distributor full-time.
KOMTRAX-Keyperson performs "Machine Machine side inspection for KOMTRAX
registration" by using KOMTRAX screen. Communication opening
• Outside Japan: When the KOMTRAX terminal is replaced,
KOMTRAX-Keyperson performs "Machine KOMTRAX Communication opening must be done
registration" and operation related to to check whether normal communication is
communication startup by using KOMTRAX available from the terminal.
screen.
The above KOMTRAX Communication opening can
When KOMTRAX terminal is replaced.
be performed on the machine monitor.
Observe the following procedure when using
KOMTRAX after replacement of KOMTRAX a To perform GPS and data communication check
terminal. when communication opening, the machine
should be desirably placed outside under an
• Inside Japan:
open sky. The KOMTRAX Communication
1. Our technician provides a new terminal, and opening may not be completed when the
records the part number and serial number. machine is placed indoor where radio wave from
2. Our technician replaces the terminal, and the satellite is blocked.
perform "Machine side inspection for
1. Selecting menu
KOMTRAX Communication opening". Our
technician notifies KOMTRAX-Keyperson of
screen.
the completion of inspection work and new
terminal information.
3. KOMTRAX-Keyperson performs "Terminal
Replacement" by using KOMTRAX screen.
4. KOMTRAX-Keyperson fills in required items
on "End of the Use Sheet", and send it to
KOMTRAX support center.
• Outside Japan:
1. Our technician provides a new terminal, and
records the part number and serial number.
Our technician notifies KOMTRAX-
Keyperson of the new terminal information.
2. KOMTRAX-Keyperson performs "Terminal
Replacement" and operation related to
communication startup by using KOMTRAX
After "KOMTRAX Settings" screen is displayed,
screen.
select "GPS & Communication State."
3. KOMTRAX-Keyperson fills in required items
on "Terminal Replacement Sheet", and send
it by email to KOMTRAX support center via
KOMTRAX administrator in the subsidiary.
4. KOMTRAX-Keyperson confirms that
communication has started on KOMTRAX
screen, and notifies to the site that the
terminal has been replaced.
5. Our technician replaces the terminal, and
perform "Machine side inspection for
KOMTRAX Communication opening". Our
technician notifies KOMTRAX-Keyperson of
the completion of inspection of the work.
6. KOMTRAX-Keyperson handles
communication startup operation on 3. Implementation of KOMTRAX Communication
KOMTRAX screen. opening
1) After "GPS & Communication State" screen
is displayed, perform the following operation.
30-156 HB215LC-2
Electrical system
Switch operation: While pressing numeral a While waiting for the approval, you may
input switches "4", press the buttons in the do what you want to do like displaying
sequence of "1"o"2"o"3". other screens, turning the starting switch
to OFF position or starting the engine.
If there is nothing abnormal, KOMTRAX
Communication opening finishes
automatically. Select "KOMTRAX
Settings" o "Terminal State" of "Service
Menu" to make sure that "Already Open."
is indicated for the item in "KOMTRAX
Settings, "KOMTRAX Communication".
a The opening may not be completed when
the machine is placed indoor where radio
wave from the satellite is blocked.
a If "Modem" does not become "OK", check
2) The screen confirms if you want to the communication antenna and cable for
implement KOMTRAX Communication external failure. If any, repair it and repeat
opening. Answer affirmatively to it and start KOMTRAX Communication opening
the operation. again.
Return switch: Returns the display to "GPS & a If "GPS" does not become "OK", check
Communication State" screen the communication antenna and cable for
Enter switch: Executes KOMTRAX external failure. If any, repair it and repeat
Communication opening. KOMTRAX Communication opening
a When KOMTRAX Communication again.
opening is already completed, this screen
does not appear.
4) When all items are "OK", "KOMTRAX

Communication Opened." screen is
3) The screen displays the state of KOMTRAX automatically displayed.
Communication opening. Check on this Press Enter switch. If "GPS &
screen that all item are "OK". Communication State" appears, the machine
Modem: "OK" is displayed when the system side opening is completed.
enters the communication range.
GPS: "OK" is displayed when it acquires
GPS data.
Transmission: "OK" is displayed when it
transmits data correctly.
Inspection state: The inspection completes
when the modem, GPS and transmission are
all "OK".
a It takes 90 seconds to 15 minutes to
approve all items.
HB215LC-2 30-157
Electrical system
30-158 HB215LC-2
Electrical system
Adjusting rearview camera angle (HB205-Q162-001-K-00-A)
When adjusting the angle of the rear view camera,

prepare the work stand to secure the working place.
If you stand on the counterweight to perform the
work, you may fall and this may lead to serious
personal injury or death
a Adjust it so that the people in the area (W) of 1m
rear of the machine can be displayed on the
machine monitor.
a The claw of cover (2) is made of plastic, so

be careful not to break it when removing.
a If the image displayed on the monitor is out of

position, remove cover (1) of the camera and
adjust installed angle (A) of the rearview
camera.
• Angle (A) can be adjusted in the range shown in
2. Remove bolts (3) (2 places).
the following figure.
3. Remove cover (1).
a Check where and how many shims (6) have
been used.
Shims (6) are put on cover (1). Be careful not
to drop them.
Adjusting (PC220-Q162-270-K-01-A)
1. Remove cover (1) by inserting flat-head

screwdriver [1], etc. in the hole in cover (2) and
then pressing the internal claw.
HB215LC-2 30-159
Electrical system
5. After adjusting, tighten bolts (4).

3 Camera mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Install cover (1) with bolt (3) to install cover (2).
a By using shims (6), adjust the difference
between the upper and lower clearances
between the counterweight and cover (1) to 2
mm or less.
4. Loosen camera mounting bolts (4) (at 3 places)

and adjust camera mounting angle (A) so that
corner (B) of mounting bracket (5) is aligned with
horizontal line (C) of the camera.
a Since shim (6) may be caught in cover (1),

insert it from outside to the cover after
inserting the bolt temporarily.
a Machine is displayed partially on the

machine monitor screen.
30-160 HB215LC-2
Electrical system
Handling voltage circuit of engine controller (PC220-AP40-2A4-K-00-A)
1. Disconnecting or connecting work of the

connector between the engine controller and the
engine must be performed only when the
starting switch and disconnect switch are in OFF
position and the system operating lamp goes
out.
k Before connecting the wiring harness

connector, be sure to completely remove
sand, dust, water, etc., inside the
connector on the controller side.
2. If the T-adapter is inserted in or connected to the
connector between the engine controller and
engine harness for troubleshooting, do not start
the engine.
a You may turn the starting switch to OFF or
ON position but must not turn it to START
position.
HB215LC-2 30-161
Electrical system
Handling battery disconnect switch (HB205-AW1P-100-K-00-A)
1. When the battery disconnect switch is turned to

OFF position, be sure to remove switch key (1).
kA hazard can result if an unauthorized

person turns switch key (1) to ON position
carelessly.
2. The operating condition of each controller can
be checked with the system operating lamp (2)
to prevent the abnormal end of the
disconnection of the battery power supply circuit
while the controllers are in operation.
1) Before shutting off the battery power supply
circuit, turn the starting switch to OFF
position, and check that system operating
lamp (2) goes out, then turn the battery
disconnect switch to OFF position.
2) If the battery disconnect switch is turned to
OFF position (battery power supply circuit is
OFF) while the system operating lamp (2) is
lit, data loss error of controller may occur.
Never operate the battery disconnect switch
while the system operating lamp (2) is lit.
3) System operating lamp (2) goes out in 2
minutes longest after the starting switch is
turned to OFF position.
4) System operating lamp (2) may sometimes
light up while the starting switch is turned to
OFF position because KOMTRAX terminal
may maintain its communication under this
condition.
5) System operating lamp (2) may look slightly
luminous in the dark after it is turned off. It is
due to the minute leakage of current and not
an abnormal phenomenon.
• After the starting switch is turned to OFF
position, KOMTRAX terminal repeats the
start and stop to maintain the periodic
communication.
• The start and stop cycle (sleep cycle) of
KOMTRAX terminal varies depending on
the factors including the communication
state and machine stop time. So the lamp
can be lit as long as approximately 1
hour.
6) When you want to cut off the battery circuit
for maintenance but the system operating
lamp (2) is kept lit, turn the starting switch to
ON position once, turn it to OFF position, and
the lamp (2) goes out in 2 minutes at the
latest. After system operating lamp (2) goes
out, turn the battery disconnect switch
immediately to OFF position.
30-162 HB215LC-2
Electrical system
Testing diodes (ALL-E300-001-P-00-A)
a Test the diode array (8-pin) and the single diode

(2-pin) according to the following procedure.
a The continuity directions of the diode array are
as follows.
2. When using analog tester

1) Selects the resistance range screen.
2) Check the movement of the pointer when
performing the following connection.
1] Apply the red (+) lead of the multimeter to
a The continuity direction of the single diode is the anode (P) side of the diode and apply
indicated on the surface of the diode. the black (-) lead to the cathode (N) side.
Testing (PC220-E300-36J-P-00-A) 2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and
1. When using a digital tester apply the black (-) lead to the anode (P)
1) Select the diode range screen to check the side.
displayed values. 3) Evaluate the condition of the diode by the
a When an ordinary circuit tester is used, movement of the pointer.
the voltage of the internal battery is • The pointer does not move by the above
indicated. 1] connection, but it does by the 2]
2) Apply the red (+) lead of the multimeter to the connection: Normal (however, the
anode (P) side of the diode and apply the movement of the pointer (resistance)
black (-) lead to the cathode (N) side and varies by type of tester, or selection of
check the indicated value. measuring range).
3) Evaluate the condition of the diode by the • The pointer moves by either connection
indicated value. of the above 1], and 2]:
• Indicated value does not change: No Defective (internal short circuit)
continuity (defective) • The pointer moves by neither connection
• Indicated value changes: Continuity the above 1], nor 2]: Defective (internal
(normal) (note) open circuit)
Note: In the case of a silicon diode, a value in
the range from 460 to 600 mV is indicated.
• The indicated value is 0 or approximate
0:
The diode has internal short circuit
(defective).
HB215LC-2 30-163
Pm clinic
Pm clinic (ALL-2160-001-A-00-A)
Pm Clinic service (HB205-2160-209-A-01-A)
Model Serial No. Service meter

T HB215LC-2 h
User name Date of inspection Inspector
Specification
Main parts Attachment Shoe width
T Standard
( )
Boom T Breaker T 600 mm T( )
T Standard
Arm ( ) T( ) T 700 mm
Bucket T Standard
( )
Check of oil and coolant levels
T Radiator coolant T Hydraulic oil T Motor-generator case oil
T Hybrid radiator coolant When necessary T Electric swing motor case oil
T Engine oil T Final drive case oil T Machinery case oil
Ambient temperature Altitude
°C m
Operator's comment
Result of visual inspection
Abnormality record in mechanical systems Abnormality record in electrical systems

989EKX Times/First time h/Latest h Times/First time h/Latest h
A900FR Times/First time h/Latest h Times/First time h/Latest h
A900NY Times/First time h/Latest h Times/First time h/Latest h
A900N6 Times/First time h/Latest h Times/First time h/Latest h
AA10NX Times/First time h/Latest h Times/First time h/Latest h
AB00KE Times/First time h/Latest h Times/First time h/Latest h
B@BAZG Times/First time h/Latest h Times/First time h/Latest h
B@BAZK Times/First time h/Latest h Times/First time h/Latest h
B@BCNS Times/First time h/Latest h Times/First time h/Latest h
B@BCZK Times/First time h/Latest h Times/First time h/Latest h
B@HANS Times/First time h/Latest h Times/First time h/Latest h
CA234 Times/First time h/Latest h Times/First time h/Latest h
30-164 HB215LC-2
Pm clinic
Max. range of engine coolant temperature gauge
Water temperature gauge level Coolant temperature Color of monitor light (a)
6 105°C
Red
5 102°C
4 100°C
3 85°C Blue
2 60°C
1 30°C White
Max. range of hydraulic oil temperature gauge
Oil temperature level Hydraulic oil temperature Color of monitor light (a)
6 105°C
Red
5 102°C
4 100°C
3 85°C Blue
2 40°C
1 20°C White
HB215LC-2 30-165
Pm clinic
Check sheet (HB205-2160-033-A-01-A)

HB215LC-2
a Perform the checks after warming up the engine sufficiently.
Date of
Model Serial No. Service meter User name Inspector
inspection
HB215LC-2 / /
Engine
Engine SAA4D107E-2 No
Go-
Standard Mea- goo-
od
Item Testing conditions Unit value for new Repair limit sured d
machine item
• Coolant temperature: 60 to 100°
C
• Hydraulic oil temperature: 45 to
Engine high 55°C
• Fuel control dial: MAX 1,180 to 1,180 to
idle speed
• Working mode: P mode 1,320 1,320
(*1)
• Auto-deceleration switch: OFF
• Work equipment control lever:
All NEUTRAL
C
Engine low 55°C
idle speed • Fuel control dial: MIN
650 to 750 650 to 750
(*1) • Working mode: P mode
• Auto-deceleration switch: ON
All NEUTRAL rpm
C
Engine • Hydraulic oil temperature: 45 to
speed at 2- 55°C 1,600 to 1,600 to
pump relief • Fuel control dial: MAX 1,800 1,800
(*1) • Working mode: P mode
• Work equipment control: Arm IN
relief
Engine C
speed at 2- • Hydraulic oil temperature: 45 to
pump relief 55°C
+ One- • Fuel control dial: MAX 1,820 to 1,820 to
touch • Working mode: P mode 2,020 2,020
power • Swing lock switch: OFF
maximizing • Work equipment control: Arm
is ON (*1) digging relief + One-touch
power maximizing ON
30-166 HB215LC-2
Pm clinic

Go-
Standard Mea- goo-
od
machine item
Engine C
speed • Hydraulic oil temperature: 45 to
when auto- 55°C
decelera- • Fuel control dial: MAX
650 to 750 650 to 750
tion is • Working mode: P mode
operated • Swing lock switch: OFF
(*1) • Auto-deceleration switch: ON
All NEUTRAL
C
Engine oil 55°C MPa Min. 0.29 Min. 0.25
pressure • Fuel control dial: MAX {kg/cm2} {3.0} {2.5}
• Work equipment control: Aem In
relief
*1: Items that can be inspected in special functions of machine monitor.
HB215LC-2 30-167
Pm clinic

Go-
Standard Mea- goo-
od
machine item
C
Engine oil 55°C MPa Min. 0.10 Min. 0.07
pressure • Engine: Low idle {kg/cm2} {1.0} {0.7}
All NEUTRAL
C
55°C kPa
Blowby Max. 0.98 Max. 1.96
• Engine: High idle {mmH2-
pressure {100} {200}
• Working mode: P mode O}
• Work equipment control: Arm
digging relief + One-touch
power maximizing ON
Work equipment speed

Go-
Standard Mea- go-
od
Item Testing conditions Unit value for new Repair limit sured od
machine item
55°C
• Work equipment mode: P mode
• Measurement range: Between
Boom ground touch point of bucket
and RAISE stroke end 3.1 to 3.9 Max. 4.8
RAISE
• Measurement posture: Boom is
extended fully. See "Work
equipment 2" in "Machine
posture and procedure for
measuring performance".
• Hydraulic oil temperature: 45 to sec.
55°C
arm OUT stroke end and arm IN
Arm IN stroke end 3.3 to 4.1 Max. 4.5
• Measurement posture: Boom
top surface is horizontal. (See
"Work equipment 3" in
"Machine posture and
procedure for measuring
performance".)
30-168 HB215LC-2
Pm clinic

Go-
Standard Mea- go-
od
Item Testing conditions Unit value for new Repair limit sured od
machine item
55°C
arm IN stroke end and arm OUT
Arm OUT stroke end 2.4 to 3.0 Max. 3.5
• Measurement posture: Boom
top surface is horizontal. (See
"Work equipment 3" in
performance".)
55°C
bucket DUMP stroke end and
Bucket bucket CURL stroke end
• Measurement posture: Boom 2.3 to 2.9 Max. 3.3
CURL
top surface is horizontal and
arm cylinder is fully retracted.
See "Work equipment 4" in
performance".
HB215LC-2 30-169
Pm clinic
Swing speed
Go-
Standard Mea- goo-
od
machine item
Swing RIGHT
• Hydraulic oil temperature:
45 to 55°C
• Engine: High idle 21.7 to 26.7 Max. 30
• Measurement range: Time
Swing required to complete 5 sec.
swings after 1 swing
Swing LEFT
• Measurement posture: See
21.7 to 26.7 Max. 30
performance", "Swing 1".
Travel speed
Go-
Standard Mea- goo-
od
machine item
Reverse Forward Reverse Forward Reverse Forward
48.6 to 59.8 48.6 to 63.8
Lo
• Hydraulic oil
temperature: 45 to 55°C 48.6 to 59.8 48.6 to 63.8
• Working mode: B mode
• Measurement range:
Time required to 36.7 to 44.9 36.7 to 48.9
complete 5 idle turns
Travel Mi sec.
with track off ground
after 1 idle turn
• Measurement posture: 36.7 to 44.9 36.7 to 48.9
See "Travel 1" in
performance". 28.9 to 32.1 28.9 to 34.1
Hi
28.9 to 32.1 28.9 to 34.1
30-170 HB215LC-2
Pm clinic
Hydraulic drift of work equipment

Go-
Standard Mea- goo-
od
machine item
55°C
• Engine: Stopped
• Load: Heaped up of soil (2:1
slope) or rated load in bucket
(0.8m3:1,440kg)
Hydraulic
drift
NEUTRAL
measured mm/15
• Measurement posture: Boom Max. 600 Max. 900
at bucket tip min.
top surface is horizontal, arm
(entire work
cylinder is fully retracted, and
equipment)
bucket cylinder is fully extended
on a level and flat ground
See "Work equipment 1" in
performance".
HB215LC-2 30-171
Pm clinic
Hydraulic circuit
Go-
Standard Mea- goo-
od
machine item
55°C
Control • Engine: High idle
• Working mode: P mode MPa 2.93 to 3.43 2.75 to 3.45
circuit oil
• Swing lock switch: OFF {kg/cm2} {30 to 35} {28 to 35}
pressure
• Auto-deceleration switch: OFF
NEUTRAL
Unload • Hydraulic oil temperature: 45 to
pressure 55°C
(pump • Engine: High idle MPa 2.5 to 4.5 2.5 to 4.5
outlet • Working mode: P mode {kg/cm2} {26 to 46} {26 to 46}
pressure) • Work equipment control lever:
(*1) NEUTRAL
55°C
• Engine: High idle 33.6 to 36.3 33.1 to 37.2
• Swing lock switch: OFF {343 to 370} {338 to 380}
Arm IN relief
Work
(When one-touch power
equipment
maximizing is ON) MPa
(arm) relief
• Hydraulic oil temperature: 45 to {kg/cm2}
pressure
(*1) 55°C
• Engine: High idle 36.1 to 38.8 36.1 to 39.7
• Working mode: P mode {368 to 395} {368 to 405}
Arm IN relief
• One-touch power maximizing
switch: ON
• R.H.
Travel
locked
• Right 36.7 to 39.7 36.7 to 40.2
• Hydraulic oil forward {375 to 405} {365 to 415}
temperature: 45 to or
Travel relief 55°C reverse
relief MPa
pressure • Engine: High idle
• L.H. {kg/cm2}
(*1) • Working mode: P
mode Travel
• Travel speed: Hi locked
• Left 36.7 to 39.7 36.7 to 40.2
forward {375 to 405} {375 to 410}
or
reverse
relief
30-172 HB215LC-2
Pm clinic

Go-
Standard Mea- goo-
od
machine item
55°C
LS • Working mode: B mode
differential • Travel speed: Hi MPa 1.7 to 1.85 1.7 to 1.85
pressure • Travel control: One-side idle {kg/cm2} {17 to 18.5} {17 to 18.5}
(*1) turn while the lever is at half
stroke
• LS differential pressure = Pump
pressure - LS pressure
Front pump 36.1 to 38.8 36.1 to 38.8
discharged
• Hydraulic oil pressure {368 to 395} {368 to 395}
temperature: 45 to Above value Above value
55°C Servo
PC valve x x
• Engine: High idle piston inlet
outlet approximate- approximate-
pressure • Working mode: P pressure MPa ly 0.6 ly 0.6
(servo mode {kg/cm 2 }
Rear pump 36.1 to 38.8 36.1 to 38.8
piston inlet • Swing lock switch: discharged
pressure) ON {368 to 395} {368 to 395}
pressure
• Work equipment
control: Arm IN Above value Above value
Servo
relief x x
piston inlet
approximate- approximate-
pressure
ly 0.6 ly 0.6
temperature: 45 to {Approx. 30} {Approx. 30}
PC mode 55°C Low idle (reference (reference
selector • Working mode: P value) value)
pressure mode MPa
(PC-EPC • Swing lock switch: {kg/cm2}
valve output ON
pressure) High idle 0 {0} 0 {0}
• Work equipment
control lever:
NEUTRAL
• Hydraulic oil Travel Approx. 2.9 Approx. 2.9
temperature: 45 to speed: Lo (Approx. 30) (Approx. 30)
55°C
LS set
selector
• Working mode: P
pressure MPa
mode
(LS-EPC Travel {kg/cm2}
• Swing lock switch: 0 {0} 0 {0}
valve output speed: Hi
OFF
pressure)
• Travel control
lever: Lifting
operation
HB215LC-2 30-173
Pm clinic
30-174 HB215LC-2
SHOP MANUAL
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
40 Troubleshooting
6 40 Troubleshooting
HB215LC-2 40-1
40 Troubleshooting
Table of contents

40 Troubleshooting............................................................................................................................ 40-1
Related information on troubleshooting....................................................................................... 40-10
Troubleshooting points ....................................................................................................... 40-10
Sequence of events in troubleshooting................................................................................. 40-12
Checks before troubleshooting ............................................................................................ 40-14
Inspection procedure before troubleshooting ........................................................................ 40-16
Preparation for troubleshooting of electrical system............................................................... 40-37
Classification and procedures for troubleshooting ................................................................. 40-43
Symptom and troubleshooting numbers ............................................................................... 40-46
Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................... 40-51
Connector list and layout .................................................................................................... 40-53
Connector contact identification........................................................................................... 40-64
T-branch box and T-branch adapter table ........................................................................... 40-102
Fuse location table ........................................................................................................... 40-107
Failure codes table........................................................................................................... 40-109
Troubleshooting by failure code (Display of code) ...................................................................... 40-120
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-120
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-121
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-122
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-123
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-124
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-125
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-126
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-127
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-128
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-129
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-130
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-131
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-132
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3............................................ 40-133
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 ............................................ 40-134
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2............................................ 40-135
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-136
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-138
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-140
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-141
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-142
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-143
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-145
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-146
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-147
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-149
Failure code [CA131] Throttle Sensor High Error................................................................. 40-151
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-153
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-155
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-157
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-159
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-161
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-165
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-167
Failure code [CA234] Eng Overspeed ................................................................................ 40-170
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-171
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-172
40-2 HB215LC-2
40 Troubleshooting
Table of contents
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-173

Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-175
Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-177
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-186
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-187
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-190
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-192
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-195
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-197
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-199
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-200
Failure code [CA442] Battery Voltage High Error................................................................. 40-202
Failure code [CA449] Rail Press Very High Error................................................................. 40-203
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-204
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-206
Failure code [CA466] KVGT Motor Driver Position Error ...................................................... 40-208
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-210
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-211
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-213
Failure code [CA553] Rail Press High Error ........................................................................ 40-215
Failure code [CA559] Rail Press Low Error......................................................................... 40-218
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-220
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-222
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-224
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-226
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-227
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-228
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-229
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-232
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-233
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-234
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-235
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-237
Failure code [CA1896] EGR Valve Stuck Error.................................................................... 40-239
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-240
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error............................................. 40-241
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-242
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-244
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-246
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-247
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-249
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-250
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-252
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-254
Failure code [CA2373] Exhaust Manifold Press Sens High Error .......................................... 40-255
Failure code [CA2374] Exhaust Manifold Press Sens Low Error ........................................... 40-257
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-259
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-261
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-263
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-264
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-265
HB215LC-2 40-3
40 Troubleshooting
Table of contents
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-267
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-269
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-270
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-271
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-273
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error........................................ 40-275
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-277
Failure code [CA3918] KVGT Stuck Error........................................................................... 40-278
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ............................................ 40-279
Failure code [CA3921] KVGT Servo Error 2........................................................................ 40-280
Failure code [CA3922] KVGT Motor Driver Open Error ........................................................ 40-281
Failure code [CA3923] KVGT Motor Driver Short Error ........................................................ 40-283
Failure code [D110KB] Battery Relay Drive Short Circuit...................................................... 40-285
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-287
Failure code [D811MC] KOMTRAX Error............................................................................ 40-290
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-291
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-292
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-294
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-295
Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-296
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-297
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-303
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ....................................... 40-305
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ....................................... 40-307
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-308
Failure code [DA2RKR] CAN1 Discon (Pump Con) ............................................................. 40-311
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-312
Failure code [DAF0MC] Monitor Error ................................................................................ 40-313
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-314
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-316
Failure code [DAFGMC] GPS Module Error........................................................................ 40-317
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-318
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-320
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-321
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-322
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-323
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-327
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-332
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-338
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-340
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................. 40-341
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-344
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality........................................ 40-347
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ................................... 40-349
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality................................... 40-351
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality .................................. 40-353
Failure code [DHSAKZ] Swing RH PPC Press Sensor Abnormality ...................................... 40-355
Failure code [DHSBKZ] Swing LH PPC Press Sensor Abnormality....................................... 40-357
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .................................... 40-359
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-361
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ............................... 40-363
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .............................. 40-365
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ............................... 40-367
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ............................... 40-369
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt. ..................................... 40-371
Failure code [DHVAL8] HYB Swing-R PPC Pr. Sen. Signal Mismatch ................................... 40-374
Failure code [DHVAMA] HYB Swing-R PPC Sensor Malfunction .......................................... 40-375
40-4 HB215LC-2
40 Troubleshooting
Table of contents
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen. Opn/Short Cir........................................ 40-377
Failure code [DHVBL8] HYB Swing-L PPC Pr. Sen. Signal Mismatch ................................... 40-379
Failure code [DHVBMA] HYB Swing-L PPC Sensor Malfunction .......................................... 40-380
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality....................................... 40-382
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality ...................................... 40-385
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-392
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-394
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-396
Failure code [DW45KA] Swing Brake Sol Open Circuit ........................................................ 40-398
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-401
Failure code [DW45KK] Swing Brake Sol. Valve Low Sup. Voltage ....................................... 40-404
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. ............................................. 40-406
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-408
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-410
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-412
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-414
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..................................................... 40-416
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit...................................................... 40-418
Failure code [DWK2KA] Variable Back Press Sol Open Circuit............................................. 40-420
Failure code [DWK2KB] Variable Back Press Sol Short Circuit ............................................. 40-422
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-424
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-426
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-428
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-430
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-432
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-434
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................ 40-436
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................. 40-438
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ................................................ 40-440
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ................................................ 40-442
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ................................................... 40-444
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ................................................... 40-446
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-448
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-450
Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-452
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...................................................... 40-454
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ....................................................... 40-456
Failure code [GA****] Precautions related to hybrid components and troubleshooting of high
voltage parts ...................................................................................................... 40-458
Failure code [GA——] Table and check sheet of monitoring items on hybrid
components ....................................................................................................... 40-487
Failure code [GA00NS] HYB Equipment Overheat .............................................................. 40-492
Failure code [GA01KA] Power Cable Interlock Open Circuit................................................. 40-493
Failure code [GA01KB] Power Cable Interlock Short Circuit ................................................. 40-495
Failure code [GA02KZ] DC Line Open & Short Circuit ......................................................... 40-497
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster ........................................... 40-498
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster............................................ 40-499
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster ............................................. 40-500
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster .......................................... 40-501
Failure code [GA08KG] Abnorm. DC HW Volt. After Booster ................................................ 40-502
Failure code [GA09KG] Abnorm. DC SW Volt. After Booster ................................................ 40-503
Failure code [GA09KP] Low DC SW Output Volt. After Booster ............................................ 40-504
Failure code [GA0AKZ] DC Vlt. Sen. Op./Shrt Cir. Aft. Booster ............................................. 40-505
Failure code [GA0BKZ] AC Line Open & Short Circuit ......................................................... 40-506
Failure code [GA10MA] HYB Controller Malfunction ............................................................ 40-507
Failure code [GA10MC] HYB Controller Error ..................................................................... 40-508
Failure code [GA12NK] High-Voltage Line Start-up Failure .................................................. 40-509
HB215LC-2 40-5
40 Troubleshooting
Table of contents
Failure code [GA13KP] Low HYB Control. Sen. Power Sup. ................................................ 40-510
Failure code [GA13KY] HYB Control. Sen. Power Short Cir ................................................. 40-511
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir........................................ 40-512
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure ............................................ 40-513
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded.................................................. 40-514
Failure code [GA18MC] Gen. Mo.Dr. Excite. Pow. Sup. Failure ............................................ 40-515
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure..................................... 40-516
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. ...................................... 40-517
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction ......................................... 40-518
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure .......................................... 40-519
Failure code [GA1FMA] Abnormal Swing Motor Driver ........................................................ 40-520
Failure code [GA1GKR] Swg Mot. Driver Sub-CPU Comm. Failure....................................... 40-521
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal ...................................... 40-522
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded.................................... 40-523
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir ..................................... 40-524
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir ...................................... 40-525
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir..................................... 40-526
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens. Opn/Shrt Cir ........................................ 40-527
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen. Opn/Shrt Cir. .......................................... 40-528
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat ................................................ 40-529
Failure code [GA1SFS] Contactor Locked .......................................................................... 40-530
Failure code [GA1SMC] Contactor Failure.......................................................................... 40-531
Failure code [GA1TKP] Capacitor Low Output Voltage ........................................................ 40-532
Failure code [GA1TNS] Capacitor Overheat ....................................................................... 40-533
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/short Cir. ........................................... 40-535
Failure code [GA1VFS] Capacitor Contactor Locked ........................................................... 40-537
Failure code [GA1VMC] Capacitor Contactor Failure........................................................... 40-539
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ.......................................... 40-540
Failure code [GA1YNS] Booster Inductor Overheat ............................................................. 40-541
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. ...................................... 40-542
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat .............................................. 40-543
Failure code [GA22NS] Booster IGBT Junction Overheat .................................................... 40-544
Failure code [GA27KZ] DC Cur. Sens. Bef. Booster Opn/Short Cir ....................................... 40-551
Failure code [GA2QKR] CAN2 Discon (Hyb Con) ............................................................... 40-552
Failure code [GA2RKR] CAN1 Discon (Hyb Con)................................................................ 40-554
Failure code [GA60KZ] Generator Motor Open/Short Circuit ................................................ 40-555
Failure code [GA60MC] Generator Motor Failure ................................................................ 40-556
Failure code [GA60N1] Generator Motor Overrun ............................................................... 40-558
Failure code [GA61KZ] Gen. Motor Temp. Sens. Opn/Short Cir. ........................................... 40-559
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat ........................................ 40-561
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir ....................................... 40-562
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir ........................................ 40-563
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction........................................ 40-564
Failure code [GA62MC] Gen. Mot. Ph-A Cur. Sen. Defect Op............................................... 40-565
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir ....................................... 40-566
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir ........................................ 40-567
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction........................................ 40-568
Failure code [GA63MC] Gen. Mot. Ph-B Cur. Sen. Defect Op............................................... 40-569
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir....................................... 40-570
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir ........................................ 40-571
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction........................................ 40-572
Failure code [GA64MC] Gen. Mot. Ph-C Cur. Sen. Defect Op. ............................................. 40-573
Failure code [GA70KB] HYB Swing Motor Short Circuit ....................................................... 40-574
40-6 HB215LC-2
40 Troubleshooting
Table of contents
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion ........................................ 40-575
Failure code [GA70NS] HYB Swing Motor Overheat ........................................................... 40-576
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. ..................................... 40-577
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction .......................................... 40-579
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op. ........................................... 40-581
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ.......................................... 40-582
Failure code [GAA0KB] HYB Con. Battery Relay Drive Short Cir. ......................................... 40-583
Failure code [GAA2KB] Swing Brake Sol. Supply Line Short Cir. .......................................... 40-585
Failure code [GAA6KP] Low HYB Control. Sen. Power 2 Sup. ............................................. 40-587
Failure code [GAA6KY] HYB Control. Sen. Power 2 Short Cir .............................................. 40-588
Failure code [GACLKA] Operating Lamp Open Circuit (HYB Con) ........................................ 40-589
Failure code [GACLKB] Operating Lamp Short Circuit (HYB Con) ........................................ 40-591
Troubleshooting of electrical system (E-mode) .......................................................................... 40-592
E-1 Engine does not start (Engine does not crank) .............................................................. 40-592
E-2 Manual preheating system does not work..................................................................... 40-598
E-3 Automatic preheating system does not work................................................................. 40-601
E-4 While preheating is working, preheating monitor does not light up .................................. 40-603
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-605
E-6 When starting switch is turned to ON position (before starting engine), engine oil level
monitor lights up in yellow.................................................................................... 40-609
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant
level monitor lights up in yellow ............................................................................ 40-610
E-8 Engine coolant temperature monitor lights up in white while engine is running ................. 40-611
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-612
E-10 Charge level monitor lights up in red while engine is running ........................................ 40-613
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-614
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-615
E-13 Water separator monitor lights up in red while engine is running ................................... 40-616
E-14 Engine coolant temperature monitor lights up in red while engine is running .................. 40-617
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-618
E-16 Hybrid temperature monitor lights up in red while engine is running .............................. 40-619
E-17 Engine oil pressure monitor lights up in red while engine is running .............................. 40-621
E-18 Fuel gauge display does not move from minimum or maximum .................................... 40-622
E-19 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-623
E-20 Engine coolant temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-624
E-21 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full
nor empty).......................................................................................................... 40-625
E-22 Hydraulic oil temperature gauge does not move from minimum or maximum ................. 40-626
E-23 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor
empty) ............................................................................................................... 40-628
E-24 Hybrid temperature gauge does not move from minimum or maximum.......................... 40-629
E-25 Hybrid temperature gauge indicates incorrect temperature (indicates neither full nor
empty) ............................................................................................................... 40-630
E-26 Contents of display on machine monitor is different from actual machine
condition ............................................................................................................ 40-632
E-27 Some areas of machine monitor screen are not displayed............................................ 40-633
E-28 Function switch does not work................................................................................... 40-634
E-29 Automatic warm-up system does not operate (in cold season)...................................... 40-635
E-30 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration
switch is operated ............................................................................................... 40-636
E-31 Auto-deceleration function does not operate or is not canceled while lever is
operated ............................................................................................................ 40-637
E-32 Working mode selection screen is not displayed while working mode selector switch is
operated ............................................................................................................ 40-639
E-33 Setting of engine and hydraulic pump is not changed while working mode is
changed............................................................................................................. 40-640
E-34 Travel speed monitor does not change when travel speed switch is operated ................ 40-641
E-35 Travel speed does not change while travel speed selection is changed......................... 40-642
HB215LC-2 40-7
40 Troubleshooting
Table of contents
E-36 Alarm buzzer does not stop sounding......................................................................... 40-643

E-37 Service meter is not displayed, while starting switch is in OFF position.......................... 40-644
E-38 Service mode cannot be selected .............................................................................. 40-645
E-39 None of work equipment, swing or travel works........................................................... 40-646
E-40 Any of work equipment, swing and travel cannot be locked .......................................... 40-648
E-41 Upper structure does not swing while swing parking brake cancel switch is set to
CANCEL position................................................................................................ 40-650
E-42 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
position .............................................................................................................. 40-653
E-43 One-touch power maximizing function does not operate, or indicator is not displayed on
monitor .............................................................................................................. 40-655
E-44 One-touch power maximizing function cannot be canceled .......................................... 40-657
E-45 Alarm does not sound during travel ............................................................................ 40-658
E-46 Alarm does not stop sounding while machine is stopped.............................................. 40-659
E-47 Horn does not sound ................................................................................................ 40-660
E-48 Horn does not stop sounding..................................................................................... 40-662
E-49 Wiper monitor does not light up, or does not go out, while wiper switch is
operated ............................................................................................................ 40-663
E-50 Wiper does not operate while wiper switch is operated ................................................ 40-664
E-51 Window washer does not operate while window washer switch is operated ................... 40-666
E-52 Boom LOWER is not displayed correctly with monitoring function ................................. 40-667
E-53 Arm OUT is not displayed correctly with monitoring function......................................... 40-668
E-54 Arm IN is not displayed correctly with monitoring function ............................................ 40-669
E-55 Boom RAISE is not displayed correctly with monitoring function ................................... 40-670
E-56 Bucket CURL is not displayed correctly with monitoring function................................... 40-671
E-57 Bucket DUMP is not displayed correctly with monitoring function.................................. 40-672
E-58 Swing is not displayed correctly with monitoring function.............................................. 40-673
E-59 Travel is not displayed correctly with monitoring function ............................................. 40-674
E-60 Service is not displayed correctly with monitoring function ........................................... 40-675
E-61 Attachment hydraulic circuit cannot be changed.......................................................... 40-678
E-62 KOMTRAX system does not operate normally ............................................................ 40-679
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-680
Information described in troubleshooting table (H-mode) ..................................................... 40-680
System chart of hydraulic and mechanical systems............................................................. 40-681
Failure mode and cause table ........................................................................................... 40-683
H-1 All of work equipments and travel operations lack speed or power.................................. 40-689
H-2 Engine speed drops significantly or engine stalls .......................................................... 40-692
H-3 None of work equipment or travel works....................................................................... 40-695
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-696
H-5 Fine control performance or response is poor ............................................................... 40-697
H-6 Boom speed or power is low ....................................................................................... 40-699
H-7 Arm speed or power is low .......................................................................................... 40-703
H-8 Bucket speed or power is low...................................................................................... 40-708
H-9 Work equipment does not move in single operation....................................................... 40-711
H-10 Hydraulic drift of boom is large .................................................................................. 40-712
H-11 Hydraulic drift of arm is large ..................................................................................... 40-713
H-12 Hydraulic drift of bucket is large ................................................................................. 40-714
H-13 Time lag of work equipment is large ........................................................................... 40-715
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-717
H-15 One-touch power maximizing function does not operate .............................................. 40-718
H-16 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-719
H-17 Machine does not travel straight ................................................................................ 40-720
H-18 Travel speed is slow ................................................................................................. 40-723
H-19 Machine is hard to steer or travel power is low ............................................................ 40-726
H-20 Travel speed does not change, or travel speed is too slow or fast ................................. 40-730
H-21 One of tracks does not run ........................................................................................ 40-731
H-22 Upper structure does not swing to the right or left ........................................................ 40-733
40-8 HB215LC-2
40 Troubleshooting
Table of contents
H-23 Upper structure swings only to the right or left............................................................. 40-734

H-24 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-735
H-25 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-736
H-26 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-737
H-27 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-738
H-28 Shock is large when upper structure stops swinging.................................................... 40-739
H-29 Large unusual noise is heard when upper structure stops swinging .............................. 40-740
H-30 Swing drift on a slope is large while swing parking brake is applied............................... 40-741
H-31 Swing drift on a slope is large while swing parking brake is released............................. 40-742
H-32 Attachment hydraulic circuit cannot be changed while attachment is installed................ 40-743
H-33 Oil flow in attachment circuit cannot be controlled ....................................................... 40-744
Troubleshooting of engine (S-mode)......................................................................................... 40-745
Information mentioned in troubleshooting table (S mode)..................................................... 40-745
S-1 Engine does not crank when starting switch is turned to START position......................... 40-746
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-747
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-748
S-4 Engine startability is poor ............................................................................................ 40-749
S-5 Engine does not pick up smoothly ............................................................................... 40-751
S-6 Engine stops during operation ..................................................................................... 40-753
S-7 Engine runs rough or is unstable ................................................................................. 40-755
S-8 Engine lacks power .................................................................................................... 40-756
S-9 Exhaust smoke is black .............................................................................................. 40-758
S-10 Engine oil consumption is excessive .......................................................................... 40-760
S-11 Oil becomes contaminated quickly ............................................................................. 40-761
S-12 Fuel consumption is excessive .................................................................................. 40-762
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-763
S-14 Oil pressure drops .................................................................................................... 40-764
S-15 Fuel mixes into engine oil.......................................................................................... 40-765
S-16 Water mixes into engine oil (milky) ............................................................................. 40-766
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-767
S-18 Unusual noise is heard ............................................................................................. 40-768
S-19 Vibration is excessive ............................................................................................... 40-769
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-770
Troubleshooting for hybrid systems (Y mode)............................................................................ 40-771
Precautions related to hybrid equipment ............................................................................ 40-771
Y-1 Hybrid monitor does not go out .................................................................................... 40-772
Y-2 Machine does not swing.............................................................................................. 40-773
Y-3 Swing acceleration or swing speed is low ..................................................................... 40-776
Y-4 Upper structure overruns excessively when it stops swinging ......................................... 40-777
Y-5 Shock is large when upper structure stops swinging ...................................................... 40-778
Y-6 Large unusual noise is heard when upper structure stops swinging ................................ 40-779
Y-7 Swing drift on a slope is large ...................................................................................... 40-780
Y-8 Electric swing motor temperature increases abnormally................................................. 40-781
Y-9 Motor-generator temperature increases abnormally....................................................... 40-782
Y-10 Inverter temperature increases abnormally ................................................................. 40-783
Y-11 Capacitor temperature increases abnormally .............................................................. 40-784
HB215LC-2 40-9
40 Troubleshooting
Related information on troubleshooting
Related information on troubleshooting (ALL-5100-001-A-00-A)
Troubleshooting points (ALL-5130-42A-A-00-A)
(Rev. 2012/11)
k Place the machine on a level ground, and make sure that the frame lock bar, chocks, and parking
brake are applied.
k When performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k Ifthe 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 Before disconnecting wiring, remove the key and turn the battery disconnect switch to OFF
position.
k When removing the plug or cap from a component which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
k Drain l of coolant beforehand, because you may get scalded by hot water
approximately 10l
spurting out from mounting location of coolant temperature sensor when removing radiator cap
during checking and replacing coolant temperature sensor.
k When performing checking and replacement of engine oil pressure sensor (switch), open oil filler
port, and check that engine oil temperature cools down enough not to get scalded.
k Loosen the oil filler cap of the hydraulic tank to release the pressure in the hydraulic tank. For
details, see Testing and adjusting "Releasing remaining pressure in hydraulic circuit" when
checking and replacing oil temperature sensor and oil pressure sensor. Check the code with
monitoring function and display the hydraulic oil temperature, then check that the temperature is
40°C or lower and cool enough not to burn.
Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the
cause of the given undesirable symptom.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• 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 performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting 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 performed before the failure? When were these repairs performed?
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.
40-10 HB215LC-2
40 Troubleshooting
3) Make checks of other items.

4) Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Checking failure
Check the extent of the failure by yourself, and judge whether it is a real failure or 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 inspection in Items 2 to 4 to narrow down the probable causes of
the 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 information.
6. Measures to remove root cause of failure
Fixing a trouble in hand does not necessarily prevents its recurrence unless the primary cause is
eliminated. To that end, you must locate and eliminate the primary cause behind the given failure.
HB215LC-2 40-11
40 Troubleshooting
Sequence of events in troubleshooting (ALL-5140-42A-A-00-A)
(Rev. 2011. 7)
40-12 HB215LC-2
40 Troubleshooting
HB215LC-2 40-13
40 Troubleshooting
Checks before troubleshooting (HB205-5150-208-A-00-A)
No. Item Criteria Remedy

1 Check of unusual noise and smell - Repair
2 Check of engine for dirt - Remove
3 Check of engine for water leakage - Repair
4 Check of engine for oil leakage - Repair
5 Check of fuel line for leakage - Repair
a: Engine, lubricating oil, and coolant
6 Check of radiator for clogging - Remove

7 Check of fuel level and type - Refilling with fuel
8 Check of foreign material in fuel - Clean and drain
9 Check of fuel prefilter - Replace
10 Check of fuel main filter - Replace
Between H
11 Check of engine oil level (in oil pan) and type Refilling with oil
and L
Between H
12 Check of motor-generator case oil level Refilling with oil
and L
Between H Refilling with
13 Check of coolant level (in sub tank)
and L coolant
Machine
monitor
14 Check of air cleaner for clogging does not Clean or replace
indicate
clogging
15 Check of KDOC for dirt - Remove
16 Check for gas leakage around the KDOC - Repair
1 Check of unusual noise and smell - Repair
Check for oil leakage - Repair
b: Hydraulic and mechanical equipment
2
Between H
3 Check of hydraulic oil level Refilling 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 Refilling with oil
and L
Between H
7 Check of electric swing motor case oil level Refilling with oil
and L
8 Check of final drive case oil level - Refilling with oil
Bleeding air
9 Perform air bleeding. -
40-14 HB215LC-2
40 Troubleshooting

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 to 30 V Charge or replace
Between H
5 Check of battery electrolyte level Add or replace
and L
Check of wiring harness for discoloration, burnt areas and cover
6 peeling - Repair or replace
c: Electrical equipment
Check for coming off of wiring harness clamp and sagging of

7 wiring harness - Repair
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 of connector for water and foreign material -
replace
12 Check of wiring harness for open or short circuit - Repair or replace
13 Check of fuse for blowing out and corrosion - Replace
27.5 to 29.5
Check of alternator voltage (when engine speed is medium or V after few
14 higher) Replace
minutes
operation
Check of battery relay operation sound (when starting switch is
15 turned to ON or OFF position) - Replace
16 Check and cleaning of rearview camera - Clean or repair
Monitor
d Hybrid components
1 Temperature check of hybrid components lights up in Cool engine

red
Between H Refilling with
2 Check of coolant level
and L coolant
2 LED
3 Check of capacitor lamps light Charge
up
1 Check of undercarriage - Repair

e Exterior parts
2 Check of handrails and steps - Repair
3 Check of mirrors - Clean or repair
1 Check of gauges and monitors - Clean or replace

f Interior parts
2 Check of seat belt - Replace
HB215LC-2 40-15
40 Troubleshooting
Inspection procedure before troubleshooting (ALL-5150-001-A-00-A)
Walk-around check (HB205-5150-289-A-00-A)
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, wiring harnesses for play, and accumulation of dust in places that reach
high temperatures.
k Accumulated combustibles around hot engine parts such as the engine, KDOC, and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. If any abnormality is found, be sure to repair
it
a a1, a2, ..., b1, b2, ..., etc. correspond to the symbol in the table of the previous page.
a1. and b1. Check for unusual sounds and Check the work equipment, cylinders, linkage, and
smells hoses for breakage, wear, and clearance. If any
Check for unusual sounds or smells. abnormality is found, repair it.
If the machine is operated under the unusual b3. Check of hydraulic equipment, hydraulic
sounds or smells, the cause of it may damage the tank, hoses, and joints for oil leakage
machine, so stop the operation immediately once Check for oil leaks. If any abnormality is found,
you recognize it. repair it.
a2. Check around engine and dirt removal c1. Check around batteries and dirt removal
Check if there is any accumulated dirt around the Check for any accumulated dirt and combustibles
engine, and combustibles (dead leaves, twigs, etc.) (dead leaves, twigs, etc.) around the batteries. If any,
on engine itself, KDOC, turbocharger, or the other remove them.
surroundings of engine parts that reach high c16. Check and clean rearview camera
temperature. If any, remove them.
Check the rearview camera for abnormality. If any
a3. Check for water leakage around engine abnormality is found, repair it
a4. Check for oil leakage around engine e1. Check of undercarriage for abnormality, wear,
Check for oil leakage from engine and coolant looseness of bolts, and oil leakage
leakage from cooling system. If any abnormality is If any abnormality is found, repair it.
found, repair it.
e2. Check of handrails and steps for abnormality
a5. Check for leakage from fuel line and looseness of bolts
Check for fuel leakage, check hoses and pipes for If any abnormality is found, repair it and tighten any
damage. If any abnormality is found, repair it. loose bolts.
a6. Check for radiator and dirt removal e3. Check and clean rearview mirrors
Check if there is any accumulated dirt and any Check rearview mirror for abnormality. If any, repair
combustibles (dead leaves, twigs, etc.) around the it.
radiator. If any, remove them.
Clean the mirror surface and adjust the mirror angle
For removal of dirt from the radiator, see the so that the rear of the machine can be seen from
Operation and Maintenance Manual, "Cleaning and the operator's seat.
testing of radiator fins, oil cooler fins, aftercooler fins,
f1. Check of gauges and monitors for
fuel cooler fins and air conditioner condenser fins
abnormality
(machine with the air conditioner)".
Check gauges and monitors in the operator's cab
a15. Check around the KDOC and dirt removal
for abnormality. If any abnormality is found, replace
Check if there is any accumulated dirt and any it with a new one.
combustibles (dead leaves, twigs, etc.) around the
Clean up the surfaces.
KDOC. If any, remove them.
f2. Check of seat belt and mounting hardware
a16. Check for gas leakage around the KDOC
Check the hook, the lock, and hook mounting part
Check the pipe between the KDOC and
for damage. If any abnormality is found, replace it
turbocharger, and also the KDOC connection for
with a new one.
leakage of exhaust gas (or sticking of soot, etc.). If
any abnormality is found, repair it.
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
40-16 HB215LC-2
40 Troubleshooting
Testing in accordance with testing procedure (HB205-5150-280-A-00-A)

a. Engine, lubricating oil, and coolant
a7. Check of fuel level and type
k Fuel is highly flammable and dangerous.
Never bring open flames near fuel.
k When adding fuel, never spill it or let it

overflow.
k Wipe off any spilled fuel. If fuel spills over

soil or sand, remove all the fuel and soil or
sand together.
1. Turn the starting switch to ON position and

check the fuel level with fuel level gauge (1) on
the monitor panel. • If breather hole (3) in the oil filler cap is
After checking, turn the switch back to OFF clogged, the pressure in the tank decreases
position. and fuel may not be supplied. To prevent this,
clean the breather hole.
2. If the fuel level is low, open fuel filler cap (F) of

the fuel tank and add fuel through the fuel filler a8. Check of foreign material in fuel
port to the necessary level, referring to the 1. Open the side cover on the rear right side of the
position of float gauge (G). machine.
3. After adding fuel, push float gauge (G) straight 2. Prepare a container below drain hose (1) to
down with fuel filler cap (F) and tighten fuel filler receive the fuel.
cap (F) securely while taking care the float 3. Turn drain valve (2) to "OPEN" position (O) to
gauge (G) is not be caught in tab (2) of fuel filler discharge the sediment and water in the bottom
cap (F). together with the fuel.
4. When only the clean fuel flows out, turn drain
valve (2) to "CLOSE" position (S).
5. Close the side cover.
a9. Check of fuel prefilter
HB215LC-2 40-17
40 Troubleshooting
k Immediately after the engine is stopped, its a This machine is equipped with sensor which
parts and oil are still very hot, and may cause detects water accumulated in transparent
burn injury. Accordingly, wait until all parts cup (2).
have cooled down before starting the work.
a Drain the water when water separator
monitor (5) lights up in red on machine
k High pressure is generated inside the engine
monitor, since it shows water accumulated in
fuel piping system when the engine is
transparent cup (2).
running. Stop the engine and wait at least 30
seconds until the inner pressure is released
and then replace the filter.
k Never bring open flames near fuel.
a A special filter with high-efficiency filtering

properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel prefilter cartridge is used, foreign a If the water in transparent cup (2) is frozen,
materials may enter and problem may occur in the water separator monitor may not light up.
the injection system. Do no use substitute parts. After the engine is started, when the frozen
a During testing or maintenance of the fuel system, water is melted because of the increase of
take extreme care not to allow any foreign the temperature around fuel prefilter (1),
material to enter the fuel system. If any dust or water separator monitor (5) may light up
other material sticks to any part, wash the part suddenly. Accordingly, drain the water
thoroughly with clean fuel. frequently in the cold weather even if water
separator monitor (5) is not lit.
• Prepare a container to receive drained oil.
• Prepare a filter wrench. a If water in transparent cup (2) is frozen, drain
The water separator inspection, and drainage of water only after confirming that it has
water and sediments completely melted.
1. Open the side cover. a If you cannot visually identify the presence of
• The water separator is integrated with fuel water due to stains on transparent cup (2),
prefilter (1). clean transparent cup (2) when replacing fuel
2. Through the transparent cup (2), existence of prefilter cartridge (1).
water or sediment can be visually checked. If a When you have removed drain valve (4) for
they are found accumulated, place a container the above cleaning process, coat the O-ring
to receive water under the drain hose (3). with grease and tighten drain valve until it
3. Loosen drain valve (4) to drain the water. touches the bottom.
4. If drain hose (3) starts to discharge fuel, close Replace fuel prefilter cartridge
drain valve (4) immediately. 1. Turn valve (1) at the bottom of the fuel tank to
"CLOSE" position (S).
40-18 HB215LC-2
40 Troubleshooting
a Be sure to add fuel through 8 small holes (A)

on the dirty side without removing center cap
(B).
a After adding fuel, remove cap (B) and install
the fuel filter.
a Add clean fuel and take care that dirt does
not enter the cartridge. In particular, since the
central portion is a clean side, add fuel
without removing cap (B) and take care that
dirt does not enter the clean side.
2. Open the side cover on the rear right side of the

machine.
3. Place a container under the fuel prefilter
cartridge to receive the fuel.
4. Loosen drain valve (2) and drain water and
sediments from transparent cup (3), and also
drain all the fuel from filter cartridge (4).
5. Remove connector (5). Wrap the removed
connector with a plastic bag, etc. to protect it
from fuel, oil and water.
6. Turn transparent cup (3) by using the filter
wrench, and remove it. (This cup is reused.) 11.When installing, tighten it by 3/4 turn after the O-
7. Using the filter wrench, turn filter cartridge (4) to ring comes in contact with the sealing surface of
remove. the filter holder.
8. Install currently removed transparent cup (3) to
the bottom of the new filter cartridge. a If the filter cartridge is over tightened, fuel will
leak because the O-ring is damaged. If the
a At this time, replace O-ring (6) with a new filter cartridge is not tightened sufficiently,
one. fuel will also leak through the clearance of
the O-ring. Therefore, observe the tightening
angle.
a When using a filter wrench for tightening,
take care not to leave flaws or dents on the
filter.
12.Make sure that drain valve (2) is securely
closed.
13.Remove the plastic bag wrapping connector (5),
then connect connector (5).
a If water gets on connector (5), the sensor
may malfunction and the water separator
monitor may light up. When removing
9. When installing the transparent cup, apply a thin connector (5), be extremely careful that
film of oil to the O to ring, set it against the water does not attach to connector.
sealing surface of filter cartridge (4), and then
tighten the transparent cup by turning 1/4 to 1/2 a If water attaches to connector (5), dry it
turn. completely before connecting it.
a If the transparent cup is fastened too much,

the O-ring will be damaged and this leads to
leakage of fuel. If it is too loose, fuel will also
leak from gaps of the O-ring. Therefore, be
sure to observe the fastening 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 install it to the filter holder.
HB215LC-2 40-19
40 Troubleshooting
a10. Check of main filter

k Immediately after the engine is stopped, its 2. Open the side cover on the rear right side of the
parts and oil are still very hot, and may cause machine.
burn injury. Accordingly, wait until all parts 3. Place a container under the filter cartridge to
have cooled down before starting the work. receive the fuel.
4. Using the filter wrench, rotate filter cartridge (2)
k High pressure is generated inside the engine
to remove.
fuel piping system when the engine is
running. Stop the engine and wait at least 30 a After removing the filter cartridge, fuel falls in
seconds until the inner pressure is released drops from the filter head.
and then replace the filter. In order to prevent fuel from flowing out, be
sure not to leave the machine without the
k Never bring open flames near fuel. filter cartridge.
a A special filter with high-efficiency filtering
properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel prefilter cartridge is used, foreign
materials may enter and problem may occur in
the injection system. Do no use substitute parts.
a During testing or maintenance of the fuel system,
take extreme care not to allow any foreign 5. Clean the filter holder. Apply a thin film of oil to
material to enter the fuel system. If any dust or the packing of the new filter cartridge and install
other material sticks to any part, wash the part it to the filter holder.
thoroughly with clean fuel. a Replace inside seal (3) with a new one.
• Prepare a container to receive drained oil.
• Prepare a filter wrench.
1. Turn valve (1) at the bottom of the fuel tank to
"CLOSE" (S) position.
a Do not fill the new filter cartridge with fuel.
40-20 HB215LC-2
40 Troubleshooting
a Remove cap (A) at the center, and then for damage of the O-ring and entry of foreign
install the filter cartridge. material. If any trouble is found, replace the
cartridge with a new one and perform steps 5.
and after.
a11. Check of engine oil level (in oil pan) and
type
k Immediately after the engine is stopped, its
parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until all parts
a When checking the oil level after the engine has

been operated, wait at least 15 minutes after
stopping the engine.
a If the machine is at an angle, make it level
6. When installing the filter cartridge, tighten it by 3/
before checking.
4 turn after the O-ring comes in contact with the
sealing surface of the filter holder. a When the ambient temperature is low, water or
emulsified matter may stick to the dipstick, oil
a If the filter cartridge is over tightened, fuel will
filler cap, etc. or the drained oil may be milky
leak because the O-ring is damaged. If the
white because of water vapor in the blowby gas.
filter cartridge is not tightened sufficiently,
However, if the coolant level is normal, it is not a
fuel will also leak through the clearance of
problem.
the O-ring. Therefore, observe the tightening
angle. 1. Stop the engine.
7. Turn valve (1) at the fuel tank bottom to "OPEN" 2. Open the engine hood.
(O) position. 3. Remove dipstick (G) and wipe off oil on the
8. Bleed air according to the following procedure. gauge with a cloth.
4. Insert dipstick (G) fully and pull it out.
1) Fill up the fuel tank with fuel (to the level
where the float is at the highest position).
2) Loosen feed pump knob (4) and draw it out
once, then push and pull several times until
its movement becomes stiff.
• You do not need to remove the plugs at
the head of the fuel prefilter and fuel main
filter.
• If fuel is used up, bleed air by operating
feed pump knob (4) in the same manner.
5. If the oil level is between lines H and L on

dipstick (G), it is at the correct level.
If the oil level is below the L mark, add oil
through oil filler port (F).
3) Push in and tighten feed pump knob (4).

9. After replacing the filter cartridge, run the engine
at low idle for approximately 10 minutes.
10.Check the filter seal surface for fuel leakage. If 6. If the oil level is above line H, drain the extra
fuel leaks, check the tightening condition of the engine oil through drain valve (P) at the bottom
filter cartridges. If fuel still leaks, remove the filter of the engine oil pan and check the oil level
cartridge according to steps 1. to 4. and check again.
HB215LC-2 40-21
40 Troubleshooting
7. If the oil is at the correct level, tighten the oil filler

cap securely and close the engine hood.
a12. Check of motor-generator case oil level

a Immediately after the engine is stopped, its parts
and oil are still very hot, and may cause burn
injury. Accordingly, wait until all parts have
cooled down before starting the work.
1. Remove dipstick (G) and wipe off oil on the
gauge with a cloth.
2. Insert dipstick (G) fully into the guide.
3. Pull out dipstick (G) and check that the oil level
is between lines H and L on the dipstick.
• Between lines H and L a13. Check of coolant level (in sub tank)
4. If the oil level is below stamped line (L) of k The radiator cap does not need to be opened
dipstick (G), remove the cap of oil filler port (F) for standard checks. When checking the
and add oil. coolant level, check it in sub-tank when the
• When the oil level is below line H engine is cooled down.
5. If the oil level is above line H of dipstick (G),
loosen drain valve (P) to drain the excessive oil. k Immediately after the engine is stopped, the
• When the oil level is above line H coolant is still very hot and the pressure is
• When draining the oil, place an oil container accumulated in the radiator.
under drain valve (P). If the cap is opened under these conditions,
6. After checking the oil level and adding oil, install you may be scalded. If you need to remove
dipstick (G) and oil filler cap (F). the radiator cap, wait until the temperature
drops before you do. Then turn the cap
slowly to release the pressure and remove it
with care.
1. Open side cover on the rear left of the machine,

check the coolant level is within "FULL - LOW"
range at reservoir tank (1) (shown in the figure
below). If coolant is insufficient, add coolant up
to FULL level through water filler port at
reservoir tank (1).
2. After refilling with coolant, tighten the cap
securely.
3. If the reservoir tank is vacant, coolant may have
leaked.
If any abnormality is found in the check for
leakage, repair it immediately. If no abnormality
is found, check the level of the coolant in the
radiator. If it is low, add coolant to the radiator
and then to the reservoir tank.
40-22 HB215LC-2
40 Troubleshooting
4. If reservoir tank (1) is dirty and it is difficult to

check the coolant level, clean it.
a Do not clean the element until the air cleaner

clogging monitor on the monitor panel lights up.
If you clean the element frequently before the air
cleaner clogging monitor lights up on the monitor
panel, the true performance of the air cleaner is
not used and the filtration efficiency deteriorates.
a Inspection, cleaning or servicing while the
engine is running allows entry of dusts and can
damage the engine since dusts attached to the
element drop into the secondary element more
frequently during the cleaning process. Be sure
to stop the engine before cleaning.
Cleaning of primary element
1. Open the side cover at the rear left side of the
a14. Check of air cleaner for clogging machine and disengage 4 clips (2) to remove
cover (3).
k When using compressed air for cleaning, put
on personal protective items such as
protective eyeglasses, gloves, dust mask,
etc. to protect yourself from dirt that will fly
out.
k When removing the primary element from

the air cleaner body, do not forcibly pull it out,
otherwise it can be dangerous.
Be careful not to fall from a high location on
unsafe scaffolding as a reaction when pulling
out the primary element.
Diagnostic Tests
2. Remove primary element (4).
If air cleaner clogging monitor (1) on monitor panel
lights up, clean the air cleaner element. a Never remove secondary element (5). If it is
removed, dirt will enter and can lead to
engine troubles.
a Do not clean and reuse the secondary
element.
a Replace the primary element with a new one
when replacing the primary element.
HB215LC-2 40-23
40 Troubleshooting
3. Clean the inside of the air cleaner body and 5. After clearing the element, check it. If it has a
cover (3). small hole or thin part, replace it.
a When cleaning the element, do not hit it or hit
anything with the element.
a Do not use the element if its folds or gasket
or seal are damaged.
a Wrap an unused element and keep it in a dry
place.
4. Blow dry compressed air (0.2 MPa {2.1 kg/cm2}

and below) to the clean side (secondary element
side) of the primary element from inside along its
pleats.
1) Replace the primary element if it is cleaned 6
times repeatedly or used throughout a year.
Replace the secondary element as well at
the same time.
2) Replace both primary and secondary k When installing cover (3), check O-ring (6)
elements when the red dust indicator for scratches and replace it with a new
appears soon after cleaning the primary one if any.
element even though it has not been cleaned
6 times yet.
6. Set the cleaned primary element, then install

cover (3) and fix them with mounting clips (2).
3) Peel off a seal after cleaning the element Replacement of element
each time.
40-24 HB215LC-2
40 Troubleshooting
1. Open the side cover at the rear left side of the

machine and disengage 4 clips (2) to remove
cover (3).
b. Hydraulic and mechanical equipment

b3. Check of hydraulic oil level
2. Remove primary element (4). parts and oil are still very hot, and may cause
k When removing the oil filler cap, the oil may

spurt out. Turn it slowly to release the
internal pressure, then remove it.
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, start the engine, fully retract
the cylinder rods for arm and bucket at
Do not remove secondary element (5) at this engine low idle. Then lower the boom until
time. bucket teeth touch the ground, then stop the
engine.
3. Clean the inside of the air cleaner body and

cover (3). 2. Turn the starting switch to ON position within 15
4. Remove secondary element (5), then quickly seconds from the engine stop and operate
install the new secondary element. control levers (work equipment and travel) to the
travel end in each direction to release internal
k When installing cover (3), check O-ring (6) pressure.
for scratches and replace it with a new 3. Open the cover on the right side of the machine,
one if any. and check the oil level through the sight gauge
5. Set new primary element (4), then install cover (G). If it is between line H and L, it is appropriate.
(3) and fix them with clip (2). a If the oil level is below line L, add oil through
6. Replace the seal stuck to cover (3) with a new oil filter port (F).
one.
HB215LC-2 40-25
40 Troubleshooting
a Do not add oil above line H since it can k Immediately after the engine is stopped, its
damage the hydraulic circuit or it may cause parts and oil are still very hot, and may cause
oil to spurt out. burn injury. Accordingly, wait until all parts
a If oil is added above line H, stop the engine,
wait for the oil temperature to cool down,
k When you remove the oil filler cap, oil may
discharge excessive oil from drain plug (P)
spurt out. Be careful to rotate it slowly, and
under the suction tube.
release inner pressure gradually.
1. Stop the engine and remove oil filler cap (F) of

the hydraulic tank to release the internal
pressure.
2. Remove the bolts to remove cover (1).
3. When removing the bolts, keep pressing down
cover (1) since it may jump out by spring (2).
4. Hold the top of rod (3) and pull it up to remove
spring (2) and strainer (4).
5. Remove any dirt stuck to strainer (4), then wash
it in flushing oil. If strainer (4) is damaged,
replace it with a new one.
6. Insert and set strainer (4) in projected portion (5)
of the tank.
7. While pressing down spring (2) with the
projection at the bottom of cover (1), install the
bolts. Tighten the mounting bolts.
b.5 Check of hydraulic oil filter

k When you remove the oil filler cap, oil may

spurt out. Be careful to rotate it slowly, and
release inner pressure gradually.
Since the oil level varies according to the oil
temperature, use the followings as a guide. 1. Set the work equipment in the posture on a level
• Before start of operation (oil temperature 10 and firm ground as shown below, and stop the
to 30°C), between lines H and L engine.
• During normal operation (oil temperature: 50
to 80°C), the oil level should be near line H.
b4. Check of hydraulic oil strainer
40-26 HB215LC-2
40 Troubleshooting
10.Install oil filler cap (F).

11.To bleed air, run the engine at low idle for 10
minutes.
12.Stop the engine.
b6. Check of swing machinery case oil level
1. Remove dipstick (G) and wipe off oil on the

gauge with a cloth.
2. Insert dipstick (G) fully into the guide.
2. Remove oil filler cap (F) of the hydraulic tank to
3. Pull out dipstick (G) and check the oil level. If the
oil level is between lines(H and L on the dipstick,
it is at the correct level.
4. If the oil does not reach the (L) mark on dipstick
(G), add oil through oil filler (F).
5. If the oil level is above line H of dipstick (G),
loosen drain valve (P) to drain the excessive oil.
• 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).
3. Remove the bolts, and remove cover (1).

When removing the bolts, keep pressing down
cover (1) since it may jump out by spring (2).
4. Remove spring (2), valve (3) and strainer (4),
and then remove element (5).
• Check the bottom of the filter case for dirt or
other material, and remove any if found. At
that time, take extreme care for any dirt or
other material not to drop into the hydraulic
tank.
5. Clean the removed parts using cleaning oil.
6. Install new element (5).
7. Place strainer (4), valve (3) and spring (2) onto
the element.
8. Set cover (1) and install it with the mounting
bolts while pressing it by hand.
9. Tighten the mounting bolts.
HB215LC-2 40-27
40 Troubleshooting
b7. Check of electric swing motor case oil level

1. Remove dipstick (J) and wipe off oil on the

gauge 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 stamped lines H and L on
the dipstick, it is appropriate.
4. If the oil level is below line (L) on dipstick (J),
add oil through oil filler (K). When adding oil, b8. Check of final drive case oil level
remove dipstick (J). k Since the oil may spurt out due to internal
5. If the oil level is above line H of dipstick (J), pressure, rotate the plug gradually from its
loosen drain valve (Q) to drain the excessive oil. side to release the internal pressure and then
• When draining the oil, place an oil container remove it carefully.
under drain valve (Q).
6. After checking the oil level and adding oil, install k Immediately after the engine is stopped, its
dipstick (J) and oil filler cap (K). parts and oil are still very hot, and may cause
• Refill capacity (right and left): 5.0 l

• Prepare a handle for the work.
1. Set the TOP mark at the top, and the line
running on TOP mark and plug (P)
perpendicular to the ground.
2. Place the oil container to receive oil under plug
(P).
3. Remove plugs (P) and (F) by using the handle,
and drain oil.
a Check for damages on O-ring attached to the
plugs. Replace it if necessary.
4. Tighten plug (P).
5. Refill oil through plug (F) hole.
6. If oil flows out of the plug (F) hole, install the plug
(F).
3 Tightening torque of plugs (P) and (F):
68.6 ± 9.8 Nm {7 ± 1 kgm}
40-28 HB215LC-2
40 Troubleshooting
k There are 2 plugs (F). For refilling, use the

one which is easier for refilling and inner
gear is not seen through.
c3. Check of starting motor terminal for

looseness and corrosion
• Check starting motor (1) terminal B and terminal
C for open circuit, looseness and corrosion.
c4. Check of battery voltage (with engine

b9. Bleeding air
stopped)
• For the bleeding air from the fuel system, see
• Check the battery voltage by using the battery
Testing and adjusting, "Bleeding air from fuel
tester while the engine is stopped.
circuit".
c5. Check of battery electrolyte level
• For bleeding air from the hydraulic system, see
Testing and adjusting, "Bleeding air from Check before operating the machine.
hydraulic circuit". k Do not use the battery while its electrolyte
c. Electric equipment level is below LOWER LEVEL. If it is used
c1. Check of battery terminal for looseness and under that condition, its inside becomes
corrosion deteriorate, its service life is shortened, and
1. Open covers on the front right side of the it may lead to an explosion.
machine, and check terminal of battery for
k Since the battery produces combustible gas
looseness and corrosion.
2. Check and remove any accumulated dirt and that can explode, do not bring any open
combustibles (dead leaves, twigs, etc.) around flame near it.
the batteries.
k Battery electrolyte is dangerous. Take care
c2. Check of alternator terminal for looseness
that it does not come in contact with your
and corrosion
eyes or skin. If it does, wash it away with
• Check alternator terminal B (1) for open circuit, water and contact your doctor.
looseness and corrosion.
a Do not add the electrolyte to the battery
exceeding UPPER LEVEL line. If the electrolyte
level is too high, it may leak and cause damage
to the paint surface or corrode other parts.
a To avoid freezing, add the purified water (such
as a commercial battery fluid) before starting the
work in the next day.
HB215LC-2 40-29
40 Troubleshooting
• When checking the electrolyte level through the • (A) Correct level: Since the electrolyte level
side face of the battery reaches to the sleeve bottom, the shape of
1. Wipe and clean the battery surface, especially the electrode plates will appear distorted due
around the battery level lines with a wet cloth, to the surface tension.
and check to see that the battery fluid is • (B) Low level: Electrolyte level does not
between the UPPER LEVEL and LOWER reach the bottom of sleeve, so pole plates
LEVEL lines. appear straight and not bent.
3. After adding fluid, tighten cap (2).
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 a If the purified water is added to above
between the U.L. and L.L. lines, remove cap (2) UPPER LEVEL (U.L.) line, remove the fluid
and add purified water (example: commercially by using a syringe to lower the level to
available battery fluid) to the U.L. line UPPER LEVEL (U.L.) line. Neutralize the
immediately. removed fluid with baking soda (sodium
3. After adding the purified water, tighten cap (2) bicarbonate), then flush it away with a large
securely. amount of water.
c6. Check of wiring harness for discoloration,
burn and cover peeling
• Check the wiring harness and cables for
discoloration and burn.
a If discolored or burnt, the circuit may be shorted
or grounded.
• Check the wiring harnesses and cables for
damage and peeling of the covers.
• If any abnormality is found, repair or replace the
wiring harness or cables.
c7. Check for coming off of wiring harness
clamp and sagging of wiring harness
• Check wiring harness for sagging and looseness
a If the purified water is added to above
due to coming off of harness clamp
UPPER LEVEL (U.L.) line, remove the fluid
by using a syringe to lower the level to a In particular, carefully check the wiring harness
UPPER LEVEL (U.L.) line. Neutralize the around the hot and movable parts.
removed fluid with baking soda (sodium • If removed from the clamp, secure it with the
bicarbonate), then flush it away with a large clamp.
amount of water.
• When electrolyte level cannot be checked
through the side face of the battery
1. Remove cap (2) on the top of battery. (described
previously)
2. Look into filler port (3) and check the surface of
fluid. If the fluid level is below sleeve (4), always
add the purified water (such as a commercial
battery fluid) until it reaches the bottom of sleeve
(the UPPER LEVEL).
40-30 HB215LC-2
40 Troubleshooting
c8. Check of grounding • Open the battery cover on the front right side of
the machine.
a Be especially careful for loose ground terminals
• Cab ground T02
and corrosion.
• Check the connection of ground terminal (60B), a Since (T02) is situated at the bottom on the
(T01), (T15), and (T18). rear left side of the cab and connected to
(T01), it is not particularly necessary to be
checked.
• Check the connection of ground terminals (T04)

to (T07), (T09), and (T10).
HB215LC-2 40-31
40 Troubleshooting
• Remove the pump undercover.

• Check the connection of generator ground
terminal (GE).
• Open engine undercover under the engine.

a Checking of engine ground can be performed by • Remove top cover (3) of the control valve.
removing the undercover under the engine.
• Check the connection of ground terminal (T12)
and (40B) of engine controller (EC).
• Check the connection of ground terminal (T13B).

CV: Control valve
• Check the connection of ground terminal (T08).
• Check the connection of ground terminal (T13A).
40-32 HB215LC-2
40 Troubleshooting
CV: Control valve
• Check the connectors for unlocking, and check

• Check the connection of ground terminal (T16). the lock and connector housing for cracking.
• Check lock screws (L) of engine controller (EC)
for looseness.
a Use a hexagonal wrench with 4 mm width
across flats.
• Check the connection of capacitor ground (1).
c10. Check the connector pins for corrosion,

bending and deformation
• Disconnect the connectors, and check their pins
for corrosion, bending, sinking than other pins,
and extension of female pins.
• If pins are defective, repair or replace them.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect the
connectors several times to shine them. (If the
pins do not become shiny, connect and
c9. Check for loose connector and damaged disconnect the connectors 10 times)
lock c11. Check of connector for entering of water
• Check the connection of male and female and foreign material inside the connector
connectors by pulling them by hand. • Disconnect connectors, and check them for
• If the connection is loose, secure it. entering of water or foreign material inside the
connector.
HB215LC-2 40-33
40 Troubleshooting
• Visually check wiring harnesses for peeling of

a If there is entering of water or foreign material
harness covers and the pins for contact with
inside connector, the seals may be damaged.
adjacent pins due to defective crimping.
Check the seals for damage.
c13. Check of fuse for breakage and corrosion
• If the seal is defective, repair or replace it.
• Dry the inside of the connector with a dryer. a When replacing a fuse, be sure to turn off the
power (turn the starting switch to OFF position)
and turn the battery disconnect switch to OFF
position.
• A fusible link is a large-capacity fuse.
• If a fuse is corroded and coated with white
powder, or there is any play between the fuse
and fuse holder, replace the fuse.
• Replace each fuse with the one of the same
capacity.
Remove the cover at the rear right of the operator
seat, and the fuse holder is seen.
• Wipe and remove any foreign material inside

connector with a cloth or others, and blow the air
to clean the connector.
Fusible link (F04) and (F05) are in the battery case.
c12. Check of wiring harness for open or short

circuit
• Check the connection (crimped part) between
connector pins and wiring harness.
• If the line is open as shown as (A), repair or
replace the wiring harness or cables.
40-34 HB215LC-2
40 Troubleshooting
c14. Check of alternator voltage (when engine coolant of the specified concentration through
speed is medium or higher) the water filler port until you see it in sight glass
1. Open the engine hood. (3).
2. Connect the positive (+) lead of the multimeter to
alternator terminal (B) and connect the negative
(-) lead to the chassis ground.
3. Start the engine and warm it up and measure
the voltage while running the engine at a
medium or a higher speed.
• If the voltage is abnormal, repair or replace
the alternator.
c15. Check of battery relay operation sound
1. Open the side cover on the left side of the
machine.
2. Turn the starting switch to ON and OFF
positions, and check whether the battery relay d3. Check of capacitor
operation sound is heard or not.
1. Turn the starting switch key to ON (B) position.
• If the operation sound is not heard, check the
related circuits, referring to the description of a Important
troubleshooting for E-1 described in the E Do not start the engine at this point.
mode troubleshooting.
• If the relating circuit is normal, replace the
battery relay.
d. Hybrid components
d1. Temperature check of hybrid components
2. Open the cover at the rear left of the machine,

look into inspection window (1) of the capacitor,
and check that LED lamp (1 piece) is lit.
a Remarks
The number of the lit LED lamps seen
through the inspection window of the
Monitor (1) lights up in red to warn temperature rise capacitor indicates the following state;
of the hybrid components. When it lights up in red, • tt (2 are lit): High voltage is being
stop the operation and run the engine at low idle or output.
stop it until the monitor goes off. • Tt (1 is lit): Capacitor is charged with
d2. Check of coolant level high voltage.
• TT (None is lit): Capacitor is not charged
1. Open the rear left door of the machine and
(Storage voltage is 30 V or lower).
check that the coolant level is in the range of the
sight glass. If it is insufficient, add coolant • After the engine is stopped for a long time, all
through the water filler port up to the level of LED lamps may go off.
sight glass (3). If all LED lamps are OFF, start engine and
2. After refilling with coolant, tighten the cap (2) run it for approximately 2 minutes, stop the
securely. engine, and check again.
3. If the coolant cannot be seen in the sight glass
(1), it may be leaking. If any abnormality is found
after the check, repair it immediately. If no
abnormality is found, check the coolant level of
hybrid radiator. If the coolant level is low, add
HB215LC-2 40-35
40 Troubleshooting
3. Turn the starting switch key to START position

(C) to start the engine.
4. Look into inspection window (1) of the capacitor

again and check that both LED lamps are lit.
40-36 HB215LC-2
40 Troubleshooting
Preparation for troubleshooting of electrical system (HB205-C050-42C-K-01-A)
a When performing troubleshooting of electrical system of machine monitor, engine controller, pump
controller, hybrid controller (inverter), and KOMTRAX communication modem related, expose applicable
connector part according to the following procedure.
a For connectors whose lock method is special, perform disconnection and connection.
Preparation (HB205-C050-42C-K-00-A)
1. Machine monitor
1) Remove screws (3 pieces) mounting cover
(1).
a One of the 3 screws is covered with cap
(2).
a Disconnect connector P31 of sunlight
sensor, and remove cover (1).
4) Insert or connect troubleshooting T-adapters

to connectors CM01, CM02, and CM04 on
machine monitor (7).
2) Remove a mounting bolt, and remove duct

(6).
3) Insert a flat-head screwdriver in slit (3) and
pull it upward, and remove cover (5) while
avoiding lug (4).
1) Remove undercover.
a The engine controller is mounted to the
engine (on the counterweight side).
2) Insert or connect troubleshooting T-adapters
into or to connectors ECMJ1, ECMJ2, and
CE03 of engine controller (8).
a Since the connectors is secured with
screws, loosen them before
disconnecting the connector.
a When restore them, tighten the screws to
the specified torque.
3 Screw: 3 ±1 Nm {0.3 0.1 kgm}±
HB215LC-2 40-37
40 Troubleshooting
a The connectors of the pump controller

have a special locking mechanism.
Disconnect them according to steps (a) to
(c) and connect them according to steps
(d) to (f) as shown below.
Disconnection: (a) Unlock - (b) Slide lever
- (c) Disconnect connector
Connection: (d) Position connector - (e)
Slide lever - (f) Lock
3. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove mounting bolts (5 pieces), and
remove cool and hot box (9).
a While removing it, disconnect the drain
hose.
3) Remove mounting bolts (2 pieces) and
fastener (1 pieces), and remove magazine
box (10).
4) Remove the mounting bolts (3 pieces), and 4. Hybrid controller (inverter)
remove cover (11). 1) Open side cover on the left side of the
5) Remove the mounting bolts (7 pieces), and machine.
remove cover (14).
a The hybrid controller is mounted just
before the radiator.
2) Remove clamping bolt (1) (3 pieces), and
remove cover (2).
6) Connect test adapters to connectors CP01

and CP02 of pump controller (15).
a Install the adapters to the wiring harness
side only. 3) Insert or connect troubleshooting T-adapters
into or to connectors HC01 and HC02 of
hybrid controller.
a Since HC01 and HC02 are secured with
screws, loosen them before
disconnecting.
a When returning HC01 and HC02, tighten
the screws to the specified torque.
3 Connector mounting screw:
2.6 to 3.1Nm {0.27 to 0.32 kgm}
40-38 HB215LC-2
40 Troubleshooting
Engine Ne speed sensor (CRANK SENSOR)

Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
Exhaust gas pressure sensor (EXHAUST
PRESSURE)
Crankcase pressure sensor (P57)
Mass air flow and temperature sensor (P55)
a Disconnection and connection of connectors
Since the connectors of the ambient
pressure sensor, engine Ne speed sensor,
engine Bkup speed sensor and engine oil
5. KOMTRAX communication module pressure switch have a special lock
1) Slide the operator's seat and seat stand to mechanism, disconnect them in the order of
the forward end. (a) to (c), and connect them in the order of
2) Remove mounting bolts (5 pieces), and (d) to (f) as shown in the following figure.
remove cool and hot box (9). Disconnection: (a) Slide the lever, (b) unlock,
a While removing it, disconnect the drain and (c) disconnect the connectors.
hose. Connection: (d) Connect the connectors, (e)
3) Remove mounting bolts (2 pieces) and engage the lock, and (f) slide the lever.
fastener (1 pieces), and remove magazine
box (10).
4) Remove the mounting bolts (3 pieces), and
remove cover (11).
5) Remove the mounting bolts (7 pieces), and
remove cover (14).
a Removal and installation of sensor body

Since a deep socket is necessary when
performing removal and installation of engine
oil pressure switch, see "Tools for testing,
adjusting, and troubleshooting".
6) Connect troubleshooting T-adapters to 7. Boost pressure and temperature sensor
connectors CK01 and CK02 of KOMTRAX (BOOST PRES & IMT)
communication module (15).
The connector of the boost pressure
temperature sensor has a special locking
mechanism. Disconnect it according to steps
(a) to (b), and connect it according to steps
(c) to (d) as shown below.
Disconnection: (a) Unlock and (b) disconnect
the connectors.
Connection: (c) Connect the connectors and
(d) engage the lock.
6. Ambient pressure sensor (AMBAIR

PRESSURE)
HB215LC-2 40-39
40 Troubleshooting
a Removal and installation of sensor body a Precautions for disconnection of connectors

Since a TORX wrench is necessary when The direction of the lock for connector may
removing and installing the charge (boost) be changed toward the difficult direction
pressure and temperature sensor, see "Tools (facing to the bottom or to the engine side)
for testing, adjusting, and troubleshooting". for unlocking depending on the position
8. Supply pump IMV solenoid (FUEL where the sensor is screwed in.
REGULATOR) In such a case, turn the lock to the direction
a Disconnection and connection of connectors (a) by using the needle nose pliers with
curved tip (commercially available) [1], then
The connector of the supply pump IMV
the lock can be canceled easily.
solenoid has a special locking mechanism.
Disconnect it according to steps (a) to (b), Since the lock is canceled with "click" sound,
and connect it according to steps (c) to (d) as listen to the sound and disconnect the
shown below. connectors.
the connectors.
a Precautions for connecting connectors

When connecting connectors, pay attention
not to connect the connectors reverse.
Engage lock portion (e) on the harness side
9. Common rail pressure sensor (FUEL RAIL to triangle notch portion (f). (Pay attention not
PRESS) to take square guide portion (g) on the
a Disconnection and connection of connectors opposite side of triangle notch portion (f) by
mistake.)
The connector of the common rail pressure
sensor has a special locking mechanism.
Disconnect it according to steps (a) to (b),
and connect it according to steps (c) to (d) as
shown below.
the connectors.
40-40 HB215LC-2
40 Troubleshooting
2) Lower red lock (L1).

10.Engine coolant temperature sensor
3) Check lock (L2) at the side.
(COOLANT TEMP)
a A slit is provided on one side only. (back
side)
The connector of the engine coolant
temperature sensor has a special locking
mechanism. Disconnect it according to steps
(a) to (b), and connect it according to steps
(c) to (d) as shown below.
the connectors.
4) While pinching lock (L2), lower side cover (3)

until it touches lock (L1).
a Removal and installation of sensor body

Since a deep socket is necessary when
removing and installing the engine coolant
temperature sensor, see "Tools for testing,
adjusting, and troubleshooting".
11.Engine intermediate connector 5) Grab the intermediate connector body (black
part on both male and female sides) to
a Disconnecting connectors disconnect the connector.
1) Remove clip (1) to release intermediate
connector OEM CONNECTION/E24 (2).
HB215LC-2 40-41
40 Troubleshooting
40-42 HB215LC-2
40 Troubleshooting
Classification and procedures for troubleshooting (HB380-5160-40D-A-00-A)

Classification of troubleshooting
Mode Content
Display of Troubleshooting by failure code
code
E-mode Troubleshooting electrical system
H-mode Troubleshooting hydraulic and mechanical system
S-mode Troubleshooting engine
Y-mode Troubleshooting of hybrid components
Procedure for troubleshooting

If a problem occurs in the machine, go to the corresponding troubleshooting section according to the following
procedure.
1. Troubleshooting procedure to be taken when action level and failure code are displayed on
machine monitor:
If an action level and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding [Display of code] according to the displayed failure code.
a If multiple problems occur simultaneously, all the failure codes for the problems are displayed
repeatedly in order. Record all the failure codes.
2. Troubleshooting procedure to be taken when action level and failure code are not displayed on
normal screen of 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 corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes once and reproduce them, and
then see if the trouble is still detected. (See [*2])
a A failure code of the mechanical system cannot be deleted.
a If abnormality related to air conditioner is displayed in electrical system abnormality record, perform
"Check with self-diagnosis" in "Air conditioner".
2) If no failure code is recorded in the abnormality record, a failure 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 problem which seems to be a failure again and select the same problem from
the table of "Problem which seems to be failures and troubleshooting Nos.", and then carry out
troubleshooting corresponding to that problem in the [E-mode], [H-mode], [S-mode], or [Y-mode].
3. Actions to take after failure is repaired
Referring to following page, delete all failure codes in electrical system abnormality record.
[*1]、[*2]
1. On the normal operation screen, while pressing number key [4] in the panel switch section, press [1], [2],
and [3] in this order.
2. On the service menu screen, press switch [F3] (R) in the panel switch section twice, and then select "03
Abnormality Record".
HB215LC-2 40-43
40 Troubleshooting
3. Press switch [F6] in the panel switch section to confirm, and then enter the "Abnormality record" screen.
4. Press switch [F6] in the panel switch section to confirm, and then enter the "Mechanical system failure
record" screen.
5. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a A failure code of the mechanical system cannot be deleted.
6. Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
7. Similarly to 2 and 3, enter the "Electrical system abnormality record" screen.
8. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a If [E] is displayed on the left of a failure code, that failure code is "active" (the failure is still occurring or
normal resetting is not confirmed yet). If [E] is not displayed on the left of a failure code, that failure
code is "non-active" and disappears in the following clearing step. Accordingly be sure to take record
of that failure code.
9. While pressing number key [4] in the panel switch section, press [1], [2], and [3] in this order to enter the
"Clearing mode". (Same as 1)
10.Press switch [F2] (CLEAR) in the panel switch section.
40-44 HB215LC-2
40 Troubleshooting
11.Press switch [F6] in the panel switch section to clear all failure codes temporarily.
12.Press switch [F5] (return) in the panel switch section to return to the "Electrical system abnormality record"
screen. Check if there is any failure code still displayed and take record.
13.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
14.Take record of information of all columns.

a Similarly to the electrical system abnormality record, if "E" is displayed on the left of a failure code, that
failure code is "active"
(the failure is still occurring or normal resetting is not confirmed yet).
15.Press switch [F2] (CLEAR) in the panel switch section to clear all codes temporarily. Check if "Abnormal"
is still displayed and take record. (Same as 10 in [*1] and [*2])
16.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
HB215LC-2 40-45
40 Troubleshooting
Symptom and troubleshooting numbers (HB205-5540-441-A-00-A)
Symptom and troubleshooting numbers

Troubleshooting
No. Symptom of failure
Index
Action level and failure code
Action level is displayed on the machine monitor. Press function switch [F5] to
1 display the "Occurred error list". Perform
Failure code is displayed on mechanical system abnormality record. troubleshooting for
2
failure code
3 Failure code is displayed on electrical system abnormality record
Symptom related to engine
4 Engine startability is poor. S-4
5 Engine does not start. E-1, S-1
6 Engine does not crank when starting switch is turned to "START" position S-1, E-1
7 Engine cranks but no exhaust smoke comes out. S-2
Fuel is being injected but engine does not start (misfiring: engine cranks but does
8 not start). S-3
9 Engine does not pick-up smoothly. S-5
10 Engine stops during operation. S-6, H-2
11 Engine runs rough or is unstable. S-7
12 Engine lacks power. S-8
13 Exhaust smoke is black. S-9
14 Oil consumption is excessive. S-10
15 Oil becomes contaminated early. S-11
16 Fuel consumption is excessive. S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down) S-13
18 Oil pressure drops. S-14
19 Fuel mixes into engine oil. S-15
20 Water mixes into engine oil (milky). S-16
21 Coolant temperature rises too high (overheating). S-17
22 Unusual noise is heard. S-18
23 Vibration is excessive. S-19
24 Air cannot be bled from fuel circuit. S-20
25 Manual preheating system does not work. E-2
26 Automatic preheating system does not work. E-3
27 While preheating is working, preheating monitor does not light up. E-4
28 Automatic warm-up system does not operate (in cold season). E-29
When auto-deceleration switch is operated, auto-deceleration monitor does not
29 light up or does not go off. E-30
Auto-deceleration function does not operate or is not canceled while lever is
30 operated. E-31
31 Motor-generator temperature increases abnormally. Y–9
32 Inverter temperature increases abnormally. Y–10
33 Capacitor temperature increases abnormally. Y–11
Symptom related to work equipment, and swing and travel system
34 None of work equipment, swing or travel works. E-39, H-3
35 Any of work equipment, swing, and travel cannot be locked. E-40
36 All of work equipment, swing and travel operation lacks speed and power. H-1
37 Engine speed drops significantly or engine stalls. H-2, S-6
Working mode selection screen is not displayed while working mode selector
38 switch is operated. E-32
Setting of engine and hydraulic pump is not changed while working mode is
39 changed. E-33
40 Unusual noise is heard from around hydraulic pump. H-4
40-46 HB215LC-2
40 Troubleshooting
Troubleshooting
Index
41 Fine control performance or response is poor. H-5
Symptom related to work equipment
42 Boom speed or power is low. H-6
43 Arm speed or power is low. H-7
44 Bucket speed or power is low. H-8
45 Work equipment does not move in single operation. H-9
46 Hydraulic drift of boom is large. H-10
47 Hydraulic drift of arm is large. H-11
48 Hydraulic drift of bucket is large. H-12
49 Time lag of work equipment is large. H-13
When single work equipment is relieved hydraulically, other work equipment
50 H-14
moves.
51 One-touch power maximizing function does not operate. H-15, E-43
52 One-touch power maximizing function cannot be canceled. E-44
53 Attachment hydraulic circuit cannot be changed while attachment is installed. H-32, E-61
54 Oil flow in attachment circuit cannot be changed. H-33
Symptom related to combined operation
In combined operation of work equipment, equipment having heavier load moves
55 H-16
slower.
57 In combined operation of swing and travel, travel speed drops largely. H-18
Symptom related to travel
58 Machine does not travel straight. H-17
59 Travel speed is slow. H-18
60 Machine is not steered well or steering power is low. H-19
61 Travel speed does not change, or travel speed is too slow or fast. H-20, E-34, E-35
62 One of tracks does not run. H-21
63 Alarm does not sound during travel. E-45
64 Alarm does not stop sounding while machine is stopped. E-46
Symptom related to swing
65 Upper structure does not swing to the right or left. Y-2
66 Upper structure swing only to the right or left. Y-2
67 Swing acceleration or swing speed is low in both directions (right and left). Y-3
Swing acceleration performance is poor or swing speed is slow in only one
68 Y-3
direction.
69 Upper structure overruns excessively when it stops swinging (both right and left). Y-4
70 Upper structure overruns excessively when it stops swinging (either right or left). Y-4
71 Shock is large when upper structure stops swinging. Y-5
72 Large unusual noise is heard when upper structure stops swinging. Y-6
73 Swing drift on a slope is large while swing parking brake is applied. Y-7
74 Swing drift on a slope is large while swing parking brake is released. Y-7
Upper structure does not swing while swing parking brake cancel switch is set to
75 CANCEL position. E-41
Swing brake does not operate while swing parking brake cancel switch is set to
76 NORMAL position. E-42
77 Electric swing motor temperature increases abnormally. Y-8
Symptom related to machine monitor
78 When starting switch is turned to ON position, machine monitor displays nothing. E-5
When starting switch is turned to ON position (with engine stopped), engine oil level
79 monitor lights up in red. E-6
When starting switch is turned to ON position (with engine stopped), radiator
80 coolant level monitor lights up in red. E-7
81 Engine coolant temperature monitor lights up in white while engine is running. E-8
82 Hydraulic oil temperature monitor lights up in white while engine is running. E-9
HB215LC-2 40-47
40 Troubleshooting
Troubleshooting
Index
83 Charge level monitor lights up while engine is running. E-10
84 Fuel level monitor lights up in red while engine is running. E-11
85 Air cleaner clogging monitor lights up in red while engine is running. E-12
86 Water separator monitor lights up while engine is running. E-13
87 Engine coolant temperature monitor lights up in red while engine is running. E-14
88 Hydraulic oil temperature monitor lights up in red while engine is running. E-15
89 Hybrid temperature monitor lights up in red while engine is running. E-16
90 Engine oil pressure monitor lights up in red while engine is running. E-17
91 Fuel gauge display does not move from minimum or maximum. E-18
92 Fuel gauge indicates incorrect amount (indicates neither full nor empty). E-19
Engine coolant temperature gauge display does not move from minimum or
93 E-20
maximum.
Engine coolant temperature gauge indicates incorrect temperature (indicates
94 neither minimum nor maximum). E-21
95 Hydraulic oil temperature gauge does not move from minimum or maximum. E-22
Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither
96 minimum nor maximum). E-23
97 Hybrid temperature gauge does not move from minimum or maximum. E–24
Hybrid coolant temperature gauge indicates incorrect temperature (indicates
98 neither full nor empty). E-25
99 Contents of display on machine monitor is different from actual machine condition. E-26
100 Some areas of machine monitor screen are not displayed. E-27
101 Function switch does not work. E-28
102 Alarm buzzer does not stop sounding. E-36
103 Service meter is not displayed while starting switch is in OFF position. E-37
104 Service mode cannot be selected. E-38
105 Horn does not sound. E-47
106 Horn does not stop sounding. E-48
107 Wiper monitor does not light up, or does not go out, while wiper switch is operated. E-49
108 Wiper does not operate while wiper switch is operated. E-50
109 Window washer does not operate while window washer switch is operated. E-51
"Procedure for
Air conditioner does not operate normally (including failure codes related to air testing and
110 conditioner). troubleshooting" in
Chapter 80
111 Lever operation signal is not displayed correctly with monitoring function. E-52 to 60
112 Hybrid monitor does not go out. Y-1
Others
113 KOMTRAX system does not operate normally E-62
40-48 HB215LC-2
40 Troubleshooting
Information in troubleshooting table (ALL-5170-421-A-01-A)
(Rev. 2011/12)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen
Display on Failure
machine of the machine monitor
machine monitor
monitor
Detail of Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by
controller the machine monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is
machine performed by the machine monitor or controller.
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defective — <Contents of description>
Open or short circuit in wiring • Procedure
2
harness • Measuring location
Open circuit in wiring harness
a "Between A and B" denotes measuring values such as voltage
3 (wire breakage or defective and resistance between A and B.
contact of connector)
Ground fault in wiring harness a "Between A and ground" means the measurement of voltage,
4 resistance or others between terminal A and the place which has
(contact with ground circuit) a continuity with chassis frame such as unpainted hexagonal
5 Hot short circuit head bolt or bolt hole which has no rust, etc.
• Criteria to judge probable causes (standard value), remarks
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific
instruction, proceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been
corrected.
<Failures in wiring harness>
Short circuit in wiring harness
6 • Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power circuit comes into
contact with the power circuit accidentally.
• Short circuit
An independent wire in the harness erroneously comes into contact
with another independent wire.
(poor insulation at connector and others)
HB215LC-2 40-49
40 Troubleshooting

<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless
otherwise specified.
• When "male" or "female" is not indicated with a connector number,
disconnect the connector, and insert T-adapter between the male
and female connectors.
• When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter to the male or
7 Defective controller female connector.
• "Male and female" means male and female of connector pins, not
connector housings.
• Male and female of connector pins and housing in DT series, etc, are
opposite to those described in this manual. Take care.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wire indicated first.
• Connect the negative (-) lead to a pin or wire indicated second.
Related circuit diagram

This is the excerpted circuit diagram related to
troubleshooting
• The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
• The "/" in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female
sides
Example: BREAK OUT/E24
• The circuit diagram contains the destination or
source of the branch line in a wiring harness.
• The arrow (io) indicates a rough installation
position on the given machine.
• NO: Normally Open
• NC: Normally Closed
• Signal names such as GND and 24 V are included
in addition to connector numbers at junctions, etc.
in circuit diagrams.
• Except for GND and 24 V, a signal name indicated
at a junction, etc. shows that the wire is connected
to another junction or controller at where the same
signal name is indicated.
40-50 HB215LC-2
40 Troubleshooting
Diagnostic procedure for wiring harness open curcuit of pressure

sensor system (ALL-E720-42A-P-00-A)
a Since the pressure sensor consists not only of resistors but also "electronic circuits" such as amplifiers, it
may have the differences among the resistances measured and its own polarities. So troubleshooting
must be performed carefully.
Failure codes that require this diagnosis
• CA123: Boost pressure sensor low error
• CA451: Common rail pressure sensor high error
Procedure
1. Measure and record resistance of the pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the connector on the sensor side.
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 those of the sensor.
a If measured value is infinite, measure the resistances with multimeter probes exchanged each
other to reverse their polarities and record the finite value obtained as a measured value.
a Since measured values may disperse, measure several times.
Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times.
Consider this dispersion when determining 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) Connect the pressure sensor to be measured, disconnect connector (3) on the engine controller side,
and connect T-adapter (4) to the connector on the wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
3. Determining 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, determine that "wiring harness is open".
a "Apparent difference" means a difference of 10 or more times.
HB215LC-2 40-51
40 Troubleshooting
Pressure sensor measuring locations and reference values

Measuring location of Internal resistance of
Sensor sensor pins sensor (reference) Remarks
Boost pressure R2: Between (2) and (4) Approx. 100 z Sensor is common to engine
sensor R1: Between (1) and (4) Approx. 200 z models 107 and 114
R2: Between (3) and (1) Approx. 23 kz Sensor is common to engine
Common rail models 107 and 114
pressure sensor R1: Between (1) (+) and If polarities are inverted,
Approx. 10 Mz
(2) (-) resistance is infinite
*: Other connectors to be disconnected when measuring R2' are shown below. (See circuit diagram related to
each failure code)
• When measuring R2' of boost pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
• When measuring R2' of common rail pressure sensor (CA451):
Connectors of boost pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
Note the measurements in the table below. (For measuring locations, see the related circuit diagram
described in the troubleshooting page for the failure code.)
Sensor + Wiring
Sensor unit
harness
(Measuring location ofMeasured value (Measuring location of Measured value
Sensor
pins of sensor side
harness side connector
connector)
of engine controller)
R2': Between (37) and
R2: Between (2) and (4)
Boost pressure (47) (*)
sensor R1': Between (44) and
(47)
R2': Between (37) and
Common rail (47) (*)
pressure sensor R1: Between (1) (+) and R1': Between (47) (+)
(2) (-) and (25) (-)
40-52 HB215LC-2
40 Troubleshooting
Connector list and layout (HB205-C050-055-K-01-A)
Number
Connector No. Model Equipment name Address
of pins
A08 SWP 12 Intermediate connector J-1, S-9
A13 DT 2 Intermediate connector I-1
A15 DT 2 Intermediate connector AJ-2
A40 DT 4 Rearview camera I-9
A41 DT 4 Camera 2 S-1
A42 DT 4 Camera 3 S-1
A63 DT 8 Fuel identification sensor AJ-3
AB Terminal 2 Alternator (terminal B) AH-9
AC01 YAZAKI 10 Air conditioner unit X-5
AC02 X 4 Air conditioner unit X-7
AC03 X 1 Air conditioner compressor solenoid clutch AF-5
AIR(AMB.AIR
― 3 Ambient pressure sensor AI-1
PRESSURE)
BOOST
(BOOST SUMITOMO 4 Boost pressure and boost temperature sensor AJ-1
PRESS & IMT)
CAM(CAM
FRAMATOME 3 Engine Bkup speed sensor AE-1
SENSOR)
CC01 70 14 ID key authorization controller ―
CE03 DRC 40 Engine controller AE-2
CK01 AMP 14 KOMTRAX communication module X-7
CK02 AMP 10 KOMTRAX communication module X-6
CM01 70 18 Machine monitor O-6
CP01 AMP 81 Pump controller V-9
CP02 AMP 40 Pump controller W-9
COOLANT Engine coolant temperature sensor
DELPHI 2 AE-4
TEMP
COMMON
RAIL Common rail pressure sensor
BOSCH 3 AI-5
PRESSURE
SENSOR
CRANK
(CRANK ― 3 Engine Ne speed sensor AE-1
SENSOR)
D01 SWP 8 Diode array M-9
D02 SWP 8 Diode array M-9
D03 SWP 8 Diode array N-9
D04 SWP 8 Diode array ―
E01 Terminal 1 Electrical intake air heater (ribbon heater) AE-3
E08 X 1 Intermediate connector AE-6
E10 D 1 Intermediate connector AE-6
E12 ― 3 Alternator (terminals IG and L) AH-9
E24 FRAMATOME 24 Intermediate connector AH-1
ECM J1 DRC26 60 Engine controller AE-3
ECM J2 DRC26 60 Engine controller AF-1
EGR SUMITOMO 8 EGR valve AG-5
EXHAUST Exhaust gas temperature sensor
FRAMATOME 2 AG-5
GAS TEMP
EXHAUST Exhaust manifold pressure
FRAMATOME 3 AH-5
PRESS.
HB215LC-2 40-53
40 Troubleshooting
Number
of pins
F01 ― ― Fuse box T-9
F04 L 2 Fusible link (65 A) A-9
F05 M 2 Fusible link (30 A) D-8
F11 1 Slow blow fuse C-9
F12 1 Slow blow fuse C-9
GM01 DT 8 Engine built-in generator I-9
GM02 ― 3 Engine built-in generator J-9
GM03 ― 3 Engine built-in generator J-9
GT5 ― 1 GPS antenna terminal ―
H08 M 4 Intermediate connector X-4, AD-4
H09 M 8 Intermediate connector X-4, AD-4
H14 Y090 22 Intermediate connector S-9
H15A DT 12 Intermediate connector (R.H. console) T-9
H15B DT 12 Intermediate connector (R.H. console) T-9
H16 S 22 Intermediate connector X-3
HB01 ― 2 Capacitor L-4
HC01 DRC 24 Inverter L-5
HC02 DRC 64 Inverter L-5
HC03 ― 3 Inverter L-6
HH05 DT 4 Intermediate connector (for service) X-8
HK01 DT 2 Capacitor L-3
HK05 DT 3 CAN terminating resistor L-7
HP01 DT 12 Capacitor L-4
HP04 AMP 3 Swing (left) pressure sensor K-9
HP06 AMP 3 Swing (right) pressure sensor K-9
INLET
METERING BOSCH 2 INLET METERING VALVE AI-1
VALVE
INJ1 DT 2 Injector #1&2 AE-5
INJ2 DT 2 Injector #3&4 AH-5
J01 ― 20 Junction connector (black) X-3
J02 ― 20 Junction connector (black) W-3
J03 ― 20 Junction connector (green) W-2
J04 ― 20 Junction connector (green) X-5
J05 ― 20 Junction connector (pink) X-6
J06 ― 20 Junction connector (orange) X-6
K01 M 2 Pump (PC) resistor M-6
K02 DT 3 CAN termination AG-1
K04 DT 2 Horn relay dummy resistance (200 Ω) X-8
L01 DT 2 Working lamp (boom) E-8
L02 DT 2 Working lamp (R.H.) E-1
L03 M 2 Room lamp AA-8 T-9
L05 SWP 2 Intermediate connector (revolving warning lamp) AC-9
L09 DT 2 Rear working lamp I-9
L15 SWP 2 Revolving warning lamp
L19 ― 2 System operating lamp A-7
M01 PA 9 Radio V-2
M02 M 2 Speaker (L.H.) AD-8
M03 M 2 Speaker (L.H.) AC-9
40-54 HB215LC-2
40 Troubleshooting
Number
of pins
M04 ― 2 Cigarette lighter S-9
M05 M 6 Wiper motor O-5
M06 YAZAKI 2 Window washer motor L-3
M07 90 2 Horn (treble tone) H-1
M08 90 2 Horn (bass tone) G-1
M09 M 2 Optional power supply connector (1) X-3
M10 M 2 Optional power supply connector (2) X-5
M11 DT 6 DC/DC converter ―
M12 M 2 Optional power supply connector (12 V) ―
M14 D 2 Travel alarm ―
Headlamp [for the headlamp installed
M40 X 2 specification] Z-8
Headlamp [for the headlamp installed
M41 X 2 specification] Y-7
M1A M 2 Continuous power supply (if equipped) ―
M13A M 2 12 V socket ―
M13B M 2 12 V socket ―
N08 D 12 Service connector N-9
O.P.S(OIL
PRESSURE FRAMATOME 2 Engine oil pressure switch (low pressure) AE-2
SWITCH)
P01 AMP 3 Bucket CURL PPC pressure sensor A-4
P02 AMP 3 Boom LOWER PPC oil pressure switch A-4
P03 AMP 3 Swing left pressure sensor A-2
P04 AMP 3 Arm IN pressure sensor A-3
P05 AMP 3 Bucket DUMP PPC pressure sensor A-3
P06 AMP 3 Boom RAISE PPC pressure sensor A-3
P07 AMP 3 Swing right pressure sensor C-3 A-4
P08 X 2 Arm OUT PPC pressure sensor A-2
P09 AMP 3 L.H. travel FORWARD pressure sensor Q-1
P10 AMP 3 L.H. travel REVERSE pressure sensor Q-1
P11 AMP 3 R.H. travel FORWARD pressure sensor ―
P12 AMP 3 R.H. travel REVERSE pressure sensor ―
Intermediate connector (service pressure
P13 X 2 switch) O-4
P14 X 2 Service PPC oil pressure switch (OP) P-1
P15 X 2 Service PPC oil pressure switch (OP) P-1
P17 S090 2 Air conditioner high- and low-pressure switch V-2
P18 S090 2 Air conditioner outside air temperature sensor L-7
P20 M 3 Fuel control dial P-8
P21 X 1 Fuel level sensor G-9
P22 D 2 Hydraulic oil temperature sensor AJ-1
P23 X 2 Air cleaner clogging sensor 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 J-9
P27 DT 3 Front pump swash plate sensor AI-5
P28 DT 3 Rear pump swash plate sensor AJ-5
P31 ― 2 Air conditioner sunlight sensor O-6
P44 DT 2 Engine oil temperature sensor AF-6
P47 DT 2 Water-in-fuel sensor AJ-4
P49 AMP 3 Service pressure sensor AJ-3
P55 FRAMATOME 3 MAF sensor L-8
HB215LC-2 40-55
40 Troubleshooting
Number
of pins
P57 FRAMATOME 3 CRANK CASE PRESSURE SENSOR AJ-4
PM01 DT 12 Swing motor ―
PM02 ― 3 Swing motor G-9
R01 Terminal 1 Battery relay (terminal E) C-7
R02 Terminal 1 Battery relay (terminal BR) D-9
R03 Terminal 1 Battery relay (terminal M) A-8
R04 Terminal 1 Battery relay (terminal B) A-9
R05 Relay 5 Lamp relay U-9
R06 Relay 5 Starting motor cut-off relay (PPC lock) V-9
R07 Relay 5 Starting motor cut-off relay (personal code) W-9
R08 Relay 5 Horn relay U-9
Rear light relay [for the rear light installed
R10 Relay 5 U-9
specification]
Cab light relay [for the cab light installed
R12 Relay 5 U-9
specification]
R15 Relay 1 Ribbon heater relay A-8
R16A Relay 1 Ribbon heater relay A-7
R16B Relay 1 Ribbon heater relay B-7
R17 DT 2 Starting motor safety relay (terminals S and R) D-9
R18 Relay 5 Relay for automatic pre-heater W-9
R21 Relay 5 Air conditioner compressor relay X-7
R28 Terminal 1 Starting motor safety relay (terminal C) D-8
R29 Terminal 1 Starting motor safety relay (terminal B) ―
R43 Relay 5 AIS operation relay (BR signal) N-9
S01 Terminal 6 Starting switch P-7
S02 SWP 6 Daytime light switch Q-8
S04 SWP 6 Swing lock switch Q-8
Revolving warning lamp switch [for the revolving
S07 SWP 6 warning lamp installed specification] Q-8
S10 2 R.H. knob switch P-8
S11 Y090 2 L.H. knob switch U-1
S14 M 3 PPC oil pressure lock switch V-2
S18 SWP 6 Engine shutdown secondary switch T-1
S19 DT 2 Seat belt fastened SW S-9
S21 ― 12 Emergency pump drive switch ―
S22 ― 6 Swing parking brake cancel switch ―
S23 ― 6 Hybrid system stop switch ―
S25 90 8 Intermediate connector O-9
S30 S 8 Model selection connector V-9
SB Terminal 2 Starting motor (terminal B) AE-7
SC Terminal 1 Starting motor (C terminal) AE-7
T01 Terminal 1 Floor frame ground W-2
T02 Terminal 1 Cab ground W-2
T04 Terminal 1 Revolving frame ground S-1
T05 Terminal 1 Revolving frame ground T-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
T12 Terminal 1 Engine cylinder block ground AG-1
T13A Terminal 1 Relay block ground A-2
40-56 HB215LC-2
40 Troubleshooting
Number
of pins
T13B Terminal 1 Revolving frame ground A-1
T14 Terminal 1 CAB ground ―
T15 Terminal 1 Revolving frame ground ―
T16 Terminal 1 Ground K-2
T18 Terminal 1 Floor frame ground ―
T19 Terminal 1 Right console frame ground ―
TERMINA- CAN terminating resistor ―
DT 3
TORPORT
V01 DT 2 PPC lock solenoid valve K-2
V02 DT 2 2-stage relief solenoid valve J-2
V03 DT 2 Swing parking brake solenoid valve K-2
V04 DT 2 Travel speed selector solenoid valve H-9
V05 DT 2 Travel junction solenoid valve K-2
Attachment return selector solenoid valve [for
V06 DT 2 the attachment installed specification] H-9
V11 D 2 F-PC-EPC valve AJ-3
V12 D 2 R-PC-EPC valve AJ-2
V19 D 2 LS-EPC valve AJ-2
V23 D 2 Merge-divider EPC valve (main) I-9
V24 D 2 Merge-divider EPC valve (LS) I-9
V25 D 2 Variable back pressure solenoid valve ―
Attachment flow adjustment EPC valve [for the
V30 DT 2 attachment installed specification] O-3
VFT - 8 Intermediate connector AE-5
W03 M 2 Rear limit switch for window AC-9
CAM Cam (Bkup) speed sensor
FRAMATOME 3 AE-1
RESISTOR
HB215LC-2 40-57
40 Troubleshooting
Layout of connectors (1/6)
40-58 HB215LC-2
40 Troubleshooting
(2/6)
HB215LC-2 40-59
40 Troubleshooting
(3/6)
40-60 HB215LC-2
40 Troubleshooting
(4/6)
HB215LC-2 40-61
40 Troubleshooting
(5/6)
40-62 HB215LC-2
40 Troubleshooting
(6/6)
HB215LC-2 40-63
40 Troubleshooting
Connector contact identification (ALL-5310-030-A-00-A)
(Rev. 2012. 09)
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.
40-64 HB215LC-2
40 Troubleshooting
HB215LC-2 40-65
40 Troubleshooting
40-66 HB215LC-2
40 Troubleshooting
HB215LC-2 40-67
40 Troubleshooting
40-68 HB215LC-2
40 Troubleshooting
HB215LC-2 40-69
40 Troubleshooting
40-70 HB215LC-2
40 Troubleshooting
HB215LC-2 40-71
40 Troubleshooting
40-72 HB215LC-2
40 Troubleshooting
HB215LC-2 40-73
40 Troubleshooting
40-74 HB215LC-2
40 Troubleshooting
HB215LC-2 40-75
40 Troubleshooting
40-76 HB215LC-2
40 Troubleshooting
HB215LC-2 40-77
40 Troubleshooting
40-78 HB215LC-2
40 Troubleshooting
HB215LC-2 40-79
40 Troubleshooting
40-80 HB215LC-2
40 Troubleshooting
HB215LC-2 40-81
40 Troubleshooting
40-82 HB215LC-2
40 Troubleshooting
HB215LC-2 40-83
40 Troubleshooting
40-84 HB215LC-2
40 Troubleshooting
HB215LC-2 40-85
40 Troubleshooting
40-86 HB215LC-2
40 Troubleshooting
HB215LC-2 40-87
40 Troubleshooting
40-88 HB215LC-2
40 Troubleshooting
HB215LC-2 40-89
40 Troubleshooting
40-90 HB215LC-2
40 Troubleshooting
HB215LC-2 40-91
40 Troubleshooting
40-92 HB215LC-2
40 Troubleshooting
HB215LC-2 40-93
40 Troubleshooting
40-94 HB215LC-2
40 Troubleshooting
HB215LC-2 40-95
40 Troubleshooting
40-96 HB215LC-2
40 Troubleshooting
HB215LC-2 40-97
40 Troubleshooting
40-98 HB215LC-2
40 Troubleshooting
HB215LC-2 40-99
40 Troubleshooting
40-100 HB215LC-2
40 Troubleshooting
HB215LC-2 40-101
40 Troubleshooting
T-branch box and T-branch adapter table (ALL-5330-305-A-00-A)
(Rev. 2012. 09)
a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Identification symbol
Number of pins
Out of kit
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
Part number Part name
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
799-601-3470 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
ECONO
799-601-2750 Adapter for ECONO 2 q q
2P
ECONO
3P
ECONO
4P
ECONO
8P
ECONO
12P
799-601-2810 Adapter for DLI 8 DLI-8P q q
Extension cable (ECONO ECONO
799-601-2840 type) 12 q q q
12P
799-601-2850 Case q
T-box (for DRC60, q
799-601-4350 ECONO) 60
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
40-102 HB215LC-2
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
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

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
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 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
HB215LC-2 40-103
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
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
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
799-601-9310 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- q q
T2)
799-601-9420 Adapter for engine (CRI- 3 A3
T3) PFUEL
Oil pressure sensor
Socket for engine (CRI-T2) q q
799-601-9430* Socket for engine(CRI-T3) 2 P
PCV
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) q q
795-799-5530* Socket for engine (CRI-T3) 2 C
Temperature sensor
Socket for engine (HPI-T2) q q
795-799-5540* Socket for engine(CRI-T3) 2 A
TIM
795-799-5460 Cable for engine (HPI-T2) 3 q
Adapter for engine (140-T3) q q
799-601-4110 4 ITT3N
PIM
799-601-4130 T3) NE, CAM 3 FCIN
799-601-4140 T3) 3 FCIG
Ambient pressure
40-104 HB215LC-2
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
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

799-601-4150 T3) POIL 3 FCIB
799-601-4160 T3) 2 4160
Oil pressure switch
799-601-4180 T3) PEVA 3 4180
799-601-4190* 3 1, 2, 3L
Rail pressure
1, 2, 3,
799-601-4230* Air intake pressure/ 4
4C
temperature
799-601-4240* 3 1, 2, 3A
PAMB
799-601-4250* 3 1, 2, 3B
PIM
Socket for engine (CRI-T3) 1, 2, 3, q q
799-601-4330* 3
G G
799-601-4340* 2 2, PA
Pump actuator
Socket for engine (CRI-T3)
(95) 1, 2, 3,
799-601-4380* 4 q
Air intake pressure/ 4T
temperature
Adapter for controller q q
799-601-4260 (ENG) 4 DTP4
Adapter for controller q
799-601-4211 (ENG) 50 DRC50
Adapter for controller q
799-601-4220 (ENG) 60 DRC60
Socket for controller (95
799-601-4390* ENG) 60 q
799-601-4280* Box for controller (PUMP) 12- q

1
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,
Multi-adapter for pins DT2
799-601-9890 3, q
to 4 and DTM2
4
*: Shows not T-adapter but socket.
HB215LC-2 40-105
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-A65-4600
799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 q

KDPF delta pressure sensor
799T-601-4611 4 799T-601-4611 q
short connector
KDPF outlet pressure sensor
799T-601-4670 4 799T-601-4670 q
short connector
KDPF dummy temperature
799T-601-4680 4 799T-601-4680 q
sensor
40-106 HB215LC-2
40 Troubleshooting
Fuse location table (HB205-5530-04D-A-00-A)

Connection table of fuse box
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 which is supplied while the starting switch is in ON position and an
unswitched power supply is the power which is supplied 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
power supply to Fuse No. Destination of power
capacity
supply fuse
Light relay, rear light relay, cab light relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
[When emergency pump drive switch is operated]
1 5A
Swing parking brake solenoid valve
[When swing parking brake cancel switch is operated]
Hybrid system stop switch
Pump controller (Solenoid power supply), inverter (power
2 30 A supply for load)
PPC oil pressure lock solenoid valve
Fusible link 3 5A Starting motor cut-off relay (PPC lock)
Switched F04 (65 A) Starting motor cut-off relay (personal code)
power
supply 4 10 A Window washer motor, cigarette lighter
5 10 A Horn, horn relay
6 5A Heater relay, electric intake air heater relay
7 10 A Revolving warning lamp (if equipped)
8 10 A Radio, speaker, left knob switch (pump controller input)
9 20A Headlamp (if equipped), rear lamp (if equipped)
10 20 A Air conditioner unit, air conditioner compressor
11 10 A Optional power supply (1)
12 20 A Optional power supply (2), power supply of 12 V
Starting 13 5A Air conditioner controller power supply
switch 14 5A Starting switch, engine shutdown secondary switch
15 10 A Working lamp
16 10 A Radio backup, room lamp, system operating lamp
Continu- Machine monitor, pump controller, inverter
Fusible link 17 20 A
ous power
F05 (30 A) 18 30 A Engine controller
supply
19 5A Air conditioner controller backup
20 10 A Optional power supply (continuous power supply)
Locations of fusible links
HB215LC-2 40-107
40 Troubleshooting
* 2 fusible links (F04) and (F05) are installed at the front side of the battery case.
Locations of fuse boxes and fuse No.
40-108 HB215LC-2
40 Troubleshooting
Failure codes table (HB205-5520-441-A-01-A)

Applicable History
Failure Failure (Displayed on screen) Action
compo- category Remarks
code level
nent
Failure code [879AKA] A/C Inner Sensor Open Electrical See in "80
879AKA Circuit(PAGE 40-120) MON ―
system Appendix."
Failure code [879AKB] A/C Inner Sensor Short Electrical See in "80
879AKB Circuit(PAGE 40-121) MON ―
system Appendix."
Failure code [879BKA] A/C Outer Sensor Open Electrical See in "80
879BKA Circuit(PAGE 40-122) MON ―
system Appendix."
Failure code [879BKB] A/C Outer Sensor Short Electrical See in "80
879BKB Circuit(PAGE 40-123) MON ―
system Appendix."
Failure code [879CKA] Ventilating Sensor Open Electrical See in "80
879CKA Circuit(PAGE 40-124) MON ―
system Appendix."
Failure code [879CKB] Ventilating Sensor Short Electrical See in "80
879CKB Circuit(PAGE 40-125) MON ―
system Appendix."
Failure code [879DKZ] Sunlight Sensor Open or Electrical See in "80
879DKZ Short Circuit(PAGE 40-126) MON ―
system Appendix."
Failure code [879EMC] Ventilation Damper Electrical See in "80
879EMC Abnormality(PAGE 40-127) MON L01 system Appendix."
Failure code [879FMC] Air Mix Damper Electrical See in "80
879FMC Abnormality(PAGE 40-128) MON L01 system Appendix."
Failure code [879GKX] Refrigerant Abnormality Electrical See in "80
879GKX (PAGE 40-129) MON L01 system Appendix."
Failure code [989L00] Engine Controller Lock Electrical
989L00 Caution1(PAGE 40-130) MON ―
system
Failure code [989M00] Engine Controller Lock Electrical
989M00 Caution2(PAGE 40-131) MON ―
system
Failure code [989N00] Engine Controller Lock Electrical
989N00 Caution3(PAGE 40-132) MON ―
system
Failure code [A900FR] Abrupt Engine Stop by Mechanical
A900FR Auto Idle Stop 3(PAGE 40-133) MON L03 system
Failure code [A900N6] Abrupt Engine Stop by Mechanical
A900N6 Auto Idle Stop 1(PAGE 40-134) MON ―
system
Failure code [A900NY] Abrupt Engine Stop by Mechanical
A900NY Auto Idle Stop 2(PAGE 40-135) MON L01 system
Failure code [AA10NX] Air Cleaner Clogging Mechanical
AA10NX (PAGE 40-136) MON L01 system
Failure code [AB00KE] Charge Voltage Low Mechanical
AB00KE (PAGE 40-138) MON L03 system
Failure code [B@BAZG] Eng Oil Press Low Mechanical
B@BAZG ENG L03
(PAGE 40-140) system
Failure code [B@BAZK] Eng Oil Level Low Mechanical
B@BAZK MON L01
B@BCN- Failure code [B@BCNS] Eng Water Overheat Mechanical
(PAGE 40-142) ENG L02 system
S
Failure code [B@BCZK] Eng Water Level Low Mechanical
B@BCZK MON L01
B@HAN- Failure code [B@HANS] Hyd Oil Overheat Mechanical
(PAGE 40-145) PUMP L02 system
S
Failure code [CA115] Eng Ne and Bkup Speed Electrical
CA115 Sens Error(PAGE 40-146) ENG L04 system
Failure code [CA122] Chg Air Press Sensor High Electrical
CA122 Error(PAGE 40-147) ENG L03 system
Failure code [CA123] Chg Air Press Sensor Low Electrical
Failure code [CA131] Throttle Sensor High Error Electrical
CA131 (PAGE 40-151) ENG L03 system
HB215LC-2 40-109
40 Troubleshooting
Applicable History
code level
nent
Failure code [CA132] Throttle Sensor Low Error Electrical
Failure code [CA144] Coolant Temp Sens High Electrical
Failure code [CA145] Coolant Temp Sens Low Electrical
Failure code [CA153] Chg Air Temp Sensor High Electrical
Failure code [CA154] Chg Air Temp Sensor Low Electrical
Failure code [CA187] Sensor 2 Supply Volt Low Electrical
Failure code [CA221] Ambient Press Sensor Electrical
CA221 High Error(PAGE 40-165) ENG L03 system
Failure code [CA222] Ambient Press Sens Low Electrical
Failure code [CA227] Sensor 2 Supply Volt High Electrical
Failure code [CA234] Eng Overspeed(PAGE 40- Electrical
CA234 170) ENG L02 system
Failure code [CA238] Ne Speed Sensor Supply Electrical
CA238 Volt Error(PAGE 40-171) ENG L01 system
Failure code [CA239] Ne Speed Sens Supply Electrical
CA239 Volt High Error(PAGE 40-172) ENG L01 system
Failure code [CA271] IMV/PCV1 Short Error Electrical
Failure code [CA272] IMV/PCV1 Open Error Electrical
Failure code [CA295] Ambient Press Sens In Electrical
CA295 Range Error(PAGE 40-177) ENG L03 system
Failure code [CA322] Inj #1(L#1) Open/Short Electrical
Failure code [CA343] ECM Critical Internal Electrical
CA343 Failure(PAGE 40-186) ENG L04 system
Failure code [CA351] Injectors Drive Circuit Electrical
Failure code [CA356] Mass Air Flow Sensor Electrical
Failure code [CA357] Mass Air Flow Sensor Low Electrical
Failure code [CA386] Sensor 1 Supply Volt High Electrical
Failure code [CA428] Water in Fuel Sensor High Electrical
Failure code [CA429] Water in Fuel Sensor Low Electrical
40-110 HB215LC-2
40 Troubleshooting
Applicable History
code level
nent
Failure code [CA435] Eng Oil Press Sw Error Electrical
Failure code [CA441] Battery Voltage Low Error Electrical
Failure code [CA442] Battery Voltage High Error Electrical
Failure code [CA449] Rail Press Very High Error Electrical
Failure code [CA451] Rail Press Sensor High Electrical
Failure code [CA452] Rail Press Sensor Low Electrical
Failure code [CA466] KVGT Motor Driver Electrical
CA466 Position Error(PAGE 40-208) ENG L03 system
Failure code [CA488] Chg Air Temp High Torque Electrical
CA488 Derate(PAGE 40-210) ENG L03 system
Failure code [CA515] Rail Press Sens Sup Volt Electrical
Failure code [CA516] Rail Press Sens Sup Volt Electrical
CA516 Low Error(PAGE 40-213) ENG L03 system
Failure code [CA553] Rail Press High Error Electrical
Failure code [CA555] Crankcase Press High Electrical
CA555 Error 1(PAGE 40-216) ENG L01 system
Failure code [CA556] Crankcase Press High Electrical
Failure code [CA559] Rail Press Low Error Electrical
Failure code [CA689] Eng Ne Speed Sensor Electrical
Failure code [CA691] Intake Air Temp Sens High Electrical
Failure code [CA692] Intake Air Temp Sens Low Electrical
Failure code [CA697] ECM Internal Temp Electrical
CA697 Sensor High Error(PAGE 40-226) ENG L01 system
Failure code [CA698] ECM Int Temp Sensor Low Electrical
Failure code [CA731] Eng Bkup Speed Sens Electrical
CA731 Phase Error(PAGE 40-228) ENG L01 system
Failure code [CA778] Eng Bkup Speed Sensor Electrical
Failure code [CA1117] Persistent Data Lost Error Electrical
Failure code [CA1695] Sensor 5 Supply Volt Electrical
Failure code [CA1843] Crankcase Press Sens Electrical
Failure code [CA1844] Crankcase Press Sens Electrical
Failure code [CA1896] EGR Valve Stuck Error Electrical
HB215LC-2 40-111
40 Troubleshooting
Applicable History
code level
nent
Failure code [CA1942] Crankcase Press Sens In Electrical
Failure code [CA1961] EGR_Motor Driver IC Electrical
CA1961 Over Temp Error(PAGE 40-241) ENG L03 system
Failure code [CA2185] Throt Sensor Sup Volt Electrical
Failure code [CA2186] Throt Sensor Sup Volt Electrical
Failure code [CA2249] Rail Press Very Low Electrical
Failure code [CA2272] EGR Valve Pos Sens Electrical
Failure code [CA2311] IMV Solenoid Error Electrical
Failure code [CA2349] EGR Valve Solenoid Electrical
CA2349 Open Error(PAGE 40-250) ENG L03 system
Failure code [CA2353] EGR Valve Solenoid Electrical
CA2353 Short Error(PAGE 40-252) ENG L03 system
Failure code [CA2357] EGR Valve Servo Error Electrical
Failure code [CA2373] Exhaust Manifold Press Electrical
CA2373 Sens High Error(PAGE 40-255) ENG L03 system
Failure code [CA2374] Exhaust Manifold Press Electrical
CA2374 Sens Low Error(PAGE 40-257) ENG L03 system
Failure code [CA2375] EGR Orifice Temp Sens Electrical
Failure code [CA2376] EGR Orifice Temp Sens Electrical
Failure code [CA2554] Exh Manifold Press Sens Electrical
CA2554 In Range Error(PAGE 40-264) ENG L03 system
Failure code [CA2555] Grid Htr Relay Volt Low Electrical
Failure code [CA2556] Grid Htr Relay Volt High Electrical
Failure code [CA2961] EGR Orifice Temp High Electrical
Failure code [CA2973] Chg Air Press Sensor In Electrical
CA3419 Sup Volt High Error(PAGE 40-271) ENG L03 system
CA3421 Sup Volt Low Error(PAGE 40-273) ENG L03 system
Failure code [CA3724] EGR/KVGT Motor Driver Electrical
CA3724 Power Low Error(PAGE 40-275) ENG L03 system
Failure code [CA3918] KVGT Stuck Error(PAGE Electrical
CA3918 40-278) ENG L03 system
Failure code [CA3919] KVGT Motor Driver IC Electrical
CA3919 Over Temp Error(PAGE 40-279) ENG L03 system
Failure code [CA3921] KVGT Servo Error 2 Electrical
Failure code [CA3922] KVGT Motor Driver Open Electrical
Failure code [CA3923] KVGT Motor Driver Short Electrical
40-112 HB215LC-2
40 Troubleshooting
Applicable History
code level
nent
Failure code [D110KB] Battery Relay Drive Short Electrical
D110KB Circuit(PAGE 40-285) PUMP L01 system
Failure code [D19JKZ] Personal Code Relay Electrical
D19JKZ Abnormality(PAGE 40-287) MON L03 system
Failure code [D811MC] KOMTRAX Error(PAGE KOM- Electrical
D811MC 40-290) ―
TRAX system
Failure code [D862KA] GPS Antenna Open KOM- Electrical
D862KA Circuit(PAGE 40-291) ―
TRAX system
Failure code [D8ALKA] Operating Lamp Open KOM- Electrical
D8ALKA Circuit (KOMTRAX)(PAGE 40-292) ―
TRAX system
Failure code [D8ALKB] Operating Lamp Short KOM- Electrical
D8ALKB Circuit (KOMTRAX)(PAGE 40-294) ―
TRAX system
Failure code [D8AQKR] CAN2 Discon Electrical
D8AQKR (KOMTRAX)(PAGE 40-295) MON ―
system
Failure code [DA20MC] Pump Controller Electrical
DA20MC Malfunction(PAGE 40-296) PUMP ―
system
Failure code [DA22KK] Pump Solenoid Power Electrical
DA22KK Low Error(PAGE 40-297) PUMP L03 system
Failure code [DA25KP] 5V Sensor 1 Power Electrical
DA25KP Abnormality(PAGE 40-299) PUMP ―
system
Failure code [DA26KP] 5V Sensor 2 Power Electrical
DA26KP Abnormality(PAGE 40-301) PUMP ―
system
Failure code [DA29KQ] Model Selection Electrical
DA29KQ Abnormality(PAGE 40-303) PUMP L01 system
Failure code [DA2LKA] Operating Lamp Open Electrical
DA2LKA Circuit (Pump Con)(PAGE 40-305) PUMP ―
system
Failure code [DA2LKB] Operating Lamp Short Electrical
DA2LKB Circuit (Pump Con)(PAGE 40-307) PUMP ―
system
Failure code [DA2QKR] CAN2 Discon (Pump Electrical
DA2QKR Con)(PAGE 40-308) MON L03 system
Failure code [DA2RKR] CAN1 Discon (Pump Electrical
DA2RKR Con)(PAGE 40-311) MON L04 system
Failure code [DAF0MB] Monitor ROM Electrical
DAF0MB Abnormality(PAGE 40-312) MON ―
system
Failure code [DAF0MC] Monitor Error(PAGE 40- Electrical
DAF0MC 313) MON ―
system
Failure code [DAF8KB] Camera Power Supply Electrical
DAF8KB Short Circuit(PAGE 40-314) MON L03 system
Failure code [DAF9KQ] Model Selection Electrical
DAF9KQ Abnormality(PAGE 40-316) MON L03 system
Failure code [DAFGMC] GPS Module Error KOM- Electrical
DAFGMC (PAGE 40-317) ―
TRAX system
Failure code [DAFLKA] Operating Lamp Open Electrical
DAFLKA Circuit (Monitor)(PAGE 40-318) MON ―
system
Failure code [DAFLKB] Operating Lamp Short Electrical
DAFLKB Circuit (Monitor)(PAGE 40-320) MON ―
system
Failure code [DAFQKR] CAN2 Discon (Monitor) KOM- Electrical
DAFQKR (PAGE 40-321) ―
TRAX system
Failure code [DAZ9KQ] A/C Model Selection Electrical
DAZ9KQ Abnormality(PAGE 40-322) MON ―
system
Failure code [DAZQKR] CAN2 Discon (Aircon Electrical
DAZQKR ECU)(PAGE 40-323) MON L01 system
Failure code [DB2QKR] CAN2 Discon (Engine Electrical
DB2QKR Con)(PAGE 40-327) MON L03 system
HB215LC-2 40-113
40 Troubleshooting
Applicable History
code level
nent
Failure code [DB2RKR] CAN1 Discon (Engine Electrical
DB2RKR Con)(PAGE 40-332) MON L04 system
Failure code [DGH2KB] Hyd Oil Sensor Short Electrical
DGH2KB Circuit(PAGE 40-338) PUMP L01 system
Failure code [DHA4KA] Air Cleaner Clog Sensor Electrical
DHA4KA Open Circuit(PAGE 40-340) MON L01 system
Failure code [DHPAMA] F Pump Press Sensor Electrical
DHPAMA Abnormality(PAGE 40-341) PUMP L01 system
Failure code [DHPBMA] R Pump Press Sensor Electrical
DHPBMA Abnormality(PAGE 40-344) PUMP L01 system
Failure code [DHS3MA] Arm Curl PPC Press Electrical
DHS3MA Sensor Abnormality(PAGE 40-347) PUMP L01 system
Failure code [DHS4MA] Bucket Curl PPC Press Electrical
Failure code [DHS8MA] Boom Raise PPC Press Electrical
Failure code [DHS9MA] Boom Lower PPC Press Electrical
Failure code [DHSAKZ] Swing RH PPC Press Electrical
DHSAKZ Sensor Abnormality(PAGE 40-355) PUMP L03 system
Failure code [DHSBKZ] Swing LH PPC Press Electrical
DHSBKZ Sensor Abnormality(PAGE 40-357) PUMP L03 system
Failure code [DHSCMA] Arm Dump PPC Press Electrical
DHSCMA Sensor Abnormality(PAGE 40-359) PUMP L01 system
Failure code [DHSDMA] Bucket Dump PPC Electrical
DHSDMA Press Sensor Abnormality(PAGE 40-361) PUMP L01 system
Failure code [DHSFMA] Travel Fwd LH PPC Electrical
DHSFMA Press Sensor Abnormality(PAGE 40-363) PUMP L01 system
Failure code [DHSGMA] Travel Fwd RH PPC Electrical
DHSGMA Press Sensor Abnormality(PAGE 40-365) PUMP L01 system
Failure code [DHSHMA] Travel Rev LH PPC Electrical
DHSHMA Press Sensor Abnormality(PAGE 40-367) PUMP L01 system
Failure code [DHSJMA] Travel Rev RH PPC Electrical
DHSJMA Press Sensor Abnormality(PAGE 40-369) PUMP L01 system
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Electrical
DHVAKZ Sen. Opn/Short Cirt.(PAGE 40-371) HYB L03 system
Failure code [DHVAL8] HYB Swing-R PPC Pr. Electrical
DHVAL8 Sen. Signal Mismatch(PAGE 40-374) HYB L03 system
Failure code [DHVAMA] HYB Swing-R PPC Electrical
DHVAMA Sensor Malfunction(PAGE 40-375) HYB L03 system
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Electrical
DHVBKZ Sen. Opn/Short Cir.(PAGE 40-377) HYB L03 system
Failure code [DHVBL8] HYB Swing-L PPC Pr. Electrical
DHVBL8 Sen. Signal Mismatch(PAGE 40-379) HYB L03 system
Failure code [DHVBMA] HYB Swing-L PPC Electrical
DHVBMA Sensor Malfunction(PAGE 40-380) HYB L03 system
Failure code [DKR0MA] F Pump Swash Plate Electrical
DKR0MA Sensor Abnormality(PAGE 40-382) PUMP L01 system
Failure code [DKR1MA] R Pump Swash Plate Electrical
DKR1MA Sensor Abnormality(PAGE 40-385) PUMP L01 system
Failure code [DR21KX] Camera 2 Picture Rev. Electrical
DR21KX Drive Abnormality(PAGE 40-388) MON L01 system
Failure code [DR31KX] Camera 3 Picture Rev. Electrical
DR31KX Drive Abnormality(PAGE 40-390) MON L01 system
40-114 HB215LC-2
40 Troubleshooting
Applicable History
code level
nent
Failure code [DV20KB] Travel Alarm Short Electrical
DV20KB Circuit(PAGE 40-392) PUMP L01 system
Failure code [DW43KA] Travel Speed Sol Open Electrical
DW43KA Circuit(PAGE 40-394) PUMP L01 system
Failure code [DW43KB] Travel Speed Sol Short Electrical
DW43KB Circuit(PAGE 40-396) PUMP L01 system
Failure code [DW45KA] Swing Brake Sol Open Electrical
DW45KA Circuit(PAGE 40-398) HYB L03 system
Failure code [DW45KB] Swing Brake Sol Short Electrical
DW45KB Circuit(PAGE 40-401) HYB L03 system
Failure code [DW45KK] Swing Brake Sol. Valve Electrical
DW45KK Low Sup. Voltage(PAGE 40-404) HYB L03 system
Failure code [DW45KY] Swing Brake Sol. Val. Electrical
DW45KY Pow. Short Cir.(PAGE 40-406) HYB L03 system
Failure code [DW91KA] Travel Junction Sol Electrical
DW91KA Open Circuit(PAGE 40-408) PUMP L01 system
Failure code [DW91KB] Travel Junction Sol Electrical
DW91KB Short Circuit(PAGE 40-410) PUMP L01 system
Failure code [DWA2KA] Attachment Sol Open Electrical
DWA2KA Circuit(PAGE 40-412) PUMP L03 system
Failure code [DWA2KB] Attachment Sol Short Electrical
DWA2KB Circuit(PAGE 40-414) PUMP L03 system
Failure code [DWK0KA] 2-Stage Relief Sol Electrical
DWK0KA Open Circuit(PAGE 40-416) PUMP L01 system
Failure code [DWK0KB] 2-Stage Relief Sol Short Electrical
DWK0KB Circuit(PAGE 40-418) PUMP L01 system
Failure code [DWK2KA] Variable Back Press Sol Electrical
DWK2KA Open Circuit(PAGE 40-420) PUMP L01 system
Failure code [DWK2KB] Variable Back Press Sol Electrical
DWK2KB Short Circuit(PAGE 40-422) PUMP L01 system
Failure code [DXA8KA] PC-EPC (F) Sol Open Electrical
DXA8KA Circuit(PAGE 40-424) PUMP L03 system
Failure code [DXA8KB] PC-EPC (F) Sol Short Electrical
DXA8KB Circuit(PAGE 40-426) PUMP L03 system
Failure code [DXA9KA] PC-EPC (R) Sol Open Electrical
DXA9KA Circuit(PAGE 40-428) PUMP L03 system
Failure code [DXA9KB] PC-EPC (R) Sol Short Electrical
DXA9KB Circuit(PAGE 40-430) PUMP L03 system
Failure code [DXE0KA] LS-EPC Sol Open Electrical
DXE0KA Circuit(PAGE 40-432) PUMP L01 system
Failure code [DXE0KB] LS-EPC Sol Short Electrical
DXE0KB Circuit(PAGE 40-434) PUMP L01 system
Failure code [DXE4KA] Attachment Flow EPC Electrical
DXE4KA Open Circuit(PAGE 40-436) PUMP ―
system
Failure code [DXE4KB] Attachment Flow EPC Electrical
DXE4KB Short Circuit(PAGE 40-438) PUMP ―
system
Failure code [DXE5KA] Merge-divide Main Sol Electrical
DXE5KA Open Circuit(PAGE 40-440) PUMP L01 system
Failure code [DXE5KB] Merge-divide Main Sol Electrical
DXE5KB Short Circuit(PAGE 40-442) PUMP L01 system
Failure code [DXE6KA] Merge-divide LS Sol Electrical
DXE6KA Open Circuit(PAGE 40-444) PUMP L01 system
Failure code [DXE6KB] Merge-divide LS Sol Electrical
DXE6KB Short Circuit(PAGE 40-446) PUMP L01 system
HB215LC-2 40-115
40 Troubleshooting
Applicable History
code level
nent
Failure code [DY20KA] Wiper Working Electrical
DY20KA Abnormality(PAGE 40-448) PUMP ―
system
Failure code [DY20MA] Wiper Parking Electrical
DY20MA Abnormality(PAGE 40-450) PUMP ―
system
Failure code [DY2CKB] Washer Drive Short Electrical
DY2CKB Circuit(PAGE 40-452) PUMP ―
system
Failure code [DY2DKB] Wiper Drive (Fwd) Short Electrical
DY2DKB Circuit(PAGE 40-454) PUMP ―
system
Failure code [DY2EKB] Wiper Drive (Rev) Short Electrical
DY2EKB Circuit(PAGE 40-456) PUMP ―
system
Failure code [GA00NS] HYB Equipment Electrical
GA00NS Overheat(PAGE 40-492) HYB L02 system
Failure code [GA01KA] Power Cable Interlock Electrical
GA01KA Open Circuit(PAGE 40-493) HYB L03 system
Failure code [GA01KB] Power Cable Interlock Electrical
GA01KB Short Circuit(PAGE 40-495) HYB L03 system
Failure code [GA02KZ] DC Line Open & Short Electrical
GA02KZ Circuit(PAGE 40-497) HYB L04 system
Failure code [GA04KG] Abnormal DC HW Volt. Electrical
GA04KG Before Booster(PAGE 40-498) HYB L03 system
Failure code [GA05KG] Abnormal DC SW Volt. Electrical
GA05KG Before Booster(PAGE 40-499) HYB L03 system
Failure code [GA05KP] Low DC SW Output Volt. Electrical
GA05KP Bef. Booster(PAGE 40-500) HYB L03 system
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Electrical
GA06KZ Cir. Bef. Booster(PAGE 40-501) HYB L03 system
Failure code [GA08KG] Abnorm. DC HW Volt. Electrical
GA08KG After Booster(PAGE 40-502) HYB L03 system
Failure code [GA09KG] Abnorm. DC SW Volt. Electrical
GA09KG After Booster(PAGE 40-503) HYB L03 system
Failure code [GA09KP] Low DC SW Output Volt. Electrical
GA09KP After Booster(PAGE 40-504) HYB L03 system
Failure code [GA0AKZ] DC Vlt. Sen. Op./Shrt Electrical
GA0AKZ Cir. Aft. Booster(PAGE 40-505) HYB L03 system
Failure code [GA0BKZ] AC Line Open & Short Electrical
GA0BKZ Circuit(PAGE 40-506) HYB L04 system
Failure code [GA10MA] HYB Controller Electrical
GA10MA Malfunction(PAGE 40-507) PUMP L04 system
Failure code [GA10MC] HYB Controller Error Electrical
GA10MC (PAGE 40-508) HYB ―
system
Failure code [GA12NK] High-Voltage Line Start- Electrical
GA12NK up Failure(PAGE 40-509) HYB L03 system
Failure code [GA13KP] Low HYB Control. Sen. Electrical
GA13KP Power Sup.(PAGE 40-510) HYB L03 system
Failure code [GA13KY] HYB Control. Sen. Electrical
GA13KY Power Short Cir(PAGE 40-511) HYB L03 system
Failure code [GA15KZ] HYB Cont. Bad Insul. Electrical
GA15KZ Sen. Opn/Short. Cir(PAGE 40-512) HYB L03 system
Failure code [GA17KR] Gen. Mot. Drv. Electrical
GA17KR Communication Failure(PAGE 40-513) HYB L03 system
Failure code [GA17MB] Gen. Mot. Drv. Function Electrical
GA17MB Degraded(PAGE 40-514) HYB ―
system
Failure code [GA18MC] Gen. Mo.Dr. Excite. Electrical
GA18MC Pow. Sup. Failure(PAGE 40-515) HYB L03 system
40-116 HB215LC-2
40 Troubleshooting
Applicable History
code level
nent
Failure code [GA19KR] Gen. Motor Driver Sub- Electrical
GA19KR CPU Comm. Failure(PAGE 40-516) HYB L01 system
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Electrical
GA19KT Drv. Sub-CPU Con.(PAGE 40-517) HYB L03 system
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Electrical
GA1BMA Sens. Malfunction(PAGE 40-518) HYB L01 system
Failure code [GA1FKR] Swing Mot. Drv. Electrical
GA1FKR Communication Failure(PAGE 40-519) HYB L03 system
Failure code [GA1FMA] Abnormal Swing Motor Electrical
GA1FMA Driver(PAGE 40-520) HYB L03 system
Failure code [GA1GKR] Swg Mot. Driver Sub- Electrical
GA1GKR CPU Comm. Failure(PAGE 40-521) HYB L03 system
Failure code [GA1GKT] Swing Mot. Drv. Sub- Electrical
GA1GKT CPU Cont. Abnormal(PAGE 40-522) HYB L03 system
Failure code [GA1GMB] Swing Mot. Drv. Sub- Electrical
GA1GMB CPU Funct. Degraded(PAGE 40-523) HYB ―
system
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Electrical
GA1HKZ Sens Opn/Shrt Cir(PAGE 40-524) HYB L03 system
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Electrical
GA1JKZ Sens Opn/Shrt Cir(PAGE 40-525) HYB L03 system
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Electrical
GA1KKZ Sens Opn/Shrt Cir(PAGE 40-526) HYB L03 system
Failure code [GA1LKZ] Swg Mot. Dr. Current. Electrical
GA1LKZ Sens. Opn/Shrt Cir(PAGE 40-527) HYB L03 system
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Electrical
GA1MKZ Sen. Opn/Shrt Cir.(PAGE 40-528) HYB L03 system
Failure code [GA1NNS] Swing Motor Driver Electrical
GA1NNS IGBT Overheat(PAGE 40-529) HYB ―
system
Failure code [GA1SFS] Contactor Locked(PAGE Electrical
GA1SFS 40-530) HYB L03 system
Failure code [GA1SMC] Contactor Failure(PAGE Electrical
GA1SMC 40-531) HYB L03 system
Failure code [GA1TKP] Capacitor Low Output Electrical
GA1TKP Voltage(PAGE 40-532) HYB L03 system
Failure code [GA1TNS] Capacitor Overheat Electrical
GA1TNS (PAGE 40-533) HYB ―
system
Failure code [GA1UKZ] Capacitor Temp. Sensor Electrical
GA1UKZ Opn/short Cir.(PAGE 40-535) HYB L01 system
Failure code [GA1VFS] Capacitor Contactor Electrical
GA1VFS Locked(PAGE 40-537) HYB L03 system
Failure code [GA1VMC] Capacitor Contactor Electrical
GA1VMC Failure(PAGE 40-539) HYB L03 system
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Electrical
GA1XKZ Open/Shrt. Circ.(PAGE 40-540) HYB L01 system
Failure code [GA1YNS] Booster Inductor Electrical
GA1YNS Overheat(PAGE 40-541) HYB ―
system
Failure code [GA1ZKZ] Booster IGBT Temp. Electrical
GA1ZKZ Sens. Opn/Shrt. Circ.(PAGE 40-542) HYB L03 system
Failure code [GA1ZNS] Booster IGBT Temp. Electrical
GA1ZNS Sens. Overheat(PAGE 40-543) HYB ―
system
Failure code [GA22NS] Booster IGBT Junction Electrical
GA22NS Overheat(PAGE 40-544) HYB ―
system
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Electrical
GA23KZ Sen.0 Opn/Short Cir.(PAGE 40-545) HYB L01 system
HB215LC-2 40-117
40 Troubleshooting
Applicable History
code level
nent
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Electrical
GA24KZ Sen.1 Opn/Short Cir.(PAGE 40-546) HYB L01 system
Failure code [GA25MA] Gen. Motor Driver IGBT Electrical
GA25MA 0 Abnormality(PAGE 40-547) HYB L03 system
Failure code [GA25NS] Gen. Motor Driver IGBT Electrical
GA25NS 0 Overheat(PAGE 40-548) HYB ―
system
Failure code [GA26MA] Gen. Motor Driver IGBT Electrical
GA26MA 1 Abnormality(PAGE 40-549) HYB L03 system
Failure code [GA26NS] Gen. Motor Driver IGBT Electrical
GA26NS 1 Overheat(PAGE 40-550) HYB ―
system
Failure code [GA27KZ] DC Cur. Sens. Bef. Electrical
GA27KZ Booster Opn/Short Cir(PAGE 40-551) HYB L01 system
Failure code [GA2QKR] CAN2 Discon (Hyb Electrical
GA2QKR Con)(PAGE 40-552) MON L03 system
Failure code [GA2RKR] CAN1 Discon (Hyb Con) Electrical
GA2RKR (PAGE 40-554) MON L04 system
Failure code [GA60KZ] Generator Motor Open/ Electrical
GA60KZ Short Circuit(PAGE 40-555) HYB L01 system
Failure code [GA60MC] Generator Motor Failure Electrical
GA60MC (PAGE 40-556) HYB L03 system
Failure code [GA60N1] Generator Motor Electrical
GA60N1 Overrun(PAGE 40-558) HYB ―
system
Failure code [GA61KZ] Gen. Motor Temp. Sens. Electrical
GA61KZ Opn/Short Cir.(PAGE 40-559) HYB L01 system
Failure code [GA61NS] Generator Motor Temp. Electrical
GA61NS Sensor Overheat(PAGE 40-561) HYB ―
system
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Electrical
GA62KY Sen. Power Short Cir(PAGE 40-562) HYB L01 system
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Electrical
GA62KZ Sen. Open/Short Cir(PAGE 40-563) HYB L01 system
Failure code [GA62MA] Gen. Mot. Ph-A Current Electrical
GA62MA Sen. Malfunction(PAGE 40-564) HYB L03 system
Failure code [GA62MC] Gen. Mot. Ph-A Cur. Electrical
GA62MC Sen. Defect Op.(PAGE 40-565) HYB L01 system
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Electrical
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Electrical
Failure code [GA63MA] Gen. Mot. Ph-B Current Electrical
Failure code [GA63MC] Gen. Mot. Ph-B Cur. Electrical
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Electrical
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Electrical
Failure code [GA64MA] Gen. Mot. Ph-C Current Electrical
Failure code [GA64MC] Gen. Mot. Ph-C Cur. Electrical
Failure code [GA70KB] HYB Swing Motor Short Electrical
GA70KB Circuit(PAGE 40-574) HYB L03 system
Failure code [GA70MD] HYB Swing Motor Electrical
GA70MD Defective Stirr. Motion(PAGE 40-575) HYB L03 system
40-118 HB215LC-2
40 Troubleshooting
Applicable History
code level
nent
Failure code [GA70NS] HYB Swing Motor Electrical
GA70NS Overheat(PAGE 40-576) HYB ―
system
Failure code [GA71KZ] HYB Swing Mot. Temp. Electrical
GA71KZ Sens. Opn/Shrt Cir.(PAGE 40-577) HYB L01 system
Failure code [GA72MA] HYB Swing Motor Electrical
GA72MA Resolver Malfunction(PAGE 40-579) HYB L03 system
Failure code [GA72MC] HYB Swing Motor Electrical
GA72MC Resolver Defect Op.(PAGE 40-581) HYB L03 system
Failure code [GA81KZ] Swing Motor Power Electrical
GA81KZ Cable Opn/Shrt Circ.(PAGE 40-582) HYB L03 system
Failure code [GAA0KB] HYB Con. Battery Relay Electrical
GAA0KB Drive Short Cir.(PAGE 40-583) HYB L01 system
Failure code [GAA2KB] Swing Brake Sol. Supply Electrical
GAA2KB Line Short Cir.(PAGE 40-585) PUMP L03 system
Failure code [GAA6KP] Low HYB Control. Sen. Electrical
GAA6KP Power 2 Sup.(PAGE 40-587) HYB L03 system
Failure code [GAA6KY] HYB Control. Sen. Electrical
GAA6KY Power 2 Short Cir(PAGE 40-588) HYB L03 system
Failure code [GACLKA] Operating Lamp Open Electrical
GACLKA Circuit (HYB Con)(PAGE 40-589) HYB ―
system
Failure code [GACLKB] Operating Lamp Short Electrical
GACLKB Circuit (HYB Con)(PAGE 40-591) HYB ―
system
a In this table, failure codes are arranged in alphabetical order.

a Applicable component is the controller or machine monitor which checks the system.
MON: Machine monitor
ENG: Engine controller
PUMP: Pump controller
KOMTRAX: KOMTRAX terminal
HYB: Hybrid controller (inverter)
a The failure codes that do not have numbers in the action level columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system or mechanical system) of the service menu.
a History category means the classification of either electrical system or mechanical system which is used
for storage in the Failure History of the service menu.
For details, see "Troubleshooting by failure code (Display of code)".
HB215LC-2 40-119
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Troubleshooting by failure code (Display of code) (ALL-3840-001-A-00-A)
Failure code [879AKA] A/C Inner Sensor Open Circuit (PC220-879AKA-441-A-00-A)
See ”Failure code [879AKA] A/C Inner Sensor Open

Circuit” of Section 80 Appendix.
a Since connector of inside air temperature sensor
cannot be disconnected while air conditioner is
mounted on machine, air conditioner controller
or air conditioner unit must be replaced.
40-120 HB215LC-2
40 Troubleshooting
Failure code [879AKB] A/C Inner Sensor Short Circuit (PC220-879AKB-441-A-00-A)
See "Failure code [879AKB] A/C Inner Sensor Short

Circuit" of Section 80 Appendix.
a Since connector of inside air temperature sensor
HB215LC-2 40-121
40 Troubleshooting
Failure code [879BKA] A/C Outer Sensor Open Circuit (PC220-879BKA-441-A-00-A)
See "Failure code [879BKA] A/C Outer Sensor

Open Circuit" of Section 80 Appendix.
40-122 HB215LC-2
40 Troubleshooting
Failure code [879BKB] A/C Outer Sensor Short Circuit (PC220-879BKB-441-A-00-A)
See "Failure code [879BKB] A/C Outer Sensor

Short Circuit" of Section 80 Appendix.
HB215LC-2 40-123
40 Troubleshooting
Failure code [879CKA] Ventilating Sensor Open Circuit (PC220-879CKA-441-A-00-A)
See Chapter 80, Other items "Failure code

[879CKA] Ventilating Sensor Open Circuit".
a Since connector of ventilating sensor
(evaporator temperature sensor) cannot be
disconnected while air conditioner is mounted
on machine, air conditioner controller or air
conditioner unit must be replaced.
40-124 HB215LC-2
40 Troubleshooting
Failure code [879CKB] Ventilating Sensor Short Circuit (PC220-879CKB-441-A-00-A)
See "Failure code [879CKB] Ventilating Sensor

Short Circuit" of Section 80 Appendix.
a Since connector of ventilating sensor
(evaporator temperature sensor) cannot be
disconnected while air conditioner is mounted
on machine, air conditioner controller or air
conditioner unit must be replaced.
HB215LC-2 40-125
40 Troubleshooting
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit (PC220-879DKZ-441-A-

00-A)
See "Failure code [879DKZ] Sunlight Sensor Open

or Short Circuit" of Section 80 Appendix.
40-126 HB215LC-2
40 Troubleshooting
Failure code [879EMC] Ventilation Damper Abnormality (PC220-879EMC-441-A-00-A)
See "Failure code [879EMC] Ventilation Damper

Abnormality" of Section 80 Appendix.
a Since connector of vent changeover servomotor
HB215LC-2 40-127
40 Troubleshooting
Failure code [879FMC] Air Mix Damper Abnormality (PC220-879FMC-441-A-00-A)
See "Failure code [879FMC] Air Mix Damper

a Since the connector of air mix servo motor can
not be disconnected as long as it is installed on
the machine, change air conditioner controller or
air conditioner unit.
40-128 HB215LC-2
40 Troubleshooting
Failure code [879GKX] Refrigerant Abnormality (PC220-879GKX-441-A-00-A)
See "Failure code [879GKX] Refrigerant

HB215LC-2 40-129
40 Troubleshooting
Failure code [989L00] Engine Controller Lock Caution1 (PC200-989L00-400-A-00-A)
Action Engine controller lock caution 1

Failure code
level Failure
- (Machine monitor system)
989L00
Details of • Engine controller is locked (factor 1).
failure
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine cannot be started.
machine
• If this failure code appears after machine monitor is replaced, user password must be
Related changed to one before replacement.
information • Method of reproducing failure code: Turn starting switch to ON position.
Defective machine This failure may be caused by replacement of machine monitor.
1
monitor
40-130 HB215LC-2
40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution2 (PC200-989M00-400-A-00-A)

Failure code
level Failure
989M00
Details of Engine controller is locked (factor 2).
failure
Problem on • Engine cannot be started.
machine
• If this failure code appears after machine monitor is replaced, user password must be
Related changed to one before replacement.
Defective machine This failure may be caused by replacement of machine monitor.
1
monitor
If this failure code appears while machine monitor is not replaced, machine
Defective machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot
2
monitor be performed.)
HB215LC-2 40-131
40 Troubleshooting
Failure code [989N00] Engine Controller Lock Caution3 (PC200-989N00-400-A-00-A)

Failure code
level Failure
989N00
Details of • Engine controller is locked (factor 3).
failure
Action of • Tries automatic recovery.
Problem on
machine
Related • Method of reproducing failure code: This failure code cannot be reproduced because of
information automatic recovery.
Defective engine If this failure code appears repeatedly, engine controller may be defective. (Since
1 this is an internal defect, troubleshooting cannot be performed.)
controller
40-132 HB215LC-2
40 Troubleshooting
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3 (HB205-A900FR-
400-A-Z0-A)

Failure Abrupt Engine Stop by Auto Idle Stop 3
L03 A900FR
Detail of • Durability of turbocharger is degraded because engine speed just before the engine is
failure stopped by auto idle stop function is high, causing abrupt engine stops frequently.
• Turn the auto-deceleration setting OFF.
Action of • Auto idle stop sudden stop monitor is displayed in red on machine monitor.
controller • Is reset when next auto idle stop countdown starts or starting switch is turned OFF.
Problem on • Turbocharger may get damaged.
machine
• This failure code is displayed when activation of failure code [A900N6] exceeds 2,000
times.
• This failure code will be cleared after replacing the turbocharger assembly and resetting
Related
the auto idle stop sudden engine stop counter.
information
• Method of reproducing failure code: Before resetting the auto idle stop sudden engine
stop counter, let the engine stop by auto idle stop function with auto-deceleration turned
OFF and fuel dial set at maximum.
No. Cause Procedure, measuring location, criteria, and remarks
If this repeatedly occurs even when the auto idle stop function is OFF,
1 Defective machine monitor machine monitor may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)
HB215LC-2 40-133
40 Troubleshooting
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 (HB205-A900N6-400-
A-Z0-A)

— A900N6
Detail of • Engine speed just before the engine is stopped by auto idle stop function is high.
failure
Action of • Turn the auto-deceleration setting ON.
controller
Problem on
machine
• This failure code is displayed if auto-deceleration is not OFF and fuel dial is not at
minimum when auto idle stop function commands engine stop.
• Engine speed can be checked with monitoring function.
Related (Code: 01002)
information • Accumulated counts can be checked with auto idle stop sudden stops counter reset
menu.
• Method of reproducing failure code: Let the engine stop by auto idle stop function with
auto-deceleration turned OFF and fuel dial set at maximum.
40-134 HB215LC-2
40 Troubleshooting
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2 (HB205-A900NY-
400-A-Z0-A)

L01 A900NY
Detail of • Accumulated count of abrupt engine stops is high because engine speed just before the
failure engine is stopped by auto idle stop function is high.
• Turn the auto-deceleration setting ON.
Action of • Auto idle stop sudden stop monitor is displayed in red on machine monitor.
controller • Is reset when next auto idle stop countdown starts or starting switch is turned OFF.
Problem on • Turbocharger may get damaged.
machine
• This failure code is displayed when activation of failure code [A900N6] exceeds 1,000
times.
• This failure code will be cleared after replacing the turbocharger assembly and resetting
Related
the auto idle stop sudden engine stop counter.
information
• Method of reproducing failure code: Before resetting the auto idle stop sudden engine
stop counter, let the engine stop by auto idle stop function with auto-deceleration turned
OFF and fuel dial set at maximum.
HB215LC-2 40-135
40 Troubleshooting
Failure code [AA10NX] Air Cleaner Clogging (HB205-AA10NX-400-A-Z0-A)
Action level Failure code Air cleaner clogging

Failure
L01 AA10NX (Machine monitor system)
Detail of • Air cleaner clogging switch signal voltage is not 1 V or less while engine is running, and
failure machine monitor detects clogging of air cleaner (open of sensor contacts).
Action of • Displays air cleaner clogging monitor in yellow on machine monitor.
controller
Problem on • If machine is used as it is, engine may be damaged.
machine
• Input condition (ON/OFF) from air cleaner clogging switch can be checked with monitoring
Related function.
information (Code: 04501)
• Method of reproducing failure code: Start engine.
Air cleaner may be clogged. Check it for clogging and then clean or replace if
1 (When system works clogged.
properly)
Defective air cleaner 3. Start engine.
2 clogging switch (internal When air cleaner is
open circuit) Max. 1 z
Between P23 (male) (1) normal *1
Resistance and (2) When air cleaner is
clogged *2 Min. 1 Mz
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors CM02 and P23, and insert T-adapters into each
3 (Wire breakage or female side.
defective contact of Between CM02 (female) (4) and P23 (female) (1) Max. 1 z
Resistance
connector) Between P23 (female) (2) and ground Max. 1 z
2. Insert T-adapters into connectors CM01 and CM02.
Defective machine 3. Start engine.
4
monitor When air cleaner is
Between CM02 (4) and Max. 1 V
Voltage normal
CM01 (3)
Air cleaner is clogged Min. 10 V
• Air cleaner suction resistance
*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
40-136 HB215LC-2
40 Troubleshooting
Circuit diagram related to air cleaner clogging sensor
HB215LC-2 40-137
40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low (HB205-AB00KE-400-A-Z0-A)
Action level Failure code Charge Voltage Low

Failure
L03 AB00KE (Machine monitor system)
Detail of • While engine is running, voltage from alternator drops, and machine monitor detects that
failure battery charge voltage is low (below 7.8 V).
Action of • Displays charge level monitor red on machine monitor.
machine • Even if cause of failure disappears, machine does not become normal until starting switch
monitor is turned to OFF position.
Problem on • If machine continues to be operated, battery may not be charged.
machine
• Signal voltage of alternator can be checked with monitoring function.
information • Method of reproducing failure code: Start engine.
Loose alternator
1 terminal or open circuit 1. Turn starting switch to OFF position.
at terminal 2. Check terminal.
Defective power 2. Insert T-adapter into connector E12.
generation of alternator a Troubleshooting may be done on connector E08.
2
(When system works 3. Start engine.
properly.) Between E12 (1) and
Voltage Engine speed: Medium 27.5 to 29.5
ground or above V
Defective wiring 2. Insert T-adapter into connector CM01.
3 harness or machine 3. Start engine.
monitor
Voltage Between CM01 (16) and ground 20 to 30 V
Open circuit in wiring a If no failure is found by check on cause 2, this check is not required.
harness
4 (wire breakage or 2. Disconnect connectors CM01 and E12, and connect T-adapter to each
defective contact of female side.
connector) Resistance Between CM01 (female) (16) and E12 (female) (1) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring
harness
5 2. Disconnect connectors CM01 and E12, and connect T-adapter to either
(contact with ground female side.
circuit) Between CM01 (female) (16) or E12 (female) (1)
Resistance and ground Min. 1 Mz
Defective machine If no failure is found by above checks, machine monitor is defective.

6
monitor (Since this is an internal defect, troubleshooting cannot be performed.)
40-138 HB215LC-2
40 Troubleshooting
Circuit diagram related to alternator
HB215LC-2 40-139
40 Troubleshooting
Failure code [B@BAZG] Eng Oil Press Low (HB205-BaBAZG-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Low

Failure
L03 B@BAZG (Engine controller system)
Detail of • Engine controller determines that engine oil pressure drops abnormally (sensor contacts
failure closed) by signal voltage from engine oil pressure switch while engine is running.
• Lights up engine oil pressure monitor in red on machine monitor.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller • Limits engine output and runs engine.
Problem on • If machine is used as it is, engine may be seized.
machine
• Engine oil pressure switch signals are input to engine controller. If engine oil pressure
Related switch closes (turns ON) while engine is running, engine controller sends this failure code
information to monitor.
Lowered engine oil
pressure Engine oil pressure may drops. Check it and remove cause of failure if oil
1 pressure is low.
(When system works
properly)
If no failure is found by preceding checks, engine oil pressure monitor system
may be defective. Perform following troubleshooting.
Defective engine oil • E-14 Engine coolant temperature monitor lights up in red while engine is
2 pressure sensor system running
• E-15 Hydraulic oil temperature monitor lights up in red while engine is
running
• E-17 Engine oil pressure monitor lights up in red while engine is running.
40-140 HB215LC-2
40 Troubleshooting
Failure code [B@BAZK] Eng Oil Level Low (PC400-BaBAZK-400-A-Z0-A)
Action level Failure code Engine oil level low

Failure
L01 B@BAZK (Machine monitor system)
Detail of • While engine is running, signal voltage from engine oil level switch is not below 1 V, so
failure machine monitor determines that engine oil level is low (oil level switch is open).
Action of • Displays engine oil level monitor yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may seize up.
machine
• Input (ON/OFF) from engine oil level switch can be checked by using monitoring function.
Related (Code 04501: Monitor Input 2)
information • Method of reproducing failure code: Start engine
Low engine oil level
1 Check engine oil level. If it is low, remove cause.
(when system is normal)
Defective engine oil level 1. Turn starting switch to OFF position.
sensor 2. Disconnect connector P44 and connect T-adapter to male side.
2
Resis- Between P44 (male) (1) and ground
(internal defect) Max. 1 z
tance
Open circuit in wiring harness 2. Disconnect connectors CM02 and P44, and connect T-adapters to
3 (wire breakage or defective each female side.
contact of connector) Resis- Between CM02 (female) (2) and P44 (female)
(1) Max. 1 z
tance
If no failure is found by above checks, machine monitor is defective.
• Reference
2. Disconnect connectors CM01 and CM02 and connect T-adapters to
4 Defective machine monitor each female side.
Between CM02 (female) (2) and CM01 (female)
Voltage Max. 1 V
(3)
Circuit diagram related to engine oil level
HB215LC-2 40-141
40 Troubleshooting
Failure code [B@BCNS] Eng Water Overheat (HB205-BaBCNS-400-A-Z0-A)
Action level Failure code Engine Water Overheat

Failure
L02 B@BCNS (Engine controller system)
Detail of • Engine controller determines that engine coolant overheats while engine is running by
failure signal voltage from engine coolant temperature sensor.
• Lights up engine coolant temperature monitor in red on machine monitor.
• Closes EGR valve (depending on coolant temperature)
Problem on • If machine is used as it is, engine may be seized.
machine
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function.
Overheating of engine
coolant Engine coolant may overheat. Check coolant temperature and remove
1
(When system works cause of failure if coolant overheats.
properly)
If no failure is found by check on cause 1, engine coolant temperature
Defective engine coolant
2 sensor system may be defective. Perform troubleshooting for failure
temperature sensor system
codes [CA144] and [CA145].
40-142 HB215LC-2
40 Troubleshooting
Failure code [B@BCZK] Eng Water Level Low (HB205-BaBCZK-400-A-Z0-A)
Action level Failure code Engine Water Level Low

Failure
L01 B@BCZK (Machine monitor system)
• Machine monitor detects low radiator coolant level (sensor contacts open) because signal
Detail of voltage from radiator coolant level switch is not 1 V or below when starting switch is on
failure (engine not running) or engine is running.
Action of • Displays radiator coolant level monitor in yellow on machine monitor.
controller
Problem on • If machine is used as it is, engine may overheat.
machine
• Input condition (ON/OFF) from radiator coolant level switch can be checked with
Related monitoring function.
• Method of reproducing failure code: Turn starting switch to ON position.
Lowered radiator coolant
level Coolant level in radiator sub-tank may be low. Check coolant level and add
1 coolant as necessary.
(When system works
properly)
2. Disconnect connectors CM02 and P24 and connect T-adapters to each
Defective coolant level female side.
2 sensor
a Add coolant in advance.
(Internal defect) Between FULL and
Between P24 (male) (1) Max. 1 z
Resistance and (2) LOW lines
Below LOW line Min. 1 Mz
harness 2. Disconnect connectors CM02 and P24 and connect T-adapters to each
defective contact of a Add coolant in advance.
connector) Resistance Between CM02 (female) (3) and P24 (female) (1) Max. 1 z
• Reference
Defective machine 2. Insert T-adapters into connectors CM01 and CM02.
4 3. Turn starting switch to ON position.
monitor
Between FULL and
Between CM02 (3) and Max. 1 V
Voltage LOW lines
CM01 (3)
Below LOW line Min. 10 V
HB215LC-2 40-143
40 Troubleshooting
Circuit diagram related to radiator coolant level sensor
40-144 HB215LC-2
40 Troubleshooting
Failure code [B@HANS] Hyd Oil Overheat (HB205-BaHANS-400-A-Z0-A)
Action level Failure code Hydraulic Oil Temperature Overheat

Failure
L02 B@HANS (Pump controller system)
Detail of • Pump controller detects overheating of hydraulic oil temperature (approximately 105°C or
failure above) by signal voltage of hydraulic oil temperature sensor while engine is running.
Action of • Displays hydraulic oil temperature monitor on machine monitor in red.
Problem on • If machine is used as it is, hydraulic component may be damaged.
machine
• Signal from hydraulic oil temperature sensor is input to pump controller and then data is
transmitted to machine monitor through CAN communication system.
• Hydraulic oil temperature can be checked with monitoring function.
information • See troubleshooting for "hydraulic oil temperature gauge display" (E mode), E-22 and E-
23.
Overheating of hydraulic oil
Hydraulic oil may overheat. Check hydraulic oil temperature, and
1 (When system works remove cause of failure if hydraulic oil overheats.
properly)
If no failure is found by check on cause 1, hydraulic oil temperature
Defective oil temperature
2 system may be defective. Perform troubleshooting for failure code
gauge system
[DGH2KB].
HB215LC-2 40-145
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error (WA380_7-CA115-400-A-Z0-A)
Action level Failure code Engine Ne and Bkup Speed Sensor Error
Failure
L04 CA115 (Engine controller system)
Detail of • Both signals from engine Ne speed sensor and engine Bkup speed sensor are unusual.
failure
Action of • None in particular.
controller
Problem on • Engine stops.
machine • Engine does not start.
Related • Method of reproducing failure code: Start engine.
information
Poor connection of sensor Connectors of engine Ne speed sensor and Bkup sensor may be poorly
1 (incorrectly) connected. Check their connection.
connector
Defective Ne speed sensor
2 Perform troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
system
If no failure is found by above checks, engine controller is defective.
4 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)
40-146 HB215LC-2
40 Troubleshooting
Failure code [CA122] Chg Air Press Sensor High Error (PC160-CA122-400-A-Z0-A)
Action level Failure code Charge Air Pressure Sensor High Error
Failure
Detail of • High voltage occurs in charge (boost) pressure sensor signal circuit.
failure
• Sets charge (boost) pressure to fixed value 400 kPa {4.1 kg/cm2 }), and runs engine.
Action of • Closes EGR valve.
Problem on • Acceleration performance of engine drops.
machine • Engine output lowers.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked with
monitoring function. (Code: 36501 (V))
• Boost pressure sensed by charge (boost) pressure sensor can be checked with
monitoring function. (Code: 36500 (kPa))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
• If sensor connector is disconnected, failure code [CA123] for "Low Error" is displayed
even in normal condition.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "Related information on
Defective wiring troubleshooting", and check it.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply system for it first.
2. Disconnect connector TMAP TAG.
If failure code changes from [CA122] to [CA123], charge (boost) pressure
sensor is defective.
a Other failure code [CA153] for temperature sensor is also displayed.
Defective charge Ignore this code since this is displayed due to disconnection of sensor
3 (boost) pressure sensor connector.
• Reference
2. Insert T-adapter into connector ECM J1.
Sensor
Voltage Between ECM J1 (15) and (59) 0.3 to 4.7 V
output
1. Turn starting switch to OFF position, then perform troubleshooting.
Short circuit in wiring 2. Disconnect connectors ECM J1 and TMAP TAG, and connect T-adapter to
4
harness female side of ECM J1.
Resistance Between ECM J1 (female) (15) and (60) Min. 100 kz
2. Disconnect connector TMAP TAG, and insert T-adapter into connector
Hot short circuit in
5 ECM J1.
wiring harness
3. Turn starting switch ON (with connector TMAP TAG disconnected).
Voltage Between ECM J1 (15) and (59) Max. 1 V
HB215LC-2 40-147
40 Troubleshooting

Open circuit in wiring
harness If no failure is found by above checks, wiring harness may have open circuit.
6 (Wire breakage or (*)
defective contact of a To check open circuit in GND line
connector)
Defective engine If no failure is found by above checks, engine controller is defective. (Since
controller
*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
information on troubleshooting".
Circuit diagram related to charge pressure sensor
40-148 HB215LC-2
40 Troubleshooting
Failure code [CA123] Chg Air Press Sensor Low Error (PC160-CA123-400-A-Z0-A)
Action level Failure code Charge Air Pressure Sensor Low Error
Failure
Detail of • Low voltage occurs in charge (boost) pressure sensor signal circuit.
failure
• Sets charge (boost) pressure to fixed value 400 kPa {4.1 kg/cm2 }), and runs engine.
Problem on • Acceleration performance of engine drops.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked with
monitoring function. (Code: 36501 (V))
• Boost pressure sensed by charge (boost) pressure sensor can be checked with
monitoring function. (Code: 36500 (kPa))
• This failure code appears if sensor connector is disconnected.
harness connector
Defective power supply
system of charge If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2
(boost) pressure sensor for it first.
Short circuit in wiring 2. Disconnect connectors ECM J1 and TMAP TAG, and connect T-adapter to
3
harness female side of ECM J1.
Ground fault in wiring 1. Turn starting switch to OFF position, then perform troubleshooting.
harness 2. Disconnect connectors ECM J1 and TMAP TAG, and connect T-adapter to
4
(Contact with ground female side of ECM J1.
circuit) Resistance Between ECM J1 (female) (15) and ground Min. 100 kz
harness
If no failure is found by above checks, wiring harness may have open circuit.
5 (Wire breakage or (*)
defective contact of
connector)
a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
Defective charge 1. Turn starting switch to OFF position.
6 (boost) pressure sensor 2. Insert T-adapter into connector ECM J1.
Sensor
output
controller
*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
HB215LC-2 40-149
40 Troubleshooting
Circuit diagram related to charge pressure sensor
40-150 HB215LC-2
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error (HB205-CA131-400-A-Z0-A)
Action level Failure code Throttle Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of fuel dial sensor.
failure
• If error occurs while starting switch is ON, controller sets to fixed value used before the
Action of error has been detected and runs engine.
controller • If starting switch is turned to ON position after the error has occurred, controller uses a
value of 100%.
Problem on • Engine speed cannot be controlled by using fuel control dial.
machine
• Signal voltage from fuel control dial can be checked with monitoring function.
equipment" in "Checks before troubleshooting" of "Related
information on troubleshooting", and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector If this failure code is not displayed, wiring harness connector is
defective.
Defective throttle sensor If failure code [CA2185] or [CA2186] is also displayed, perform
2 power supply system troubleshooting for it first.
Defective throttle sensor (fuel
3 Between P20 (male) (1) and (3) 4.0 to 6.0 kz
dial) Resis- Between P20 (male) (2) and (3)
0.25 to 5.0 kz
tance
Open or short circuit in wiring 2. Disconnect connector CE03, and connect T-adapter to female side.
4
harness Resis- Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
tance Between CE03 (female) (51) and (42) 0.25 to 5.0 kz
5 Short circuit in wiring harness 2. Disconnect connectors CE03 and P20, and connect T-adapter to
either female side.
Resis- Between CE03 (female) (51) and (42), or
Min. 100 kz
tance between P20 (female) (1) and (2)
Hot short circuit in wiring 2. Disconnect connector P20 and connect T-adapter to female side.
harness
Voltage Between P20 (female) (2) and ground Max 1 V
• Reference
7 Defective engine controller 3. Turn starting switch to ON position.
4. Operate fuel dial and perform troubleshooting.
Power
Between CE03 (42) and (41) 4.75 to 5.25 V
supply
Voltage
Sensor
Between CE03 (51) and (41) 0.5 to 4.5 V
output
HB215LC-2 40-151
40 Troubleshooting
Circuit diagram related to throttle sensor
40-152 HB215LC-2
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error (HB205-CA132-400-A-Z0-A)
Action level Failure code Throttle Sensor Low Error

Failure
Detail of • Low voltage appears in signal circuit of fuel dial sensor.
failure
value of 100%.
Problem on • Engine speed cannot be controlled by using fuel control dial.
machine
• Signal voltage from fuel control dial can be checked with monitoring function.
1
defective.
Defective throttle sensor If failure code [CA2185] or [CA2186] is also displayed, perform
2 power supply system troubleshooting for it first.
Defective throttle sensor (fuel
3 Between P20 (male) (1) and (3) 4.0 to 6.0 kz
dial)
Resistance Between P20 (male) (2) and (3) 0.25 to 5.0 kz
4
harness Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
Resistance
Between CE03 (female) (41) and (51) 0.25 to 5.0 kz
2. Disconnect connectors CE03 and P20, and connect T-adapter to
Open circuit in wiring harness each female side.
5 Between CE03 (female) (42) and P20
(wire breakage or defective
(female) (1) Max. 1 z
Between CE03 (female) (51) and P20
Resistance (female) (2) Max. 1 z
Between CE03 (female) (41) and P20

6 Short circuit in wiring harness 2. Disconnect connectors CE03 and P20, and connect T-adapter to
either female side.
Between CE03 (female) (41) and (42), or
Resistance between P20 (female) (1) and (3) Min. 100 kz

Ground fault in wiring harness 2. Disconnect connectors CE03 and P20, and connect T-adapter to
7 either female side.
(contact with ground circuit)
Between ground and CE03 (female) (42) or
Resistance P20 (female) (1) Min. 100 kz
HB215LC-2 40-153
40 Troubleshooting

• Reference
8 Defective engine controller 2. Insert T-adapter into connector CE03.
4. Operate fuel dial and perform troubleshooting.
Between CE03 (42) and (41) Power supply 4.75 to 5.25 V
Voltage
Between CE03 (51) and (41) Sensor output 0.4 to 4.5 V
40-154 HB215LC-2
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error (D61-CA144-400-A-Z0-A)
Action level Failure code Coolant temperature sensor high error

Failure
Detail of • High voltage is detected in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed temperature (100 °C ),and allows engine to run.
controller
Problem on • Engine does not start easily at low temperature.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function (Code: 04105 (V)).
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
information • This failure code is displayed if temperature sensor connector is disconnected.
• Because troubleshooting "socket" for this sensor features female connector only, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed for T-adapter).
equipment" in "Checks before troubleshooting" of "General
1
connector If this failure code does not appear, wiring harness connector is
defective.
a If this failure code appears, perform following.
2. Disconnect connector COOLANT TEMP, and connect socket to male
side.
a If coolant temperature sensor has resistance of 700 z to 37 kz with
coolant temperature above 0 °C , regard coolant temperature sensor
Defective coolant as normal.
2 temperature sensor 0 °C 30 to 37 kz
Between COOLANT TEMP (male) 9.3 to 10.7
25 °C
Resis- (A) and (B) kz
tance a Coolant temperature 50 °C 3.2 to 3.8 kz
-Resistance characteristics 80 °C 1.0 to 1.3 kz
95 °C 700 to 800 z
2. Disconnect connector ECM J1 and connect T-adapter to female side
of connector.
Open or short circuit in wiring Between ECM J1 (female) (14) and (13)
3 (coolant temperature: Min. 0 °C )
harness
Resis- 700 z to 37
tance a Resistance is the same as that shown in kz
resistance characteristics table of coolant
temperature sensor of cause 2.
If no failure is found in above checks, engine controller is defective.
(Since this is internal defect, troubleshooting cannot be performed.)
HB215LC-2 40-155
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-156 HB215LC-2
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error (D61-CA145-400-A-Z0-A)
Action level Failure code Coolant temperature sensor low error

Failure
Detail of • Low voltage is detected in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed temperature (100 °C ),and allows engine to run.
controller
Problem on • Engine does not start easily at low temperature.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function (Code: 04105 (V)).
• Temperature sensed by engine coolant temperature sensor can be checked with
Related monitoring function. (Code: 04107 (°C))
• If temperature sensor connector is disconnected, this failure code is not displayed but
failure code [CA144] for "High Error" is displayed.
1
defective.
2. Disconnect connector COOLANT TEMP, and connect socket to male
side of connector.
a If coolant temperature sensor has resistance of 700 z to 37 kz with
coolant temperature above 0 °C , regard coolant temperature sensor
as normal.
Defective coolant 0 °C 30 to 37 kz
2 temperature sensor Between COOLANT TEMP (male) 9.3 to 10.7
(A) and (B) 25 °C
kz
50 °C 3.2 to 3.8 kz
Resis- a Coolant temperature
-Resistance characteristics 80 °C 1.0 to 1.3 kz
tance
95 °C 700 to 800 z
All coolant
Between (B) and ground tempera- Min. 100 kz
ture range
of connector.
Short circuit in wiring Between ECM J1 (female) (14) and (13)
3 (coolant temperature: Min. 0 °C )
harness
Resis- 700 z to 37
tance a Resistance is the same as that shown in kz
resistance characteristics table of coolant
temperature sensor of cause 2.
Ground fault in wiring 2. Disconnect connectors ECM J1 and COOLANT TEMP, and connect
4 harness (contact with ground T-adapters to female side of ECM J1.
circuit) Resis- Between ECM J1 (female) (14) and ground
Min. 100 kz
tance
HB215LC-2 40-157
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-158 HB215LC-2
40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error (PC160-CA153-400-A-Z0-A)
Action level Failure code Charge Air Temperature Sensor High Error
Failure
Detail of • High voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Sets charge temperature (boost temperature) to fixed value (70°C) and runs engine.
Problem on • Engine startability is poor at low temperatures.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 (°C))
harness connector
2. Disconnect connector TMAP TAG and connect socket to male side.
kz (-40°C to -130°C).
-40°C 41 to 48 kz
-20°C 14 to 16 kz
Defective charge 5.4 to 6.1
2 temperature sensor 0°C
kz
Between TMAP (male) (3) and (4) 1.6 to 1.8
Resistance a Charge temperature-Resistance 30°C
kz
characteristics 560 to 600
60°C
z
230 to 250
90°C
z
130°C 80 to 90 z
2. Disconnect connector ECM J1 and connect T-adapter to female side.
Open or short circuit in Between ECM J1 (female) (5) and (59)
3 wiring harness 80 z to 48
Resistance a Use Charge temperature-Resistance
characteristics table for check on cause 2 as kz
resistance criteria.
controller
HB215LC-2 40-159
40 Troubleshooting
Circuit diagram related to charge (boost) temperature sensor
40-160 HB215LC-2
40 Troubleshooting
Failure code [CA154] Chg Air Temp Sensor Low Error (PC160-CA154-400-A-Z0-A)
Action level Failure code Charge Air Temperature Sensor Low Error
Failure
Detail of • Low voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Sets charge temperature (boost temperature) to fixed value (70°C) and runs engine.
Problem on • Engine startability is poor at low temperatures.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18501 (V))
Related checked with monitoring function. (Code: 18500 (°C))
• If temperature sensor connector is disconnected, failure code [CA153] for "High error" is
displayed in place of this failure code.
harness connector
2. Disconnect connector TMAP TAG and connect socket to male side.
kz (-40°C to -130°C).
-40°C 41 to 48 kz
-20°C 14 to 16 kz
5.4 to 6.1
Defective charge 0°C
kz
2 temperature sensor Between TMAP (male) (3) and (4) 1.6 to 1.8
30°C
a Charge temperature-Resistance kz
Resistance characteristics 560 to 600
60°C
z
230 to 250
90°C
z
130°C 80 to 90 z
Between TMAP TAG (male) (3) and Whole
ground range Min. 1 Mz

Short circuit in wiring Between ECM J1 (female) (5) and (59)
3
harness 80 z to 43
Resistance a Use Charge temperature-Resistance
characteristics table for check on cause 2 as kz
resistance criteria.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors ECM J1 and TMAP TAG, and connect T-adapter to
4
(Contact with ground female side of ECM J1.
circuit) Resistance Between ECM J1 (female) (5) and ground Min. 100 kz
controller
HB215LC-2 40-161
40 Troubleshooting
Circuit diagram related to charge (boost) temperature sensor
40-162 HB215LC-2
40 Troubleshooting
Failure code [CA187] Sensor 2 Supply Volt Low Error (HB205-CA187-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage Low Error

Failure
Detail of • Low voltage occurs in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from ambient pressure sensor, sets ambient pressure to fixed value
(52.44 kPa {0.53 kg/cm2}), and runs engine.
Action of • Ignores signals from charge (boost) pressure sensor and allows engine to run taking it
controller that boost pressure is at calculated value.
• Ignores signals from crankcase pressure sensor, sets crankcase pressure to fixed value
(approximately 0 kPa), and runs engine.
• Closes EGR valve.
• Limits engine output and runs engine.
Problem on • Reduced engine output.
machine
information
1
defective.
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine
wiring harness is defective.
a Other failure codes are also displayed. This is because connector is
disconnected. Ignore all failure codes except for [CA187].
Defective sensor or wiring Sensor and wiring
2 Connector
harness harness
Cam (Bkup speed)
CAM SENSOR
sensor
Charge (Boost)
pressure sensor BOOST PRESS & IMT
Connector
Ambient pressure
AMB. AIR PRESSURE
sensor
Crankcase pressure
P57
sensor
Engine harness ECM J1
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
3
them.
2. Disconnect connector ECM J1 and connect T-adapter to male side.
4 Defective engine controller 3. Turn starting switch to ON position with connector ECM J1
disconnected.
Voltage Between ECM J1 (male) (60) and (59) 4.75 to 5.25
V
HB215LC-2 40-163
40 Troubleshooting
Circuit diagram related to sensor power supply 2 circuit
40-164 HB215LC-2
40 Troubleshooting
Failure code [CA221] Ambient Press Sensor High Error (PC160-CA221-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor High Error

Failure
Detail of • High voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
Problem on • Engine output lowers.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function. (Code: 37400 (kPa))
harness connector
Defective ambient
2 pressure sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
supply system for it first.

2. Disconnect connector AMB. AIR PRESSURE.
If failure code changes from [CA221] to [CA222], sensor is defective.
Defective ambient • Reference
3 pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ECM J1 or AMB. AIR PRESSURE.
Between ECM J1 (16) and (59), or
Sensor
Voltage between AMB. AIR PRESSURE (3) 0.3 to 4.7 V
output
and (2)
Open circuit in wiring 2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and connect
harness T-adapters to each female side.
4 (Wire breakage or
connector) Between ECM J1 (female) (59) and AMB. AIR
Resistance PRESSURE (female) (2) Max. 10 z

2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and connect
Short circuit in wiring T-adapter to either female side.
5
harness Between ECM J1 (female) (60) and (16), or
Resistance between AMB. AIR PRESSURE (female) (1) and Min. 100 kz
(3)
2. Disconnect connector AMB. AIR PRESSURE and connect T-adapter to
Hot short circuit in female side.
6 wiring harness 3. Turn starting switch to ON position.
Between AMB. AIR PRESSURE (female) (3) and
Voltage Max. 1 V
(2)
controller
HB215LC-2 40-165
40 Troubleshooting
Circuit diagram related to ambient pressure sensor
40-166 HB215LC-2
40 Troubleshooting
Failure code [CA222] Ambient Press Sens Low Error (PC160-CA222-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor Low Error

Failure
Detail of • Low voltage occurs in signal circuit of ambient pressure sensor.
failure
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
sensor, it is not usable for check of open circuit in wiring harness and voltage at sensor
connector (not designed as T-adapter).
harness connector
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
Defective ambient 1. Turn starting switch to OFF position.
2 pressure sensor power 2. Disconnect connector AMB. AIR PRESSURE and connect T-adapter to
supply system female side.
3. Switch: ON
Between AMB. AIR PRESSURE Power 4.75 to 5.25
Voltage
(female) (1) and (2) supply input V
2. Disconnect connectors AMB. AIR PRESSURE and ECM J1, and connect
Short circuit in wiring T-adapter to either female side.
3
harness
Between ECM J1 (16) and (59), or between AMB.
Resistance AIR PRESSURE (female) (3) and (2) Min. 100 kz

harness 2. Disconnect connectors AMB. AIR PRESSURE and ECM J1, and connect
4 T-adapter to either female side.
(Contact with ground
circuit) Between ground and ECM J1 (female) (16) or
Resistance AMB. AIR PRESSURE (female) (3) Min. 100 kz

2. Disconnect connectors AMB. AIR PRESSURE and ECM J1, and connect
T-adapter to female side of ECM J1.
Between ECM J1 (female) (16) and AMB. AIR
Open circuit in wiring PRESSURE (female) (3) Max. 10 z
5
harness
Resistance PRESSURE (female) (2) Max. 10 z
PRESSURE (female) (1) Max. 10 z
a If no failure is found by checks on causes 1 to 5 and failure is found by

Defective ambient check on cause 6, sensor is defective.
2. Insert T-adapter into connector ECM J1 or AMB. AIR PRESSURE.
HB215LC-2 40-167
40 Troubleshooting

Between ECM J1 (16) and (59), or
Sensor
Voltage between AMB. AIR PRESSURE (3) 0.3 to 4.7 V
output
and (2)
controller
Circuit diagram related to ambient pressure sensor
40-168 HB215LC-2
40 Troubleshooting
Failure code [CA227] Sensor 2 Supply Volt High Error (D37-CA227-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage High Error

Failure
Detail of • High voltage occurs in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from ambient pressure sensor, sets ambient pressure to fixed value
(52.44 kPa {0.53 kg/cm2}), and runs engine.
Action of • Ignores signals from charge (boost) pressure sensor, sets boost pressure to fixed value
controller (400 kPa {4.1 kg/cm2}), and runs engine.
• Ignores signals from crankcase pressure sensor, sets crankcase pressure to fixed value
(0 kPa), and runs engine.
• Closes EGR valve and opens VFT fully.
Problem on • Engine output reduces.
machine
information
Defective sensor power
supply 2 circuit
HB215LC-2 40-169
40 Troubleshooting
Failure code [CA234] Eng Overspeed (PC400-CA234-400-A-Z0-A)
Action level Failure code Engine Overspeed

Failure
Detail of • Engine speed exceeds its operating range.
failure
Action of • Regulates fuel injection rate so that engine speed lowers within operating range.
controller
Problem on • Engine speed fluctuates.
machine
Related • Engine speed can be checked with monitoring function. (Code: 01002 (rpm))
information • Method of reproducing failure code: Start engine and run at high idle.
1 Improper fuel is used. Fuel used may be improper. Check it.
2
them.
Method of using machine may be improper, so instruct operator on how
3 Improper machine usage
to use machine properly.
40-170 HB215LC-2
40 Troubleshooting
Failure code [CA238] Ne Speed Sensor Supply Volt Error (PC160-CA238-400-A-Z0-A)
Action level Failure code Ne Speed Sensor Supply Voltage Error

Failure
Detail of • High voltage occurs in Ne speed sensor power supply (5 V) circuit.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (CAM) speed sensor is also defective).
machine • Stopped engine cannot be started (when Bkup (CAM) speed sensor is also defective).
information
harness connector
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
If this failure code is not displayed, disconnected sensor or engine wiring
Defective sensor or harness is defective.
2 wiring harness
a Other failure codes are displayed at the same time. This is because of
connector being disconnected. So ignore other codes than this failure
code [CA238].
Ne speed sensor EPS MAIN (CRANK)
Connector
Engine wiring harness ECM J1
Defective engine 3. Turn starting switch to ON position with engine wiring harness
3
controller disconnected.
V
Circuit diagram related to Ne speed sensor
HB215LC-2 40-171
40 Troubleshooting
Failure code [CA239] Ne Speed Sens Supply Volt High Error (PC160-CA239-400-A-Z0-
A)
Action level Failure code Ne Speed Sensor Supply Voltage High Error
Failure
Detail of • High voltage occurs in Ne speed sensor power supply (5 V) circuit.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (CAM) speed sensor is also defective).
machine • Stopped engine cannot be started (when Bkup (CAM) speed sensor is also defective).
information
harness connector
2. Disconnect connector EPS MAIN (CRANK).
Defective Ne speed If this failure code is not displayed, disconnected sensor or engine wiring
2 harness is defective.
sensor
code [CA239].
2. Disconnect connector ECM J1.
Defective wiring If this failure code disappears, wiring harness is defective.
3
harness
code [CA239].
Defective engine 3. Turn starting switch to ON position with engine wiring harness
4
controller disconnected.
V
Circuit diagram related to Ne speed sensor
40-172 HB215LC-2
40 Troubleshooting
Failure code [CA271] IMV/PCV1 Short Error (D65-CA271-400-A-Z0-A)
Action level Failure code IMV/PCV1 Short Error

Failure
Detail of • Short circuit is detected in drive circuit of supply pump actuator (IMV).
failure
controller
• Engine speed does not increase from low idle speed.
Problem on • Engine output decreases.
machine • Common rail fuel pressure rises above command value.
information
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective supply pump 2. Disconnect connector INLET METERING VALVE.
actuator
If failure code changes from [CA271] to [CA272] , supply pump actuator
is defective.
2. Disconnect connector ECM J1 and connect T-adapters to female
Short circuit or ground fault in side.
3 wiring harness Between ECM J1 (female) (30) and (40) 1 to 5 z
Resis-
tance Between ECM J1 (female) (30) and ground Min. 100
kz
4 Short circuit in wiring harness 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
connect T-adapters to female side of ECM J1.
Resis- Between ECM J1 (female) (30) and (40) Min. 100
tance kz
2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
Ground fault in wiring harness
5 connect T-adapters to female side of ECM J1.
Between ECM J1 (female) (30) and ground Min. 100
Resis- kz
tance Between ECM J1 (female) (40) and ground Min. 100
kz
HB215LC-2 40-173
40 Troubleshooting
Circuit diagram related to IMV/PCV1
40-174 HB215LC-2
40 Troubleshooting
Failure code [CA272] IMV/PCV1 Open Error (D65-CA272-400-A-Z0-A)
Action level Failure code IMV/PCV1 Open Error

Failure
Detail of • Open circuit is detected in drive circuit of supply pump actuator.
failure
Action of None in particular.
controller
Problem on • Engine runs but its speed does not stabilize.
machine • Common rail fuel pressure rises above command value.
Related • Since female connector alone is provided for "socket" used for troubleshooting of this
information sensor, it is not connectable to female connector on sensor wiring harness side and thus
2. Disconnect connector INLET METERING VALVE.
Defective supply pump Between INLET METERING VALVE (male) (1)
2 1 to 5 z
actuator Resis- and (2)
tance Between INLET METERING VALVE (male) (1)

Open circuit or short circuit in 2. Disconnect connector ECM J1 and connect T-adapters to female
3 wiring harness side.
Resis- Between ECM J1 (female) (30) and (40)
1 to 5 z
tance
4 harness 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
(contact with ground circuit) connect T-adapters to female side of ECM J1.
Resis- Between ECM J1 (female) (30) and ground Min. 100 kz
tance Between ECM J1 (female) (40) and ground Min. 100 kz
2. Disconnect connector INLET METERING VALVE.
3. Insert T-adapters into connector ECM J1.
Hot short circuit in wiring 4. Turn starting switch to ON position (with connector INLET
5 METERING VALVE connected) and start measurement after at least
harness
one minute.
a Average voltage is displayed because of PWM control.
Voltage Between ECM J1 (30) and (40) Max. 3 V
HB215LC-2 40-175
40 Troubleshooting
Circuit diagram related to IMV/PCV1
40-176 HB215LC-2
40 Troubleshooting
Failure code [CA295] Ambient Press Sens In Range Error (PC160-CA295-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor In Range Error

Failure
Detail of • Output value from ambient pressure sensor is out of normal range.
failure
Action of
controller
• Closes EGR valve
machine
• Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function. (Code: 37400 (kPa))
Defective ambient pressure
1 Perform troubleshooting for failure codes [CA221] and [CA222].
sensor system
HB215LC-2 40-177
40 Troubleshooting
Failure code [CA322] Inj #1(L#1) Open/Short Error (D65-CA322-400-A-Z0-A)
Action level Failure code Injector #1(L#1) Open/Short Error

Failure
Detail of • Open or short circuit is detected in drive circuit of No. 1 injector.
failure
controller
Problem on • Engine runs with poor combustion or hunts.
machine • Engine output decreases.
Related • While engine is running normally, approx. 65 V of pulse voltage is supplied to injector (+)
information side. Because it is pulse voltage, it cannot be measured by using multimeter.
2. Disconnect connector INJECTOR CYL 1 & 2 and connect T-adapters
to male side.
2 Defective No. 1 injector Between INJECTOR CYL 1 & 2 (male) (3)
Max. 2 z
Resis- and (4)
tance Between INJECTOR CYL 1 & 2 (male) (3)

Open circuit or ground fault in
3 side.
wiring harness
Resis- Between ECM J1 (female) (48) and (58) Max. 2 z
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and
4 (wire breakage or defective connect T-adapters to each female side.
contact of connector) Between ECM J1 (female) (48) and
Max. 2 z
Resis- INJECTOR CYL 1 & 2 (female) (3)
tance Between ECM J1 (female) (58) and
INJECTOR CYL 1 & 2 (female) (4) Max. 2 z

5 harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and
(contact with ground circuit) connect T-adapters to either female side.
Resis- Between ground and ECM J1 (female) (48)
or INJECTOR CYL 1 & 2 (female) (3) Min. 100 kz
tance
40-178 HB215LC-2
40 Troubleshooting

2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
a Check by using multimeter in continuity mode.
Short circuit in wiring harness No continuity
6 Between ECM J1 (female) (48) and each pin
other than pin (48) (No sound is
heard)
Continuity
No continuity
Between ECM J1 (female) (58) and each pin
heard)
Defective injector of other If failure codes of other injectors are displayed, perform troubleshooting
7 cylinder for them first.
Defective injector harness of If failure codes of other injectors are displayed, perform troubleshooting
8 other cylinder for them first.
Circuit diagram related to injector #1
HB215LC-2 40-179
40 Troubleshooting
Failure code [CA324] Inj #3(L#3) Open/Short Error (PC160-CA324-400-A-Z0-A)

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (4)

3 side.
wiring harness
Max. 2 z

tance
2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and
heard)
Continuity
No continuity
heard)
40-180 HB215LC-2
40 Troubleshooting

HB215LC-2 40-181
40 Troubleshooting

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (2)

3 side.
wiring harness
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
Max. 2 z

tance
2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
heard)
Continuity
No continuity
heard)
40-182 HB215LC-2
40 Troubleshooting

HB215LC-2 40-183
40 Troubleshooting

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (2)

3 side.
wiring harness
Max. 2 z

tance
2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and
heard)
Continuity
No continuity
heard)
40-184 HB215LC-2
40 Troubleshooting

HB215LC-2 40-185
40 Troubleshooting
Failure code [CA343] ECM Critical Internal Failure (PC400-CA343-400-A-Z0-A)
Action level Failure code ECM Critical Internal Failure

Failure
Detail of • Engine controller has internal defect.
failure
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine start if it is stopped.
• Power supply voltage of engine controller can be checked with monitoring function.
information • Method of reproducing failure code: Turn starting switch to ON position
Defective engine
controller system
40-186 HB215LC-2
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error (WA380_7-CA351-400-A-Z0-A)
Action level Failure code Injectors Drive Circuit Error

Failure
Detail of • Error occurs in injector drive power supply circuit.
failure
Action of • Limits engine output and allows engine to run.
controller
• Exhaust gas color becomes black.
Problem on • Engine runs with poor combustion.
• Engine does not start
Related • Power supply voltage of engine controller can be checked with monitoring function.
information (Code: 03203(V))
1
them.
voltage circuit
HB215LC-2 40-187
40 Troubleshooting
Failure code [CA352] Sensor 1 Supply Volt Low Error (PC160-CA352-400-A-Z0-A)

Failure
Detail of • Low voltage occurs in sensor power supply 1 (5 V) circuit.
failure
• Ignores signals from exhaust manifold pressure sensor, closes EGR valve, and limits
Action of engine output.
controller • Ignores signals from EGR valve sensor and VFT position sensor, runs engine by setting
boost pressure to calculated value.
machine
information
harness connector
position each time.
If this failure code is not displayed, disconnected sensor or engine wiring
Defective sensor or harness is defective.
2 wiring harness a Other failure codes are also displayed. This is because connector is
Exhaust manifold pressure sensor EXHAUST PRESSURE
EGR valve EGR VALVE
Connector
VFT VFT ACTUATOR
Defective system
3 related to EGR valve or If other failure codes are also displayed, perform troubleshooting for them.
VFT
Defective engine
4 3. Turn starting switch to ON position with connector ECM J2 disconnected.
controller
V
40-188 HB215LC-2
40 Troubleshooting
Circuit diagram related to sensor power supply 1 (5 V)
HB215LC-2 40-189
40 Troubleshooting
Failure code [CA356] Mass Air Flow Sensor High Error (PC160-CA356-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor High Error
Failure
Detail of • High frequency occurs in signal circuit of mass air flow sensor.
failure
• Sets mass air flow to fixed value (10 kg/min) and runs engine.
controller • Limits engine output and allows engine to run.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
Related • Mass air flow sensor and intake air temperature sensor are integrated.
harness connector
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
Defective mass air flow 1. Turn starting switch to OFF position.
sensor 2. Disconnect connector P55.
(Internal defect)
If this failure code changes to [CA357], mass air flow sensor is defective.
supply system
Power Approx. 12
Voltage Between P55 (female) (2) and (3)
supply V
harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to each
connector)
Between ECM J1 (female) (22) and P55 (female)
Resistance (3) Max. 10 z

2. Disconnect connectors ECM J1 and P55, and connect T-adapter to female
Short circuit in wiring side of ECM J1.
6
harness a Check by using multimeter in continuity mode.
Between ECM J1 (female) (23) and each pin other
Resistance than pin (23) Min. 100 kz
controller
40-190 HB215LC-2
40 Troubleshooting
Circuit diagram related to mass air flow sensor
HB215LC-2 40-191
40 Troubleshooting
Failure code [CA357] Mass Air Flow Sensor Low Error (PC160-CA357-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Low Error
Failure
Detail of • Low frequency occurs in signal circuit of mass air flow sensor.
failure
• Sets mass air flow to fixed value (10 kg/min) and runs engine.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
• Mass air flow sensor and intake air temperature sensor are integrated.
Related • If sensor connector is disconnected, both this failure code and failure code [CA691] are
information displayed.
harness connector
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
Defective mass air flow 1. Turn starting switch to OFF position.
sensor 2. Replace mass air flow sensor.
(Internal defect)
If this failure code does not appear, original mass air flow sensor is defective.
supply system
Power Approx. 12
supply V
2. Disconnect connectors ECM J1 and P55, and connect T-adapters to each
female side.
a If no failure is found by check on cause 4, this
Open circuit in wiring check is not required. Max. 10 z
harness Between ECM J1 (female) (21) and P55 (female)
5 (Wire breakage or (2)
connector) Resistance a If no failure is found by check on cause 4, this
check is not required. Max. 10 z
(3)
(1) Max. 10 z

harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapter to either
6 female side.
Between ground and J1 (female) (23) or P55
circuit) Resistance (female) (1) Min. 100 kz

Short circuit in wiring 2. Disconnect connectors ECM J1 and P55, and connect T-adapter to female
7 side of ECM J1.
harness
40-192 HB215LC-2
40 Troubleshooting

Between ECM J1 (female) (23) and each pin other
Resistance than pin (23) Min. 100 kz
1. Be ready with starting switch at OFF position.

Hot short circuit in 3. Turn starting switch to ON position.
8 wiring harness
a Ignore displayed failure codes.
Voltage Between P55 (female) (1) and (3) Max. 1 V
controller
HB215LC-2 40-193
40 Troubleshooting
Failure code [CA386] Sensor 1 Supply Volt High Error (PC160-CA386-400-A-Z0-A)

Failure
Detail of • High voltage occurs in sensor power supply 1 circuit.
failure
• Ignores signals from exhaust manifold pressure sensor, closes EGR valve, and limits
Action of engine output.
controller • Ignores signals from EGR valve sensor and VFT sensor, takes it that they remain at
values before failure detection, and allows engine to run..
machine
information
Abnormally high sensor
supply voltage
40-194 HB215LC-2
40 Troubleshooting
Failure code [CA428] Water in Fuel Sensor High Error (PC300-CA428-400-A-Z0-A)
Action level Failure code Water-in-fuel sensor high error

Failure
Detail of • High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
failure
controller
Problem on • Water separator monitor is not displayed correctly.
machine
• Signal (ON/OFF) from water-in-fuel sensor of fuel pre-filter can be checked with
1
defective.
Defective water-in-fuel sensor 2. Disconnect connector P47 and connect T-adapters to male side.
2 installed to fuel pre-filter a If water is in water separator, drain it.
Resistance Between P47 (male) (1) and (2) 10 to100 kz
Short circuit or ground fault in 2. Disconnect connector ECM J1 and connect T-adapter to female
3 wiring harness side of connector.
Between ECM J1 (female) (24) and (32)
Resistance (Water sensor resistance) 10 to100 kz
a If no failure is found in checks on cause 3, this check is not required.

1. Be ready with starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and P47, and connect T-adapters to
contact of connector) Between ECM J1 (female) (32) and P47
Resistance
Between ECM J1 (female) (24) and P47

2. Disconnect connectors ECM J1 and P47, and connect T-adapters to
female side of ECM J1.
5 Short circuit in wiring harness a Check with multimeter in continuity mode.
No continuity
Between ECM J1 (female) (24) and every
Continuity (no sound is
pin other than (24)
heard.)
HB215LC-2 40-195
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-196 HB215LC-2
40 Troubleshooting
Failure code [CA429] Water in Fuel Sensor Low Error (PC300-CA429-400-A-Z0-A)
Action level Failure code Water-in-fuel sensor low error

Failure
Detail of • Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
failure
controller
Problem on • Water separator monitor is not displayed correctly.
machine
• Signal (ON/OFF) from water-in-fuel sensor of fuel pre-filter can be checked with
1
defective.
2. Disconnect connector P47 and connect T-adapters to male side.
Defective water-in-fuel
2 sensor installed to fuel pre- a If water is in water separator, drain it.
filter Between P47 (male) (1) and (2) 10 to100
Resis- kz
tance Between P47 (male) (1) and ground Min. 100 kz
Short circuit or ground fault in of connector.
3 wiring harness Between ECM J1 (female) (24) and (32) 10 to100
Resis- (water-in-fuel sensor resistance) kz
tance
Between ECM J1 (female) (32) and ground Min. 100 kz
1. Be ready with starting switch to OFF position.
4 Short circuit in wiring harness a Check with multimeter in continuity mode.

No
Between ECM J1 (female) (24) and every pin continuity
Continuity
other than (24) (no sound
is heard.)
5 harness (contact with ground 2. Disconnect connectors ECM J1 and P47, and connect T-adapters to
circuit) either female side.
Resis- Between ground and ECM J1 (female) (32) or
P47 (female) (1) Min. 100 kz
tance
HB215LC-2 40-197
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-198 HB215LC-2
40 Troubleshooting
Failure code [CA435] Eng Oil Press Sw Error (D65-CA435-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Switch Error

Failure
Detail of • Failure occurs in engine oil pressure switch signal circuit.
failure
controller
Problem on • Protection function based on engine oil pressure does not work.
machine • Engine oil pressure monitor is not displayed normally.
• Method of reproducing failure code: Turn starting switch to ON position or start engine.
• Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is
stopped), but is in OPEN (OFF) when oil pressure is high (when engine is running).
• To generate this failure code, engine controller checks whether engine oil pressure switch
is in CLOSED (ON) only when engine is stopped, that is, whether signal voltage is zero or
Related not.
information • Failure of engine oil pressure switch when engine is running is indicated by failure code
[B@BAZG].
k When performing checking and replacement of engine oil pressure switch, open oil
filler port, and check that engine oil temperature cools down enough not to get
scalded.
2. Disconnect connector OIL PRESSURE SWITCH and connect T-
Defective engine oil
2 adapters to male side.
pressure switch
Resis- Between OIL PRESSURE SWITCH (male) (1)
and ground Max. 10 z
tance
Open circuit or ground fault 2. Disconnect connector ECM J1 and connect T-adapters to female
3 in wiring harness side.
Resis- Between ECM J1 (female) (31) and ground
Max. 10 z
tance
Circuit diagram related to engine oil pressure switch
HB215LC-2 40-199
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error (HB205-CA441-400-A-Z0-A)
Action level Failure code Battery Voltage Low Error

Failure
Detail of • Low voltage occurs in engine controller power circuit.
failure
Action of • Sets power supply voltage tot fixed value (24 V) and runs engine.
controller
Problem on • Engine stops (if engine is running).
machine • Engine startability is poor (if engine is stopped).
information (Code: 03204(V))
Loose or corroded
1 Battery terminal may be loose or corroded. Check it directly.
battery terminal
Loose terminal or partial 1. Turn starting switch to OFF position.
2 open circuit at terminal Check terminals of alternator, battery relay, ground terminal (T12), etc.
Defective wiring See descriptions of wiring harness and connectors in "c: Electrical equipment"
3 harness connector in "Checks before troubleshooting" of "Related information on
troubleshooting", and check it.
Improper battery 2. Perform troubleshooting with starting switch at OFF position and when
4 voltage starting engine.
Voltage Between battery terminals (+) and (-). 20 to 30 V
2. Insert T-adapter into connector E12.
5 Defective alternator 3. Start engine. (Engine speed: Middle or faster)
Voltage Between E12 (1) and ground 27.5 to 29.5
V
Defective engine If no failure is found by above checks, engine controller is defective.
6
controller (Since this is an internal defect, troubleshooting cannot be performed.)
40-200 HB215LC-2
40 Troubleshooting
Circuit diagram related to power supply voltage
HB215LC-2 40-201
40 Troubleshooting
Failure code [CA442] Battery Voltage High Error (PC400-CA442-400-A-Z0-A)
Action level Failure code Battery Voltage High Error

Failure
Detail of • High voltage (approximately 36 V or higher) appears in controller power supply circuit.
failure
Action of • Sets power supply voltage to fixed value (24 V) and allows engine to run.
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart if it is stopped.
system of engine controller
40-202 HB215LC-2
40 Troubleshooting
Failure code [CA449] Rail Press Very High Error (WA380_7-CA449-400-A-Z0-A)
Action level Failure code Rail Pressure Very High Error

Failure
Detail of • Excessively high pressure is developed in common rail circuit.
failure
controller
Problem on • Engine sounds become louder under no load or light load.
• Common rail pressure can be checked with monitoring function.
Related (Code: (36400 Common rail pressure)
1
them.
Air may be in low-pressure circuit. Check it according to following
procedure.
2 Air in low-pressure circuit 1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
3. Check leaking level of fuel and air from pressure pickup plug hole.
a For check of pressure in fuel return circuit, see Testing and adjusting,
Defective fuel return circuit "Testing fuel pressure".
3 equipment Pressure in Max. 18.6 kPa
fuel return At low idle or during cranking {max. 0.19 kg/
circuit cm2}
Defective common rail
pressure sensor system
a For check of fuel leakage from pressure limiter, see Testing and
adjusting, "Testing fuel delivery rate, return rate and leakage".
5 Defective pressure limiter Leakage
from At low idle (for 30 seconds) Max. 8 ml
pressure
limiter
6 Defective supply pump If no failure is found by above checks, supply pump may be defective.
HB215LC-2 40-203
40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error (WA380_7-CA451-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of common rail pressure sensor.
failure
controller
Problem on
• Engine speed or output decreases.
machine
• Engine does not start.
• Signal voltage from common rail pressure sensor can be checked with monitoring
function.
(Code: 36401 Common rail pressure sensor voltage)
• Pressure sensed by common rail pressure sensor can be checked with monitoring
function.
Related (Code: 36400 (MPa))
• This failure code appears if common rail pressure sensor connector is disconnected.
• Since female connector alone is provided for "socket" used for troubleshooting of this
connector (.not designed as T-adapter).
If failure code [CA515] or [CA516] is also displayed, perform
2 pressure sensor power
troubleshooting for it first.
supply system
2. Disconnect connectors FUEL RAIL PRESS and ECM J2.
3 Short circuit in wiring harness 3. Connect T-adapters to female side of ECM J2.
Resis- Between ECM J2 (female) (31) and (44)
Min. 100 kz
tance
2. Disconnect connector FUEL RAIL PRESS and insert T-adapters into
connector ECM J2.
3. Turn starting switch to ON position (with connector FUEL RAIL
Hot short circuit in wiring PRESS disconnected).
4
harness
a Pin (31) of ECM J2 is connected to 5 V circuit via resistor inside
engine controller.
Voltage Between ECM J2 (21) and (44) 4.75 to 5.25
V
If no failure is found by above checks, wiring harness probably has open
5 Open circuit in wiring harness
circuit. (*)
a If no failure is found by checks on cases 1 to 5 and failure is found by
check on cause 6, sensor is defective.
6 pressure sensor (defective 1. Turn starting switch to OFF position.
input voltage to engine 2. Insert T-adapters in connector ECM J2.
controller) 3. Turn starting switch to ON position.
Sensor 0.2 to 4.8 V
Voltage Between ECM J2 (21) and (44)
output
40-204 HB215LC-2
40 Troubleshooting

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
Circuit diagram related to common rail pressure sensor
HB215LC-2 40-205
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error (WA380_7-CA452-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Low Error

Failure
Detail of • Low voltage appears in signal circuit of common rail pressure sensor.
failure
controller
Problem on • Engine speed or output decreases.
machine • Engine does not start.
function.
(Code: 36401 Common rail pressure sensor voltage)
Related function.
information (Code: 36400 (MPa))
• If sensor connector is disconnected even in normal condition, failure code [CA451] for
"High Error" is generated instead of this code.
If failure code [CA515] or [CA516] is also displayed, perform
2 pressure sensor power supply
system
2. Disconnect connector FUEL RAIL PRESS.
If failure code [CA452] changes to [CA451], sensor is defective.
Defective common rail • Reference
2. Insert T-adapters in connector ECM J2.
Sensor
Voltage Between ECM J2 (21) and (44)
output 0.2 to 4.8 V
Ground fault in wiring harness 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
4 (contact with ground circuit) connect T-adapters to female side of ECM J2.
Resistance Between ECM J2 (female) (44) and ground Min. 100 kz
2. Disconnect connectors FUEL RAIL PRESS and ECM J2.
5 Short circuit in wiring harness
3. Connect T-adapters to female side of ECM J2.
40-206 HB215LC-2
40 Troubleshooting
HB215LC-2 40-207
40 Troubleshooting
Failure code [CA466] KVGT Motor Driver Position Error (PC160-CA466-400-A-Z0-A)
Action level Failure code KVGT Motor Driver Position Error

Failure
Detail of • KVGT (VFT) position error has occurred.
failure
Action of • Closes EGR valve and opens VFT fully.
machine
Related
information a "KVGT" in the title of this failure code refers to "VFT" on this machine.
Defective sensor power If failure code [CA352] or [CA386] is displayed, perform troubleshooting for
1 supply system failure code [CA352] or [CA386] first.
2. Disconnect connectors ECM J2 and VFT ACTUATOR, and connect T-
adapters to each female side.
Between ECM J2 (female) (30) and VFT
ACTUATOR (female) (1) Max. 10 z
Open circuit in wiring ACTUATOR (female) (5) Max. 10 z
2
harness
Resistance ACTUATOR (female) (2) Max. 10 z

adapter to either female side.
harness Between ground and ECM J2 (female) (53) or VFT
ACTUATOR (female) (2) Min. 100 kz
3
circuit) Between ground and ECM J2 (female) (43) or VFT
Resistance ACTUATOR (female) (3) Min. 100 kz
Between ground and ECM J2 (female) (52) or VFT

Short circuit in wiring
harness Between ECM J2 (female) (43) and (53), or
between VFT ACTUATOR (female) (2) and (3) Min. 100 kz
4
(Short circuit between
wiring harnesses) Between ECM J2 (female) (53) and (52), or
Resistance between VFT ACTUATOR (female) (2) and (4) Min. 100 kz
Between ECM J2 (female) (43) and (52), or
between VFT ACTUATOR (female) (3) and (4) Min. 100 kz
VFT Position Sensor Sensor inside VFT is defective. (Since this is an internal defect,
5 troubleshooting cannot be performed.)
Error
Defective engine If no problem is found by above checks, engine controller may be defective.
6 (Since this is an internal defect, troubleshooting cannot be performed.)
controller
40-208 HB215LC-2
40 Troubleshooting
Circuit diagram related to VFT
HB215LC-2 40-209
40 Troubleshooting
Failure code [CA488] Chg Air Temp High Torque Derate (D65-CA488-400-A-Z0-A)
Action level Failure code Charge air Temperature High Torque Derate
Failure
Detail of • Temperature signal from boost pressure & temperature sensor exceeds upper limit of
failure control temperature.
Action of • Restricts engine output and allows engine to run.
controller
machine
• Boost temperature can be checked with monitoring function.
Aftercooler cooling performance may be degraded. Check for following
points:
Drop of cooling performance
1 • Defective fan rotation
of aftercooler
• Insufficient cooling air
• Clogged aftercooler fins
Unusual rise of turbocharger Outlet temperature of turbocharger may be unusually high. Check
2 outlet temperature related parts.
Defective boost temperature
sensor system
40-210 HB215LC-2
40 Troubleshooting
Failure code [CA515] Rail Press Sens Sup Volt High Error (WA380_7-CA515-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
controller
machine
function.
(Code: 36401 (V))
Related function.
Defective common rail If this failure code disappears, sensor is defective.
2 pressure sensor
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
If this failure code does not appear, wiring harness may be defective.
3 Defective wiring harness Perform following troubleshooting.
Hot short circuit in wiring 2. Disconnect connector FUEL RAIL PRESS.
4 3. Insert T-adapters into connector ECM J2.
harness
Voltage Between ECM J2 (31) and (21) 4.75 to 5.25
V
2. Disconnect connector ECM J2 and connect T-adapters to male side.
V
HB215LC-2 40-211
40 Troubleshooting
40-212 HB215LC-2
40 Troubleshooting
Failure code [CA516] Rail Press Sens Sup Volt Low Error (WA380_7-CA516-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
controller
machine
function.
(Code: 36401 (V))
Related function.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect) a Other failure codes (many codes) are also displayed. They are
If this failure code does not appear, wiring harness may be defective.
3 Defective wiring harness Perform following troubleshooting.
4 harness 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
Resis- Between ECM J2 (female) (31) and ground
Min. 100 kz
tance
Short circuit in wiring harness
5 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
Resis- Between ECM J2 (female) (21) and (31) Min. 100 kz
tance
HB215LC-2 40-213
40 Troubleshooting

2. Disconnect connector ECM J2 and connect T-adapters to male side.
V
40-214 HB215LC-2
40 Troubleshooting
Failure code [CA553] Rail Press High Error (PC160-CA553-400-A-Z0-A)
Action level Failure code Rail Pressure High Error

Failure
Detail of • High voltage (above the limit) appears and continued 10 or more seconds in signal circuit
failure of common rail pressure sensor.
controller
machine
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
1
them.
2 Improper fuel Fuel used may be improper. Check it (the viscosity is high).
Defective electric system of Electrical system of common rail pressure sensor may be defective.
3 common rail pressure sensor Perform troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system
4 of common rail pressure Common rail pressure sensor may have mechanical failure. Check it.
sensor
The overflow valve may has a damaged spring, worn seat, or ball
5 Defective overflow valve clogging trouble. Check it.
6 Clogging of overflow piping Check overflow piping for clogging.
7 Defective pressure limiter The pressure limiter may have a mechanical failure. Check it.
HB215LC-2 40-215
40 Troubleshooting
Failure code [CA555] Crankcase Press High Error 1 (PC400-CA555-400-A-Z0-A)
Action level Failure code Crankcase Pressure High Error 1

Failure
Detail of • High pressure error of crankcase pressure is detected.
failure
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
1 Clogged KCCV filter Replace KCCV filter with a new one.
When this failure code is not cleared after KCCV filter is replaced and
Blocked KCCV gas piping emulsion is found inside KCCV, KCCV blowby gas piping may be
2
blocked with emulsified matter. Perform troubleshooting for coolant
leaks.
Crankcase pressure sensor Crankcase pressure sensor system may be defective. Perform
3 troubleshooting for failure codes [CA1843] and [CA1844].
defective
40-216 HB215LC-2
40 Troubleshooting
Failure code [CA556] Crankcase Press High Error 2 (PC400-CA556-400-A-Z0-A)
Action level Failure code Crankcase Pressure High Error 2

Failure
Detail of • Crankcase pressure high error (level 2) occurs.
failure
Action of • Limits engine output and runs engine.
controller
machine
(Code: 48401 (V))
information (Code: 48400 (kPa))
• Method of reproducing failure code: Starting switch ON
1 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
2 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
sensor
If error condition is not cleared after KCCV filter is replaced and failure
code of crankcase pressure high error 2 is generated in short times,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
HB215LC-2 40-217
40 Troubleshooting
Failure code [CA559] Rail Press Low Error (WA380_7-CA559-400-A-Z0-A)
Action level Failure code Rail Pressure Low Error

Failure
Detail of • Common rail pressure low error occurs in common rail circuit.
failure
controller
• Engine does not start or engine is hard to start.
Problem on • Exhaust gas color becomes black.
• Common rail pressure can be checked with monitoring function.
Related (Code: (36400 Common rail pressure)
1 Improper fuel Fuel used may be improper. Check it.
Check fuel leakage to outside.
2 Fuel leakage to outside
(Visually check it while running engine at low idle.)
a See "Note 1" for troubleshooting.
a For check of pressure in low-pressure fuel circuit, see Testing and
adjusting, "Testing fuel pressure".
Negative pressure
at fuel supply Max. -40.7 kPa
Defective low-pressure circuit pump inlet (outlet At high idle
{max.-305 mmHg}
3 side of fuel pre-
devices
filter)
207 to 500 kPa
During cranking
{2.11 to 5.1 kg/cm2}
Inlet pressure of
207 to 650 kPa
fuel main filter
At high idle {2.11 to 6.63 kg/
cm2}
a For check of fuel leakage from pressure limiter, see Testing and
4 Defective pressure limiter adjusting, "Testing fuel delivery rate, return rate and leakage".
Leakage from
At low idle (for 30 seconds) Max. 8 ml
pressure limiter
a For check of fuel return rate from injector, see Testing and adjusting,
"Testing fuel delivery rate, return rate and leakage".
Defective injector During cranking
5 (Including high-pressure (Min. 150 rpm, for 30 Max. 45 ml
piping in cylinder head) Return rate from seconds)
injector
At low idle
Max. 125 ml
(For 30 sec)
a For check of fuel return rate from supply pump, see Testing and
adjusting, "Testing fuel delivery rate, return rate and leakage".
During cranking
6 Defective supply pump (Min. 150 rpm, for 30 Max. 575 ml
Return rate from seconds)
supply pump
At low idle
Max. 575 ml
(For 30 sec)
pressure sensor system
40-218 HB215LC-2
40 Troubleshooting
Note 1: Check following points when performing troubleshooting of low-pressure circuit devices.
1) Volume of remaining fuel
2) Clogging of fuel tank breather
3) Fuel leakage from low-pressure fuel piping and clogging of piping
4) Clogging of fuel pre-filter
5 Clogging of fuel main filter
6) After clogging of filters, etc. is removed, if this failure code does not disappear, replace fuel filter.
Reference
High pressure pipe from common rail is connected to injector via inlet connector (11) in cylinder head.
Since inlet connector (11) is tightened with retainer (10), retighten retainer (10).
3 retainer (10) : 50 ± 4 Nm {5 ± 0.4 kgm}
Width across flats 24 mm
HB215LC-2 40-219
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error (PC160-CA689-400-A-Z0-A)
Action level Failure code Engine Ne Speed Sensor Error

Failure
Detail of • Engine Ne speed sensor signal is abnormal.
failure
Action of • Runs engine by using signals from engine Bkup speed sensor.
controller
• Running engine stops (when Bkup (CAM) speed sensor is also defective).
Problem on • Stopped engine cannot be started (when Bkup (CAM) speed sensor is also defective).
machine • Engine startability is poor.
• Engine hunts.
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
Related be used to determine whether sensor is normal or not.
information • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
• Speed sensor detects passing of slot on speed sensing wheel, which is installed to inner
surface on vibration damper, to measure crankshaft speed.
harness connector
Defective Ne speed
sensor power supply If failure code [CA238] or [CA239] is also displayed, perform troubleshooting
2
system for it first.
Breakage or improper
installation (loosened) Engine Ne speed sensor may be broken or installed improperly (loosened).
3
of engine Ne speed Check it.
sensor
2. Disconnect connector EPS MAIN (CRANK), and connect T-adapter to
Defective Ne speed
female side.
4 sensor power supply
input
Between EPS MAIN (CRANK) Power 4.75 to 5.25
Voltage
(female) (1) and (2) supply input V
2. Disconnect connectors ECM J1 and EPS MAIN (CRANK).
check is not required.
Open circuit in wiring Max. 10 z
harness Between ECM J1 (female) (36) and EPS MAIN
(CRANK) (female) (1)
5 (Wire breakage or
defective contact of Resistance a If no failure is found by check on cause 4, this
connector) check is not required.
Max. 10 z
Between ECM J1 (female) (37) and EPS MAIN
(CRANK) (female) (2)
Between ECM J1 (female) (26) and EPS MAIN
(CRANK) (female) (3) Max. 10 z

Short circuit in wiring 2. Disconnect connectors ECM J1 and EPS MAIN (CRANK).
6
harness Between ECM J1 (female) (26) and (36) or
Resistance between EPS MAIN (CRANK) (female) (1) and (3) Min. 100 kz
40-220 HB215LC-2
40 Troubleshooting

Between ECM J1 (female) (26) and (37) or
between EPS MAIN (CRANK) (female) (2) and (3) Min. 100 kz
harness 2. Disconnect connectors ECM J1 and EPS MAIN (CRANK).
7
(Contact with ground Between ground and ECM J1 (female) (26) or EPS
circuit) Resistance MAIN (CRANK) (female) (3) Min. 100 kz

2. Disconnect connector EPS MAIN (CRANK).
wiring harness
Between EPS MAIN (CRANK) (female) (3) and
Voltage Max. 1 V
ground
Damage or loose
9 mounting of speed Check speed sensing wheel.
sensing wheel
Defective Ne speed If no failure is found in above checks, Ne speed sensor is defective. (Since
sensor
controller
Circuit diagram related to engine Ne speed sensor
HB215LC-2 40-221
40 Troubleshooting
Failure code [CA691] Intake Air Temp Sens High Error (PC200LC_10-CA691-400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor High Error
Failure
Detail of • High voltage is detected in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake temperature is at fixed value (25 °C ) and allows engine to run.
controller
Problem on
machine
• Mass air flow sensor and intake temperature sensor are integrated.
• Signal voltage from intake air temperature sensor can be checked with monitoring
Related • Temperature sensed by intake air temperature sensor can be checked with monitoring
information function. (Code: 18400 (°C))
• If sensor connector is disconnected, this failure code is displayed together with failure
code [CA357].
1
defective.
Defective intake temperature -30 °C 25 to 28 kz
2 sensor Between P55 (male) (4) and (3) 0 °C 5.5 to 6.1 kz
(internal defect) Resis-
tance a Intake temperature - resistance 25 °C 1.9 to 2.1 kz
characteristics 40 °C 1.1 to 1.2 kz
100 °C 180 to 185 z
Open or short circuit in wiring 2. Disconnect connector ECM J1 and connect T-adapter to female side
harness of connector.
3 (short circuit, wire breakage Resis- Between ECM J1 (female) (6) and (22) 180 z to 28
and defective contact of tance kz
connector) a Use Intake temperature - Resistance characteristics table for
troubleshooting on cause 2.
Hot short circuit in wiring 2. Disconnect connector P55.
harness 3. Insert T-adapters to connector ECM J1, or connect T-adapters to
4
female side of connector P55.
(Contact with 24 V circuit)
Between ECM J1 (6) and (22) or between
Voltage Max. 5.25 V
P55 (4) (female) (4) and (3)
a Check with multimeter in continuity mode.
Resis- Between ECM J1 (female) (6) and each pin
other than (6) Min. 100 kz
tance
40-222 HB215LC-2
40 Troubleshooting
Circuit diagram related to intake temperature sensor
HB215LC-2 40-223
40 Troubleshooting
Failure code [CA692] Intake Air Temp Sens Low Error (PC200LC_10-CA692-400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor Low Error
Failure
Detail of • Low voltage error is detected in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake temperature is at fixed value (25 °C ) and allows engine to run.
controller
Problem on
machine
• Signal voltage from intake air temperature sensor can be checked with monitoring
Related • Temperature sensed by intake air temperature sensor can be checked with monitoring
• Mass air flow sensor and intake temperature sensor are integrated.
1
defective.
2. Disconnect connector P55.
If this failure code changes to failure code [CA691], intake air
temperature sensor is defective.
•
• Reference
Defective intake temperature
2 sensor
(internal defect)
-30 °C 25 to 28 kz
Between P55 (male) (4) and (3) 0 °C 5.5 to 6.1 kz
25 °C 1.9 to 2.1 kz
Resis- a Intake temperature - resistance
tance characteristics 40 °C 1.1 to 1.2 kz
100 °C 180 to 185 z
Between P55 (male) (4) and Whole
ground (sensor body) range Min. 100 kz
Open or short circuit in wiring 2. Disconnect connector ECM J1 and connect T-adapter to female side
harness of connector.
3 (short circuit, wire breakage Resis- Between ECM J1 (female) (6) and (22) 180 z to 28
and defective contact of tance kz
connector) a Use Intake temperature - Resistance characteristics table for
troubleshooting on cause 2.
Ground fault in wiring harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to
Resis- Between ground and ECM J1 (female) (6) or
P55 (female) (4) Min. 100 kz
tance
5 Short circuit in wiring harness female side of ECM J1.
a Check with multimeter in continuity mode.
40-224 HB215LC-2
40 Troubleshooting

Resis- Between ECM J1 (female) (6) and each pin
other than (6) Min. 100 kz
tance
Circuit diagram related to intake temperature sensor
HB215LC-2 40-225
40 Troubleshooting
Failure code [CA697] ECM Internal Temp Sensor High Error (PC400-CA697-400-A-Z0-
A)
Action level Failure code ECM Internal Temperature Sensor High Error
Failure
Detail of • High voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by
Related using monitoring function (Code: 18900(°C)).
1 Improper usage of controller Check if the controller has been used in high temperature environments.
40-226 HB215LC-2
40 Troubleshooting
Failure code [CA698] ECM Int Temp Sensor Low Error (PC400-CA698-400-A-Z0-A)
Action level Failure code ECM Internal Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by

Related using monitoring function (Code: 18900(°C)).

1 Improper usage of controller Check if the controller has been used in low temperature environments.
HB215LC-2 40-227
40 Troubleshooting
Failure code [CA731] Eng Bkup Speed Sens Phase Error (PC160-CA731-400-A-Z0-A)
Action level Failure code Engine Bkup Speed Sensor Phase Error
Failure
Detail of • Abnormal phase is detected from signals of engine Ne speed sensor and engine Bkup
failure speed sensor.
Action of • Continues to control engine by using engine Ne speed sensor signal.
controller
• Engine cannot start or engine is hard to start.
Problem on • Idle speed is unstable.
machine • Exhaust gas color becomes black.
information
Damaged engine Ne
1 Engine Ne speed sensor may be damaged. Check it.
speed sensor
Damaged engine Bkup
2 Engine Bkup speed sensor may be damaged. Check it.
speed sensor
Deformation or damage
Speed sensing wheel (1) on crankshaft side may be deformed or damaged.
3 of speed sensing wheel
Check it.
on crankshaft side
Speed detection ring on camshaft side may be installed improperly or
Improper installation or damaged. Check it according to the following procedure.
damage of speed 1. Set No. 1 cylinder to compression top dead center (align stamping mark).
4
sensing ring on 2. Remove Bkup speed sensor.
camshaft side 3. Installation is correct if twin groove (single rib) (B) of speed sensing ring is
visible through sensor mounting hole (H).
Defective timing
adjustment of Timings of crankshaft and camshaft may not be matched each other. Check
5
crankshaft and them.
camshaft
Ground terminal may be poorly connected. Check following terminals:
Defective connection of • Ground terminal of machine ((–) terminal of battery)
6 ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
40-228 HB215LC-2
40 Troubleshooting
Failure code [CA778] Eng Bkup Speed Sensor Error (PC160-CA778-400-A-Z0-A)
Action level Failure code Engine Bkup Speed Sensor Error

Failure
Detail of • Engine Bkup speed (CAM) sensor signal is abnormal.
failure
Action of • Continues to control engine by using engine Ne speed sensor signal.
controller
Problem on • Engine startability is poor.
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
Related be used to determine whether sensor is normal or not.
information • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
• This speed sensor detects groove in speed sensing ring, which is installed to camshaft, to
measure camshaft speed.
harness connector
2 supply 2 circuit for it first.
Breakage or improper
installation (loosened) Engine Bkup speed (CAM) sensor may be broken or installed improperly
3 of engine Bkup speed (loosened). Check it.
(CAM) sensor
2. Disconnect connector EPS BACKUP (CAM), and connect T-adapter to
female side.
Improper power supply
4 input to engine Bkup
Power
speed sensor Between EPS BACKUP (CAM) (female) (1) and (2) 4.75 to 5.25
supply V
Voltage Between EPS BACKUP (CAM) (female) (1) and (2) 4.75 to 5.25
V
2. Disconnect connectors ECM J1 and EPS BACKUP (CAM), and connect T-
Open circuit in wiring adapters to each female side.
harness Between ECM J1 (female) (60) and EPS BACKUP
(CAM) (female) (1) Max. 10 z
5 (Wire breakage or
defective contact of Between ECM J1 (female) (59) and EPS BACKUP
connector) Resistance (CAM) (female) (2) Max. 10 z
Between ECM J1 (female) (9) and EPS BACKUP
(CAM) (female) (3) Max. 10 z

2. Disconnect connectors ECM J1 and EPS BACKUP (CAM), and connect T-
6 Between ECM J1 (female) (9) and (60) or between
harness Min. 100 kz
EPS BACKUP (CAM) (female) (1) and (3)
Resistance
Between ECM J1 (female) (9) and (59) or between
EPS BACKUP (CAM) (female) (2) and (3) Min. 100 kz

7 2. Disconnect connectors ECM J1 and EPS BACKUP (CAM), and connect T-
harness
HB215LC-2 40-229
40 Troubleshooting

(Contact with ground Between ground and ECM J1 (female) (9) or EPS
Resistance BACKUP (CAM) (female) (3) Min. 100 kz
circuit)
2. Disconnect EPS BACKUP (CAM), and connect T-adapter to female side.
wiring harness
Between EPS BACKUP (CAM) (female) (3) and
Voltage Max. 1 V
ground
Loosened camshaft Remove engine Bkup speed (CAM) sensor, and check ring through hole (H).
9 speed sensing ring a If speed sensing ring (B) is loosened, see "Reference".
If no abnormality is found by above checks, engine Bkup speed (CAM) sensor
Defective engine Bkup
10 speed (cam) sensor is defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
controller
Circuit diagram related to engine Bkup speed sensor
40-230 HB215LC-2
40 Troubleshooting
CA778 (107 series engine)
Check of camshaft ring for looseness

Remove front cover and check camshaft ring for looseness.
a See Disassembly and assembly, "Removal and installation of engine front oil seal".
a Keep the front seal, liquid gasket LG-7 and front seal tool (795-799-6400) on hand.
Removal
1. Remove fan and fan belt. For details, see
Disassembly and assembly, "Removal and
installation of engine front seal".
2. Remove damper assembly (1).
6. Check that mounting bolt (4) of camshaft ring (5)

is not loosened.
10 ± 2 Nm {0.98 ± 0.2 kgm}
3. Remove dust seal (6). (DP): Dowel pin
4. Remove front cover (2).

a Remove CAM sensor before removing front
cover. (To avoid interference between sensor
and cam shaft ring when removing cover.)
5. Remove front seal (3).
(RING): Ring
Installation
a See figures shown in removal procedure 1) Install CAM sensor.
section. 2) install front cover (3).
1. Install front cover (2). 3) Install dowel pin (DP), and install damper
assembly.
2 Front cover: 4) Install fan belt, and install the fan.
Liquid gasket (LG-7) 5) Install the cooling system assembly.
2. Install dust seal (6).
Seal insertion depth: L = 12(+0.1/–0)(mm)
3. See Disassembly and assembly, "Removal and
installation of engine front oil seal".
HB215LC-2 40-231
40 Troubleshooting
Failure code [CA1117] Persistent Data Lost Error (PC138-CA1117-400-A-Z0-A)
Action level Failure code Persistent Data Lost Error

Failure
Detail of
• Internal error occurs in controller.
failure
controller
• Engine continues to run normally, but it may stop during running or may not be able to
Problem on restart if it is stopped.
machine • Engine controller cannot store internal data correctly.
Related • Since engine controller internal data (muffler, etc.) may be lost, appropriate actions must
information be taken after system recovers from error.
Defective power supply Since the power supply circuit may be defective, perform troubleshooting for
1 failure code [CA441].
circuit
Improper operation of
2 battery disconnect Battery disconnect switch may be operated improperly.
switch
40-232 HB215LC-2
40 Troubleshooting
Failure code [CA1695] Sensor 5 Supply Volt High Error (D37-CA1695-400-A-Z0-A)

Failure
E03 CA1695 (Engine controller system)
Detail of • High voltage error occurs in sensor power supply 5 (5V) circuit.
failure
controller
Problem on
machine
information
Cause Procedure, measuring location, criteria, and remarks
Perform troubleshooting for failure code [CA1696].
HB215LC-2 40-233
40 Troubleshooting
Failure code [CA1696] Sensor 5 Supply Volt Low Error (D37-CA1696-400-A-Z0-A)

Failure
Detail of • Low voltage error occurs in sensor power supply 5 (5 V) circuit.
failure
controller
machine
Related • Sensor power supply 5 (pin 52 of connector CE03) is not used.
Defective engine
controller
Voltage Between CE03 (male) (52) and (43) 4.75 to 5.25
V
Circuit diagram related to sensor power supply 5 circuit
40-234 HB215LC-2
40 Troubleshooting
Failure code [CA1843] Crankcase Press Sens High Error (PC160-CA1843-400-A-Z0-A)
Action level Failure code Crankcase Pressure Sensor High Error

Failure
Detail of • High voltage occurs in signal circuit of crankcase pressure sensor.
failure
Action of • Sets crankcase pressure to fixed value (approximately 0 kPa) and runs engine.
controller
Problem on
machine
(Code: 48401 (V))
harness connector
2 supply system for [CA187] or [CA227] first.
Defective crankcase 2. Disconnect connector P57.
3 pressure sensor 3. Turn starting switch to ON position.
(Internal defect) If failure code changes from [CA1843] to [CA1842], crankcase pressure
Open circuit in wiring 2. Disconnect connectors ECM J1 and P57, and connect T-adapters to each
harness female side.
4 (Wire breakage or
connector) Between ECM J1 (female) (59) and P57 (female)
Resistance (2) Max. 10 z

2. Disconnect connectors ECM J1 and P57, and connect T-adapter to either
5 female side.
harness
Between ECM J1 (female) (3) and (60), or between
Resistance P57 (female) (1) and (3) Min. 100 kz

Hot short circuit in 2. Disconnect connector P57 and connect T-adapter to female side.
Voltage Between P57 (female) (3) and (2) 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.)
• Reference
Defective engine 1. Turn starting switch to OFF position.
7
controller 2. Insert T-adapter into connector ECM J1.
Sensor
output
HB215LC-2 40-235
40 Troubleshooting
Circuit diagram related to crankcase pressure sensor
40-236 HB215LC-2
40 Troubleshooting
Failure code [CA1844] Crankcase Press Sens Low Error (PC160-CA1844-400-A-Z0-A)
Action level Failure code Crankcase Pressure Sensor Low Error

Failure
Detail of • Low voltage occurs in signal circuit of crankcase pressure sensor.
failure
Action of • Sets crankcase pressure to fixed value (approximately 0 kPa) and runs engine.
controller
Problem on
machine
(Code: 48401 (V))
harness connector
for [CA187] or [CA227] first.
Defective sensor power 1. Turn starting switch to OFF position.

2 supply system 2. Disconnect connector P57 and connect T-adapter to female side.
Power 4.75 to 5.25
supply V
2. Disconnect connectors ECM J1 and P57, and connect T-adapters to each
female side.
Open circuit in wiring check is not required.
harness Resistance Max. 10 z
3 (Wire breakage or (female) (1)
connector) a If no failure is found by check on cause 2, this
check is not required.
Resistance Max. 10 z
(female) (2)
Resistance Between ECM J1 (female) (3) and P57 (female) (3) Max. 10 z
4 female side.
Between ground and ECM J1 (female) (3) or P57

5 female side.
harness
Between ECM J1 (female) (3) and (59), or between
Resistance P57 (female) (2) and (3) Min. 100 kz

Defective crankcase 2. Insert T-adapter into connector P57.
(Internal defect) Sensor
Voltage Between P57 (3) and (2) 0.3 to 4.7 V
output
HB215LC-2 40-237
40 Troubleshooting

• Reference
7
controller 2. Insert T-adapter into connector ECM J1.
Sensor
output
Circuit diagram related to crankcase pressure sensor
40-238 HB215LC-2
40 Troubleshooting
Failure code [CA1896] EGR Valve Stuck Error (PC160-CA1896-400-A-Z0-A)
Action level Failure code EGR Valve Stuck Error

Failure
Detail of • EGR valve stuck error has occurred (failed to learn zero point)
failure
machine
Related
information
Defective EGR
1 EGR may have mechanical failure. Check it.
mechanical system
Defective engine If no problem is found by above checks, engine controller is defective. (Since
controller
HB215LC-2 40-239
40 Troubleshooting
Failure code [CA1942] Crankcase Press Sens In Range Error (PC400-CA1942-400-A-

Z0-A)
Action level Failure code Crankcase Pressure Sensor In Range Error

Failure
Detail of • Output value from crankcase pressure sensor is out of normal range.
failure
controller
Problem on
machine
(Code: 48401 (V))
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
sensor
2 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
3 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
If error condition is not cleared after KCCV filter is replaced and failure
code of crankcase pressure high error 2 is generated in short times,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
40-240 HB215LC-2
40 Troubleshooting
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error (PC160-1961CA-400-A-

Z0-A)
Action level Failure code EGR Motor Driver IC Over Temperature Error
Failure
Detail of • EGR motor driver IC over temperature error occurs in engine controller.
failure
machine
Related
information
Improper use
1 environment of Check whether controller is used in high temperature environment.
controller
Defective engine If no problem is found by above checks, engine controller is defective. (Since
controller
HB215LC-2 40-241
40 Troubleshooting
Failure code [CA2185] Throt Sensor Sup Volt High Error (HB205-CA2185-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
Detail of • A high voltage occurs in throttle sensor power supply (5 V) circuit.
failure
value of 100%.
Problem on • Engine speed cannot be controlled by fuel dial.
machine
information
N- Procedure, measuring location, criteria, and remarks
Cause
o.
equipment" in "Checks before troubleshooting" of "Related information
Defective wiring harness on troubleshooting", and check it.
connector
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are displayed as well. This is because connector is
disconnected. Ignore failure codes other than [CA2185].
3 female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 1 Mz
tance than CE03 (female) (42) pin.
Hot short circuit in wiring 2. Disconnect connector P20 and connect T-adapter to female side.
harness
Voltage Between P20 (female) (1) and ground 4.75 to 5.25 V
• Reference
5 Defective engine controller 2. Insert T-adapter into connector CE03.
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
40-242 HB215LC-2
40 Troubleshooting
HB215LC-2 40-243
40 Troubleshooting
Failure code [CA2186] Throt Sensor Sup Volt Low Error (HB205-CA2186-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
Detail of • A low voltage occurs in throttle sensor power supply (5 V) circuit.
failure
value of 100%.
Problem on • Engine speed cannot be controlled by fuel dial.
machine
information
Cause
o.
equipment" in "Checks before troubleshooting" of "Related information
Defective wiring harness on troubleshooting", and check it.
connector
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are displayed as well. This is because connector is
disconnected. Ignore failure codes other than [CA2186].
Ground fault in wiring 2. Disconnect connectors CE03 and P20, and connect T-adapter to either
3 harness female side.
(Contact with ground circuit) Resis- Between ground and CE03 (female) (42) or P20
Min. 1 Mz
tance (female) (1)
Short circuit in wiring female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 1 Mz
tance than CE03 (female) (42) pin.
• Reference
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
40-244 HB215LC-2
40 Troubleshooting
HB215LC-2 40-245
40 Troubleshooting
Failure code [CA2249] Rail Press Very Low Error (PC200LC_10-CA2249-400-A-Z0-A)
Action level Failure code Rail Pressure Very Low Error

Failure
Detail of • Supply pump does not feed fuel (level 2).
failure
controller
machine
• Signal voltage from common rail pressure sensor can be checked by using monitoring
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
Supply pump pressure low Perform troubleshooting for failure code [CA559].
1
error
40-246 HB215LC-2
40 Troubleshooting
Failure code [CA2272] EGR Valve Pos Sens Low Error (PC160-CA2272-400-A-Z0-A)
Action level Failure code EGR Valve Position Sensor Low Error
Failure
Detail of • EGR position error has occurred.
failure
controller • Closes EGR valve
machine
information
harness connector
for it first.
2 2. Disconnect connector EGR VALVE and connect T-adapter to female side.
supply system
Between EGR VALVE (female) (1) Power 4.75 to 5.25
Voltage
and (5) supply V
2. Disconnect connectors EGR VALVE and ECM J2, and connect T-adapters
to each female side.
a If power supply voltage in check on cause 2 is
normal, this check is not required.
Max. 10 z
Between ECM J2 (female) (30) and EGR
Open circuit in wiring VALVE (female) (1)
harness
3 (Wire breakage or normal, this check is not required.
defective contact of Max. 10 z
connector) Resistance Between ECM J2 (female) (47) and EGR
VALVE (female) (5)
Between ECM J2 (female) (42) and EGR VALVE

2. Disconnect connectors ECM J2 and EGR VALVE, and connect T-adapter
to either female side.
Between ground and ECM J2 (female) (30) or EGR
Ground fault in wiring Min. 100 kz
VALVE (female) (1)
harness
4 Between ground and ECM J2 (female) (42) or EGR
(Contact with ground VALVE (female) (2) Min. 100 kz
circuit) Resistance
VALVE (female) (3) Min. 100 kz
Short circuit in wiring 1. Turn starting switch to OFF position.

5 2. Disconnect connectors ECM J2 and EGR VALVE, and connect T-adapter
harness
HB215LC-2 40-247
40 Troubleshooting

between EGR VALVE (female) (2) and (3) Min. 100 kz
Resistance between EGR VALVE (female) (2) and (4) Min. 100 kz
between EGR VALVE (female) (3) and (4) Min. 100 kz
Defective EGR position Sensor inside EGR may be defective. (Since this is an internal defect,
sensor
controller
Circuit diagram related to EGR valve
40-248 HB215LC-2
40 Troubleshooting
Failure code [CA2311] IMV Solenoid Error (D65-CA2311-400-A-Z0-A)
Action level Failure code Defective IMV solenoid

Failure
Detail of • Resistance value of supply pump actuator circuit is unusually high or low. Or rail pressure
failure error.
controller
machine
information
1 Defective IMV solenoid Perform troubleshooting for failure codes [CA271] and [CA272].
2 Rail pressure error Perform troubleshooting for failure code [CA449].
HB215LC-2 40-249
40 Troubleshooting
Failure code [CA2349] EGR Valve Solenoid Open Error (PC160-CA2349-400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Open Error

Failure
Detail of • Open circuit occurs in EGR valve motor circuit.
failure
controller • Closes EGR valve
machine
information
harness connector
2. Disconnect connector EGR VALVE and connect T-adapter to male side.
Defective EGR valve
2 Between EGR VALVE (male) (6) and (7) 1 to 5 z
motor
Resistance Between EGR VALVE (male) (7) and (8) 1 to 5 z
Between EGR VALVE (male) (8) and (6) 1 to 5 z
Open or short circuit in
3 wiring harness
Between ECM J2 (female) (3) and (4) 1 to 5 z
Resistance Between ECM J2 (female) (4) and (5) 1 to 5 z
Open circuit in wiring 2. Disconnect connectors ECM J2 and EGR VALVE, and connect T-adapters
harness to each female side.
4 (Wire breakage or
connector) Between ECM J2 (female) (4) and EGR VALVE
Resistance (female) (7) Max. 10 z
controller
40-250 HB215LC-2
40 Troubleshooting
HB215LC-2 40-251
40 Troubleshooting
Failure code [CA2353] EGR Valve Solenoid Short Error (PC160-CA2353-400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Short Error

Failure
Detail of
• Short circuit occurs in EGR valve motor circuit.
failure
controller • Closes EGR valve.
machine
information
harness connector
Defective EGR valve 2. Disconnect connector EGR VALVE and connect T-adapter to male side.
2 motor Between EGR VALVE (male) (6) and (7) 1 to 5 z
(Internal open circuit) Resistance Between EGR VALVE (male) (7) and (8) 1 to 5 z
Between EGR VALVE (male) (8) and (6) 1 to 5 z
3 wiring harness
2. Disconnect connectors ECM J2 and EGR VALVE, and connect T-adapter
Ground fault in wiring to either female side.
harness Between ground and ECM J2 (female) (3) or EGR
4
circuit) Resistance VALVE (female) (7) Min. 100 kz

2. Disconnect connector EGR VALVE.
Hot short circuit in 4. Turn starting switch to OFF position.
5 wiring harness
Between ground and ECM J2 (3) or (47) Max. 5.5 V
Voltage Between ground and ECM J2 (4) or (47) Max. 5.5 V
controller
40-252 HB215LC-2
40 Troubleshooting
HB215LC-2 40-253
40 Troubleshooting
Failure code [CA2357] EGR Valve Servo Error (PC160-CA2357-400-A-Z0-A)
Action level Failure code EGR Valve Servo Error

Failure
Detail of • EGR valve servo error occurs.
failure (EGR lift sensor sends back EGR valve position value that differs from command value.)
controller • Does not supply current to EGR valve (closes EGR valve).
machine
information
Defective relevant
1 If other failure codes are also displayed, perform troubleshooting for them.
system
Defective EGR valve
system
3 Defective EGR valve EGR valve may have mechanical trouble. Check it.
Defective engine If no failure is found by checks on causes 1 to 3, engine controller is defective.
4
40-254 HB215LC-2
40 Troubleshooting
Failure code [CA2373] Exhaust Manifold Press Sens High Error (PC160-CA2373-
400-A-Z0-A)
Action level Failure code Exhaust Manifold Pressure Sensor High Error
Failure
Detail of • High voltage occurs in signal circuit of exhaust manifold pressure sensor.
failure
• Runs engine by setting exhaust manifold pressure to calculated value.
machine
• Signal voltage from exhaust manifold pressure sensor can be checked with monitoring
Related • Pressure sensed by exhaust manifold pressure sensor can be checked with monitoring
information function. (Code: 48300 (MPa))
harness connector
2 supply system for failure code [CA352] or [CA386] first.
Defective charge 2. Disconnect connector EXHAUST PRESSURE.
(Internal defect) If failure code [CA2373] changes to [CA2374], exhaust manifold pressure
harness 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and connect
4 T-adapters to each female side.
wiring harnesses) Between ECM J2 (34) and (30), or between
Resistance EXHAUST PRESSURE (female) (3) and (1) Min. 100 kz

2. Disconnect connector EXHAUST PRESSURE and connect T-adapter to
Between EXHAUST PRESSURE (female) (3) and
Voltage Max. 1 V
(2)
• Reference
6 2. Insert T-adapter into connector ECM J2.
controller
Sensor
output
HB215LC-2 40-255
40 Troubleshooting
Circuit diagram related to exhaust manifold pressure sensor
40-256 HB215LC-2
40 Troubleshooting
Failure code [CA2374] Exhaust Manifold Press Sens Low Error (PC160-CA2374-
400-A-Z0-A)
Action level Failure code Exhaust Manifold Pressure Sensor Low Error
Failure
Detail of • Low voltage occurs in signal circuit of exhaust manifold pressure sensor.
failure
machine
harness connector
for failure code [CA352] or [CA386] first.
Defective sensor power 2. Disconnect connector EXHAUST PRESSURE and connect T-adapter to
2 supply system female side.
Between EXHAUST PRESSURE Power 4.75 to 5.25
Voltage
(female) (1) and (2) supply V
2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and connect
Open circuit in wiring T-adapters to each female side.
harness Between ECM J2 (female) (30) and EXHAUST
3 (Wire breakage or
defective contact of Between ECM J2 (female) (47) and EXHAUST
connector) Resistance PRESSURE (female) (2) Max. 10 z
Between ECM J2 (female) (34) and EXHAUST

Ground fault in wiring 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and connect
harness T-adapter to either female side.
4 Between ground and ECM J2 (female) (34) to
(Contact with ground Min. 100 kz
EXHAUST PRESSURE (female) (3)
circuit) Resistance
Between ground and ECM J2 (female) (30) to
EXHAUST PRESSURE (female) (1) Min. 100 kz

harness 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and connect
5 T-adapter to either female side.
Between ECM J2 (34) and (47), or between
wiring harnesses) Resistance EXHAUST PRESSURE (female) (2) and (3) Min. 100 z
HB215LC-2 40-257
40 Troubleshooting

Defective exhaust 1. Turn starting switch to OFF position.
manifold pressure 2. Insert T-adapter into connector ECM J2.
6 sensor 3. Turn starting switch to ON position.
(Internal defect) Voltage Between EXHAUST PRESSURE (3) and (2) 0.2 to 4.7 V
controller
Circuit diagram related to exhaust manifold pressure sensor
40-258 HB215LC-2
40 Troubleshooting
Failure code [CA2375] EGR Orifice Temp Sens High Error (PC160-CA2375-400-A-Z0-A)
Action level Failure code EGR Orifice Temperature Sensor High Error
Failure
Detail of • High voltage occurs in signal circuit of EGR orifice temperature sensor.
failure
• Runs engine by setting EGR orifice temperature to calculated value.
machine
• Signal voltage from EGR orifice temperature sensor can be checked with monitoring
Related • Signal voltage from EGR orifice temperature sensor can be checked with monitoring
harness connector
760 to 880
-30°C
kz
380 to 515
0°C
kz
155 to 225
25°C
Defective EGR orifice kz
temperature sensor Between EXHAUST GAS 80°C 21 to 29 kz
2
(internal defect) TEMPERATURE (male) (1) and (2)
900 to 1050
Resistance 200°C
z
150 to 200
300°C
z
400°C 40 to 56 z
500°C 15 to 22 z
Between EXHAUST GAS
Whole
TEMPERATURE (male) (2) and Min. 100 kz
range
ground (sensor body)
Open or short circuit in 2. Disconnect connector ECM J2 and connect T-adapter to female side.
wiring harness
a Use Temperature-Resistance characteristics table of EGR orifice
3 (Short circuit, wire temperature sensor that is used for check on cause 2 as resistance
breakage or defective criteria.
contact of connector) 15 z to 880
Resistance Between ECM J2 (female) (18) and (48)
kz
2. Disconnect connector EXHAUST GAS TEMPERATURE and connect T-
Hot short circuit in adapter to female side.
Between EXHAUST GAS TEMPERATURE
Voltage Max. 5.25 V
(female) (1) and (2)
controller
HB215LC-2 40-259
40 Troubleshooting
Circuit diagram related to EGR orifice temperature sensor
40-260 HB215LC-2
40 Troubleshooting
Failure code [CA2376] EGR Orifice Temp Sens Low Error (PC160-CA2376-400-A-00-A)
Action level Failure code EGR Orifice Temperature Sensor Low Error
Failure
Detail of • Low voltage occurs in signal circuit of EGR orifice temperature sensor.
failure
• Runs engine by setting EGR orifice temperature to calculated value.
machine
Related • Signal voltage from EGR orifice temperature sensor can be checked with monitoring
harness connector
Defective EGR orifice 2. Disconnect connector EXHAUST GAS TEMPERATURE.
2 temperature sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code changes to [CA2375], the EGR orifice temperature sensor
is defective.
• Reference
760 to 880
-30°C
kz
380 to 515
0°C
kz
155 to 225
Defective EGR orifice 25°C
kz
3 temperature sensor Between EXHAUST GAS 80°C 21 to 29 kz
(internal defect) TEMPERATURE (male) (1) and (2)
900 to 1050
Resistance 200°C
z
150 to 200
300°C
z
400°C 40 to 56 z
500°C 15 to 22 z
Between EXHAUST GAS
Whole
TEMPERATURE (male) (2) and Min. 100 kz
range
ground (sensor body)
Open or short circuit in 2. Disconnect connector ECM J2 and connect T-adapter to female side.
wiring harness
a Use Temperature-Resistance characteristics table of EGR orifice
4 (Short circuit, wire temperature sensor that is used for check on cause 2 as resistance
breakage or defective criteria.
contact of connector) 15 z to 880
Resistance Between ECM J2 (female) (18) and (48)
kz
harness 1. Turn starting switch to OFF position.
5 2. Disconnect connectors ECM J2 and EXHAUST GAS TEMPERATURE,
and connect T-adapter to either female side.
circuit)
HB215LC-2 40-261
40 Troubleshooting

Between ground and ECM J2 (female) (48) or
Resistance EXHAUST GAS TEMPERATURE (female) (2) Min. 100 kz
controller
Circuit diagram related to EGR orifice temperature sensor
40-262 HB215LC-2
40 Troubleshooting
Failure code [CA2387] KVGT Servo Error (HB205-CA2387-400-A-Z0-A)
Action level Failure code KVGT Servo Error

Failure
• KVGT servo error occurs.
Detail of failure (KVGT position sensor sends back KVGT position value that differs from command
value.)
machine
Related "KVGT" in the title of this failure code refers to "VFT" on this machine.

1
them.
For testing of KVGT drive pressure, see Testing and adjusting, "Testing
Insufficient KVGT drive EGR valve and KVGT drive oil pressure".
2 pressure a If KVGT drive pressure is abnormal, perform checks on causes 4
and 5.
For testing of KVGT control pressure, see Testing and adjusting,
Insufficient KVGT control "Testing EGR valve and KVGT oil pressure".
3 pressure
a If KVGT control pressure is abnormal, replace EPC valve for KVGT.
For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine oil pressure
engine oil pressure".
4 system
If engine oil pressure is not normal, perform troubleshooting (S mode).
(main circuit)
(S-14 Oil pressure drops)
5 Defective oil pump for KVGT Oil pump or relief valve for KVGT circuit may be defective. Check them.
Defective hydraulic piping for Hydraulic piping of KVGT circuit may be defective. Check it.
6
KVGT
Defective return hydraulic
7 piping for KVGT Return hydraulic piping of KVGT circuit may be defective. Check it.
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature: approximately 250°C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged
8 Defective KVGT after performing regeneration for service, KVGT is defective.
(Since the time required for manual stationary regeneration depends on
the accumulated soot level, see failure code CA2639.)
Defective KVGT position Perform troubleshooting for failure codes [CA2381] and [CA2382].
9
sensor
10 Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.)
HB215LC-2 40-263
40 Troubleshooting
Failure code [CA2554] Exh Manifold Press Sens In Range Error (PC160-CA2554-
400-A-Z0-A)
Action level Failure code Exhaust Manifold Pressure Sensor In Range Error
Failure
Detail of • Signal voltage output from exhaust manifold pressure sensor is out of normal range.
failure
Action of • Closes EGR valve
machine
• Method of reproducing failure code: Turn starting switch to ON position or start engine and
run at high idling speed.
Blocked piping of
Exhaust manifold pressure sensor piping may be blocked. Check piping for
1 exhaust manifold
clogging.
pressure sensor
Defective exhaust As exhaust manifold pressure sensor system may be defective, perform
2 manifold pressure troubleshooting for failure codes [CA2373] and [CA2374].
sensor
40-264 HB215LC-2
40 Troubleshooting
Failure code [CA2555] Grid Htr Relay Volt Low Error (HB205-CA2555-400-A-Z0-A)
Action level Failure code Grid Heater Relay Voltage Low Error
Failure
Detail of • Open circuit is in preheat relay drive circuit (primary circuit).
failure
controller
Problem on • Intake air heater does not work in auto preheating mode (resulting in degraded startability
machine and emission of white smoke at low temperatures).
checked with monitoring function. (Code: 18500 Charge Temperature)
• Method of reproducing failure code: Turn starting switch to ON position (charge
temperature: Max. -4°C).
• Troubleshooting of this failure code covers circuits from engine controller to primary circuit
General (coil) of preheat relay R18.
information • For troubleshooting of heater relay and secondary circuit of preheat relay R18, see
following E-mode troubleshooting.
• E-2 Manual preheating system does not work
• E-3 Automatic preheating system does not work
• E-4 While preheating is working, preheating monitor does not light up
1
defective.
2. Disconnect relay R18, and connect T-adapter to male side.
Resis- Between R18 (male) (1) and (2)
200 to 400 z
Defective preheating relay tance
2
R18 1. Turn starting switch to OFF position.
2. Replace relay R18 with another one.
If this failure code disappears, original preheat relay R18 is defective.
3
harness Resis- Between CE03 (female) (4) and (13)
200 to 400 z
tance a Coil resistance of relay R18
2. Disconnect connector CE03 and relay R18, and connect T-adapter
4 Open circuit in wiring harness to each female side.
Between CE03 (female) (4) and R18 (female)
Max. 10 z
Resis- (1)
tance Between CE03 (female) (13) and R18
HB215LC-2 40-265
40 Troubleshooting
Circuit diagram related to intake air heater relay
40-266 HB215LC-2
40 Troubleshooting
Failure code [CA2556] Grid Htr Relay Volt High Error (HB205-CA2556-400-A-Z0-A)
Action level Failure code Grid Heater Relay Voltage High Error
Failure
Detail of • Short circuit is in preheat relay drive circuit (primary circuit).
failure
controller
Problem on • Intake air heater does not work in auto preheating mode (resulting in degraded startability
machine and emission of white smoke at low temperatures).
checked with monitoring function. (Code: 18500 Charge Temperature)
• Method of reproducing failure code: Turn starting switch to ON position (boost
temperature: Max. -4°C).
• Troubleshooting of this failure code covers circuits from engine controller to primary circuit
Related (coil) of preheat relay R18.
information • For troubleshooting of heater relay and secondary circuit of preheat relay R18, see
following E-mode troubleshooting.
• E-2 Manual preheating system does not work
• E-3 Automatic preheating system does not work
• E-4 While preheating is working, preheating monitor does not light up
1
defective.
200 to 400 z
Defective preheating relay tance
2
R18 1. Turn starting switch to OFF position.
2. Replace relay R18 with another one.
If this failure code disappears, original preheat relay R18 is defective.
3 Ground fault in wiring harness to either female side.
Resis- Between ground and CE03 (female) (4) or
R18 (female) (1) Min. 100 kz
tance
to female side of CE03.
4 Short circuit in wiring harness a Check by using multimeter in continuity mode.
No continuity
Between CE03 (female) (4) and each pin
Continuity (No sound is
other than pin (4)
heard.)
HB215LC-2 40-267
40 Troubleshooting
Circuit diagram related to intake air heater relay
40-268 HB215LC-2
40 Troubleshooting
Failure code [CA2961] EGR Orifice Temp High Error 1 (D65-CA2961-400-A-Z0-A)
Action level Failure code EGR Orifice Temperature High Error 1

Failure
Detail of • Output signal from EGR orifice temperature sensor exceeds upper control limit or it
failure indicates value out of normal range.
controller
machine
function.
(Code: 48501(V))
Related • Temperature sensed by EGR orifice temperature sensor can be checked with monitoring
information function.
(Code: 48500 (°C))
1
them.
Increasing of EGR gas EGR gas temperature may rise excessively. Perform troubleshooting for
2 temperature it.
Defective EGR orifice EGR orifice temperature sensor system may be defective. Perform
3 temperature sensor troubleshooting for failure codes [CA2375] and [CA2376].
HB215LC-2 40-269
40 Troubleshooting
Failure code [CA2973] Chg Air Press Sensor In Range Error (PC160-CA2973-400-A-Z0-
A)
Action level Failure code Charge Air Pressure Sensor In Range Error
Failure
Detail of • Output signal from charge (boost) pressure sensor is out of normal range.
failure
• Closes EGR valve
controller • Runs engine by setting charge (boost) pressure to calculated value.
machine
• Signal voltage from charge (boost) pressure sensor can be checked with monitoring
Related • Pressure sensed by charge (boost) pressure sensor can be checked with monitoring
Defective charge Charge pressure sensor system may be defective. Perform troubleshooting
1 pressure sensor for failure codes [CA122] and [CA123].
40-270 HB215LC-2
40 Troubleshooting
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error (PC160-
CA3419-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage High Error
Failure
Detail of • High voltage occurs in mass air flow sensor power supply (12 V) circuit.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures that are similar to those for failure codes [CA356] and [CA357].
Action of
controller • Sets mass air flow to fixed value (10 kg/min) and runs engine.
machine
information
harness connector
Defective mass air flow 3. Turn starting switch to ON position.
2 sensor If this failure code does not appear, MAF sensor is defective.
(Internal defect)
a Other failure codes are displayed at the same time. This happens because
the connector is disconnected. So ignore other codes than this failure
code.
Defective wiring
3 If this failure code does not appear, wiring harness is defective.
harness
code.
Defective engine
4 Approx. 12
controller Voltage Between ECM J1 (male) (21) and (22)
V
HB215LC-2 40-271
40 Troubleshooting
40-272 HB215LC-2
40 Troubleshooting
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error (PC160-CA3421-
400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage Low Error
Failure
Detail of • High voltage occurs in mass air flow sensor power supply (12V) circuit.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures that are similar to those for failure codes [CA356] and [CA357].
Action of
controller • Sets mass air flow to fixed value (10 kg/min) and runs engine.
machine
information
harness connector
Defective mass air flow 3. Turn starting switch to ON position.
2 sensor If this failure code does not appear, MAF sensor is defective.
(Internal defect)
code.
Defective wiring
3 If this failure code does not appear, wiring harness is defective.
harness or connector
code.
4 female side.
Between ground and J1 (female) (21) or P55

5 female side.
harness
Resistance between P55 (female) (2) and (3) Min. 100 kz

Defective engine
6 Approx. 12
controller Voltage Between ECM J1 (male) (21) and (22)
V
HB215LC-2 40-273
40 Troubleshooting
40-274 HB215LC-2
40 Troubleshooting
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error (PC160-
CA3724-400-A-Z0-A)
Action level Failure code EGR/KVGT Motor Driver Power Low Error
Failure
Detail of • Low voltage error occurs in EGR/KVGT (VFT) drive power in engine controller.
failure
machine
Related a "KVGT" in the title of this failure code refers to "VFT" on this machine.
information • Power for GR valve and VFT motor driver are supplied from pin 30 of connector J2.
harness connector
position each time.
If this failure code is not displayed, disconnected motor or engine wiring
Defective motor or harness is defective.
2 wiring harness
a Other failure codes are also displayed. This is because connector is
EGR valve motor driver EGR VALVE
Connector KVGT (VFT) motor driver VFT ACTUATOR
Defective relevant
3 If other failure codes are also displayed, perform troubleshooting for them.
system
Defective engine
4 3. Turn starting switch to ON position with connector ECM J2 disconnected.
controller
V
HB215LC-2 40-275
40 Troubleshooting
Circuit diagram related to EGR valve and VFT drive motor power supply (5 V)
40-276 HB215LC-2
40 Troubleshooting
Failure code [CA3741] Rail Press Valve Trip Error (D65-CA3741-400-A-Z0-A)
Action
Failure code Rail Pressure Valve Trip Error
level Failure
(Engine controller system)
L03 CA3741
Detail of • Engine controller determines that common rail pressure limiter valve opens.
failure
Action of • Lowers indication of common rail pressure.
Problem on • Engine output lowers. Engine may not start again.
machine
function.
(Code: 36401 (V))
Related • Pressure sensed by common rail pressure sensor can be checked with monitoring
information function.
(Code: 36400 (MPa))
Common rail pressure limiter
valve is open.
HB215LC-2 40-277
40 Troubleshooting
Failure code [CA3918] KVGT Stuck Error (D37-CA3918-400-A-Z0-A)
Action level Failure code KVGT Stuck Error

Failure
Detail of • KVGT (VFT) stuck error has occurred.
failure (Failed to learn zero point of KVGT (VFT).)
machine
Defective KVGT
1 KVGT may have mechanical failure. Check it.
mechanical system
Defective engine If no failure is found by above checks, engine controller may be defective.
2
40-278 HB215LC-2
40 Troubleshooting
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error (D37-CA3919-400-A-
Z0-A)
Action level Failure code KVGT Motor Driver IC Over Temperature Error
Failure
Detail of • High KVGT (VFT) motor driver IC temperature error occurs in engine controller.
failure
machine
Improper use
1 environment of Check whether controller is used in high temperature environment.
controller
2
HB215LC-2 40-279
40 Troubleshooting
Failure code [CA3921] KVGT Servo Error 2 (D37-CA3921-400-A-Z0-A)
Action level Failure code KVGT Servo Error 2

Failure
Detail of • KVGT (VFT) servo error has occurred.
failure (KVGT (VFT) does not follow the command value for the KVGT (VFT))
machine
information • Method of reproducing failure code: Starting switch ON
Improper use
Perform checks on causes 1 to 4 in troubleshooting for failure code [CA3922]
1 environment of
first.
controller
2 Defective VFT VFT may have mechanical failure. Check it.
3
40-280 HB215LC-2
40 Troubleshooting
Failure code [CA3922] KVGT Motor Driver Open Error (PC160-CA3922-400-A-Z0-A)
Action level Failure code KVGT Motor Driver Open Error

Failure
Detail of • Open circuit occurs in KVGT (VFT) motor driver.
failure
machine
harness connector
2. Disconnect connector VFT ACTUATOR and connect T-adapter to male
side.
2 Defective VFT motor Between VFT ACTUATOR (male) (6) and (7) 8 to 15 z
Resistance Between VFT ACTUATOR (male) (7) and (8) 8 to 15 z
Between VFT ACTUATOR (male) (8) and (6) 8 to 15 z
3 wiring harness
Open circuit in wiring adapters to each female side.
harness Between ECM J2 (female) (11) and VFT
4 (Wire breakage or
defective contact of Between ECM J2 (female) (1) and VFT
connector) Resistance ACTUATOR (female) (7) Max. 10 z
controller
HB215LC-2 40-281
40 Troubleshooting
40-282 HB215LC-2
40 Troubleshooting
Failure code [CA3923] KVGT Motor Driver Short Error (PC160-CA3923-400-A-Z0-A)
Action level Failure code KVGT Motor Driver Short Error

Failure
Detail of • Short circuit occurs in KVGT (VFT) motor driver.
failure
machine
harness connector
2. Disconnect connector VFT ACTUATOR and connect T-adapter to male
Defective VFT motor side.
2 Between VFT ACTUATOR (male) (6) and (7) 8 to 15 z
(Internal open circuit)
Resistance Between VFT ACTUATOR (male) (7) and (8) 8 to 15 z
Between VFT ACTUATOR (male) (8) and (6) 8 to 15 z
3 wiring harness
2. Disconnect connectors ECM J2 and VFT ACTUATOR.
Ground fault in wiring Between ground and ECM J2 (female) (11) or VFT
harness ACTUATOR (female) (6) Min. 100 kz
4
(Contact with ground Between ground and ECM J2 (female) (1) or VFT
circuit) Resistance ACTUATOR (female) (7) Min. 100 kz
Between ground and ECM J2 (female) (2) or VFT

2. Disconnect connector VFT ACTUATOR.
5 wiring harness
Voltage Between ground and ECM J2 (1) or (47) Max. 5.5 V
controller
HB215LC-2 40-283
40 Troubleshooting
40-284 HB215LC-2
40 Troubleshooting
Failure code [D110KB] Battery Relay Drive Short Circuit (HB205-D110KB-400-A-00-A)
Action level Failure code Battery Relay Drive Short Circuit

Failure
L01 D110KB (Pump controller system)
Detail of • Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
failure
• Stops 24 V output to battery relay primary circuit (coil side).
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Each controller may fail in writing of data into its ROM (non-volatile memory).
machine
• As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
be measured at pump controller connector.
Related • Output state (ON/OFF) to battery relay can be checked with monitoring function.
• Method of reproducing failure code: Turn starting switch to ON o OFF position. Wait for
0.5 seconds.
Defective battery relay 1. Turn starting switch to OFF position.
1
(Internal short circuit) Continuity Between terminals RE and BR Continuity
2. Turn battery disconnect switch to OFF position (to prevent short
circuit during work).
Ground fault in wiring harness 3. Disconnect terminals R01 and R02, and disconnect connectors D01,
2 H15A, CP02, and HC01.
(Contact with ground circuit)
Between terminal R02 (BR) and ground Min. 1 Mz
Resis- Between ground and terminal CP02 (female)
tance (108), R02 (harness side), HC01 (female) (14), Min. 1 Mz
D01 (female) (1) or (2)
Resis- Between R43 (male) (1) and (2) 200 to 600
tance z
3 Defective AIS relay R43
2. Replace relay R43 with preheating relay R18.
If this failure code disappears, original AIS relay R43 is defective.
4 Pump controller is defective. If no failure is found by above checks, pump controller is defective.
HB215LC-2 40-285
40 Troubleshooting
Circuit diagram related to battery relay
40-286 HB215LC-2
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality (HB205-D19JKZ-400-A-Z0-A)
Action level Failure code Personal Code Relay Abnormality

Failure
L03 D19JKZ (Machine monitor system)
Detail of • Open error or short circuit occurs in primary (coil) circuit of personal code relay.
failure
• None in particular (when open error occurred)
• Stops driving personal code relay (when short circuit occurred).
Action of • If cause of failure disappears, machine becomes normal by itself (when open error
machine occurred).
monitor • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position (when short circuit occurred).
Problem on
machine
• This failure code is displayed only when engine lock function is enabled.
• Method of reproducing failure code: Turn starting switch to ON position (when open circuit
Related occurred). Failure code cannot be reproduced on the machine (when short circuit
information occurred).
• Troubleshooting for this failure code covers circuits from fuse No. 3 in fuse box F01
through primary (coil) circuit of personal code relay R07 to machine monitor.
Defective fuse No. 3 (3rd from
1 If fuse is blown, circuit may have ground fault.
the top right) of fuse box F01
200 to 600 z
tance
Defective personal code relay
2 1. Turn starting switch to OFF position.
R07
2. Replace relay R07 with preheating relay R18.
If this failure code disappears, original personal code relay R07 is
defective.
2. Remove fuse No. 3 (3rd from the top right) in fuse box F01.
3. Disconnect connectors CM01 and S14, and connect T-adapter to
Open circuit, short circuit, or
3 female side of CM01.
ground fault in wiring harness
Between F01-3 and CM01 (female) (6) 200 to 600 z
Resis-
Between F01-3 or CM01 (female) (6) and
tance Min. 1 Mz
ground
4 Open circuit in wiring harness 3. Disconnect connector CM01 and relay R07, and connect T-
Between F01-3 and R07 (female) (1) Max. 1 z
Resis-
Between R07 (female) (2) and CM01
tance

1.Turn starting switch to OFF position.
2.Remove fuse No. 3 (3rd from the top right) in fuse box F01.
3.Disconnect connector CM01 and relay R07, and connect T-adapter
5 Ground fault in wiring harness to either female side.
Between F01-3 or R07 (female) (1) and
Min. 1 Mz
Resis- ground
tance Between R07 (female) (2) and ground, or Min. 1 Mz
between CM01 (female) (6) and ground
HB215LC-2 40-287
40 Troubleshooting

3. Disconnect connectors CM01 and relay R07, and connect T-
adapter to female side of connector CM01.
No continuity
Between CM01 (female) (6) and each pin
Continuity (No sound is
other than (6)
heard.)
If no failure is found in above checks, machine monitor (KOMTRAX) is
Defective machine monitor
7 defective. (Since this is an internal defect, troubleshooting cannot be
(KOMTRAX)
performed.)
40-288 HB215LC-2
40 Troubleshooting
Circuit diagram related to personal code relay
HB215LC-2 40-289
40 Troubleshooting
Failure code [D811MC] KOMTRAX Error (PC400-D811MC-400-A-Z0-A)
Action level Failure code KOMTRAX Error

Failure
– D811MC (KOMTRAX system)
Detail of
• KOMTRAX malfunctions.
failure
Action of
controller
Problem on • KOMTRAX system does not operate properly.
machine
information
KOMTRAX is defective.
1 Malfunction of KOMTRAX
40-290 HB215LC-2
40 Troubleshooting
Failure code [D862KA] GPS Antenna Open Circuit (PC400-D862KA-400-A-Z0-A)
Action level Failure code GPS Antenna Open Circuit

Failure
- D862KA (KOMTRAX system)
Detail of • Open circuit occurs in GPS antenna circuit.
failure
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on • GPS positioning system does not work.
machine
information
Defective GPS antenna or GPS antenna may be defective, or antenna cable may have open or
1 short circuit, or poor contact at terminal area (GPS).
antenna cable
Figure of structure
HB215LC-2 40-291
40 Troubleshooting
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) (HB205-

D8ALKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (KOMTRAX)

Failure
— D8ALKA (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at approximately 5 V or less for approximately 3 seconds after
failure starting switch is turned to ON position, during which KOMTRAX outputs no current to
system operating lamp.
controller
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX memory.
• Although KOMTRAX is not able to light up system operating lamp, no trouble will result
Related unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
Defective fuse No. 16 in a If room lamp lights up, this check is not required.
1
fuse box F01. If fuse is blown, circuit probably has ground fault.

harness 2. Remove fuse No. 16 in fuse box F01.
3. Disconnect connectors CK01 and L19, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between CK01 (female) (15) and L19 (female) (2) Max. 1 z
connector) Resistance
Between F01-16 and L19 (female) (1) Max. 1 z
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective. (Since
terminal
40-292 HB215LC-2
40 Troubleshooting
Circuit diagram related to system operating lamp
HB215LC-2 40-293
40 Troubleshooting
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) (HB205-

D8ALKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (KOMTRAX)

Failure
- D8ALKB (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit shorts because voltage of output
Detail of circuit does not become low level while KOMTRAX outputs current to system operating
failure lamp.
controller
machine KOMTRAX memory.
Related • Although KOMTRAX is not able to light up system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
2. Remove fuse No. 16 in fuse box F01.
Short circuit in wiring 3. Disconnect connectors CM01, CP02, CK01, CE03, HC01, and L19, and
1
harness connect T-adapter to female side of connector L19.
Resistance Between L19 (female) (1) and (2) Min. 1 Mz
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective. (Since
terminal
40-294 HB215LC-2
40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) (HB205-D8AQKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (KOMTRAX)

Failure
- D8AQKR (Detected by machine monitor.) (Machine monitor system)
Detail of • Machine monitor does not recognize KOMTRAX over CAN communication-2 line
failure (KOMNET/c).
Action of
machine • None
monitor
Problem on
• None
machine
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• 7 different failure codes, [D8AQKR], [DA2QKR], [DAFQKR], [DAZQKR], [DB2QKR],
[F7FQKR], and [GA2QKR] are used for defective CAN communication by CAN2 when it is
detected by machine monitor. When all of these 7 failure codes are displayed, ground
fault, short circuit or hot short in wiring harness (CAN communication circuit) can be
suspected. Since air conditioner is also operated through CAN communication, you must,
in such case, check on air conditioner screen whether air conditioner is operable (ON/
OFF and air flow of air conditioner).
Related
information a Since failure code [F7FQKR] will not be displayed if ID controller is not installed,
troubleshoot for 6 failure codes [D8AQKR], [DA2QKR], [DAFQKR], [DAZQKR], [DB2QKR],
and [GA2QKR].
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
Defective power supply Perform troubleshooting for "E-59" of E mode.
3
to KOMTRAX terminal
Defective CAN
Perform checks on causes 4 to 9 in troubleshooting for failure code
4 communication 2
[DB2QKR].
system
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective.
5
terminal (Since this is an internal defect, troubleshooting cannot be performed.)
HB215LC-2 40-295
40 Troubleshooting
Failure code [DA20MC] Pump Controller Malfunction (PC400-DA20MC-400-A-Z0-A)
Action level Failure code Pump controller malfunction

Failure
– DA20MC (Pump controller system)
Detail of • Pump controller malfunctions.
failure
Action of
controller
Problem on • Pump controller does not function normally
machine
information
Malfunction of pump Pump controller is defective.
1
40-296 HB215LC-2
40 Troubleshooting
Failure code [DA22KK] Pump Solenoid Power Low Error (HB205-DA22KK-400-A-Z0-A)
Action level Failure code Pump Solenoid Power Low Error

Failure
L03 DA22KK (Pump controller system)
Detail of • Power supply voltage of controller for driving solenoids is below 18 V.
failure
• Stops detection of failures (open circuit and short circuit) in all solenoid systems while this
Action of failure code is active.
Problem on • No solenoid valve is energized properly, so machine does not work properly.
machine (Work equipment, swing, and travel systems do not work.)
• If failure code [D110KB] is displayed, perform troubleshooting for it first.
Related • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
information be measured at pump controller connector.
Defective fusible link If fusible link F04 is blown, circuit probably has ground fault (see cause 6).
1
F04
Defective fuse No. 2 in If fuse is blown, circuit probably has ground fault (see Cause 7).
2
fuse box F01
Improper battery
3 2. After measuring voltage, measure it again when starting engine.
voltage
Voltage Between battery (+) and ground 20 to 30 V
3. Disconnect connector CP02 and connect T-adapter to female side.
Defective wiring 4. Turn battery disconnect switch to ON position.
4
harness 5. Turn starting switch to ON position.
Between ground and each of CP02 (female) (116),
Voltage 20 to 30 V
(118) and (121)
a If fusible link or fuse is blown, replace it in advance.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connector CP02 and connect T-adapter to female side.
Between R03 and each of CP02 (female) (116),
5
Open circuit in wiring Resistance (118) and (121) Max. 1 z
harness
a If no failure is found by above checks, this check is not required.
1. Disconnect connector F04 and connect T-adapter to male side
furthermore.
Between F04 (male) (2) and each of CP02 (female)
Max. 1 z
Resistance (116), (118), and (121)
Between F04 (male) (1) and terminal R03 (M) Max. 1 z
Ground fault in wiring 3. Remove wire from terminal R03.
harness 4. Disconnect connectors F04 and CP02, and connect T-adapters to female
6
(Contact with ground side of CP02 and male side of F04.
circuit) Between ground and CP02 (female) (116), (118),
(121), or F04 (male) (2) Min. 1 Mz
Resistance
Between ground and F04 (male) (1) or terminal
R03 (M) Min. 1 Mz
Pump controller is If no failure is found by above checks, pump controller is defective.

7
defective. (Since this is an internal defect, troubleshooting cannot be performed.)
HB215LC-2 40-297
40 Troubleshooting
Circuit diagram related to solenoid power supply
40-298 HB215LC-2
40 Troubleshooting
Failure code [DA25KP] 5V Sensor 1 Power Abnormality (HB205-DA25KP-400-A-Z0-A)
Action level Failure code 5 V Sensor 1 Power Abnormality

Failure
- DA25KP (Pump controller system)
Detail of failure • Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
• Stops output of power from 5 V sensor power supply output 1.
Action of • Even if cause of failure disappears, machine does not become normal until starting
controller switch is turned to OFF position.
• Signal of pressure sensor is not input properly.
• The error code for the pressure sensor is displayed, as well.
Problem on • Work equipment speed is slow.
machine • Automatic travel speed selector function does not work (pump pressure sensor system).
• Auto-decelerator function remains activated or fine control performance of work
equipment is poor.
information
2. Disconnect connectors of the following sensors one by one and turn
starting switch ON each time.
a If this failure code goes out, disconnected sensor is defective.
a Since connector is disconnected, other failure codes appear.
Ignore all of displayed failure codes other than this one.
Sensor Connector
Bucket CURL pressure sensor P01
Defective pressure sensor Boom LOWER pressure sensor P02
1 Swing (left) pressure sensor P03
(Internal short circuit)
Arm IN pressure sensor P04
Bucket DUMP pressure sensor P05
Boom RAISE pressure sensor P06
Swing (right) pressure sensor P07
Arm OUT pressure sensor P08
F pump pressure sensor P25
R pump pressure sensor P26
F pump swash plate sensor P27
R pump swash plate sensor P28
Service pressure sensor (dummy) P49
a To measure voltage before controller stops output of power.
Hot short circuit in wiring 1. Turn starting switch to OFF position.
2 harness 2. Disconnect connectors P01 to P08, P25 to P28, and P49.
(Contact with 24 V circuit) 3. Connect T-adapter to female side of connector P01.
4. Turn starting switch ON (with connector disconnected).
Voltage Between P01 (female) (3) and ground 4.5 to 5.5 V
Ground fault in wiring harness 2. Disconnect connectors CP01, P01 to P08, P25 to P28, and P49.
3 3. Connect T-adapter to female side of connector CP01.
Resis- Between CP01 (female) (6) and ground
Min. 1 Mz
tance
If no failure is found by above checks, pump controller is defective.
4 Pump controller is defective.
HB215LC-2 40-299
40 Troubleshooting
Circuit diagram related to 5 V sensor power supply 1
40-300 HB215LC-2
40 Troubleshooting
Failure code [DA26KP] 5V Sensor 2 Power Abnormality (HB205-DA26KP-400-A-Z1-A)
Action level Failure code 5 V sensor 2 power abnormality

Failure
- DA26KP (Pump controller system)
• Voltage of 5 V sensor power supply output 2 circuit is 2.5 V and below or 6.0 V and
Detail of failure
above.
Action of • Even if cause of failure disappears, machine does not become normal until starting
controller switch is turned to OFF position.
• Pressure sensor signals are not input correctly.
Problem on • Error code for pressure sensor is also displayed.
machine • Travel speed is slow.
information
2. Disconnect connectors of the following sensors one by one and turn starting
switch ON each time.
a If this failure code lights off, disconnected sensor is defective.
Defective pressure a Since connector is disconnected, other failure codes appear. Ignore all the
sensor other failure codes except this one.
1
(Internal short 3. Each time troubleshooting is finished, return to step 1.
circuit) SENSOR Connector
Left front travel pressure sensor P09
Left rear travel pressure sensor P10
Right front travel pressure sensor P11
Right rear travel pressure sensor P12
a Measure voltage before controller stops output of power.
Hot short circuit in 2. Disconnect connectors P09 to P12.
2 wiring harness 3. Connect T-adapter to female side of connector P09.
Voltage Between P08 (male) (7) and ground 4.5 to 5.5 V
Ground fault in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors P09 to P12.
3 3. Connect T-adapter to female side of connector CP01.
(Contact with
ground circuit) Resistance Between CP01 (female) (63) and ground Min. 1 Mz
Defective pump If no failure is found by above checks, pump controller is defective.
4
HB215LC-2 40-301
40 Troubleshooting
Circuit diagram related to pump controller 5 V sensor power supply output 2
40-302 HB215LC-2
40 Troubleshooting
Failure code [DA29KQ] Model Selection Abnormality (HB205-DA29KQ-400-A-Z1-A)
Action level Failure code Model Selection Abnormality

Failure
L01 DA29KQ (Pump controller system)
Detail of • Model code signal for model which is not registered in controller is input.
failure
• Controls machine by regarding machine as default model (HB205 standard specification
Action of machine).
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • There is no problems in HB205 standard specification machine.
machine
• Part number of pump controller assembly can be checked with monitoring function.
(Code: 20229 Pump controller assembly part number
• Signal state (ON/OFF) of model selection signal can be checked with monitoring function.
(Code: 02201 Switch input 2)
a HB215LC-2
Related Model selection signal 1: OFF
information
Model selection signal 2: ON
Model selection signal 4: OFF
HB215LC-2
Pump controller with wrong 1. Use monitoring function to display assembly part number and check
1 part number whether the number is same as the one listed in Parts book.
2. Disconnect connector S30, and connect T-adapter to female side.
Between S30 (female) (1) and (2) Min. 1 Mz
Defective model selection Between S30 (female) (1) and (8) Min. 1 Mz
2 connector Between S30 (female) (3) and (4) Min. 1 Mz
(Internal open or short circuit) Resis- Between S30 (female) (4) and (7)
Min. 1 Mz
tance
Between S30 (female) (2) and (3) Max. 1 z
Open circuit in wiring harness 2. Disconnect connector CP01 and connect T-adapter to female side.
3 (Wire breakage or defective Between CP01 (female) (21) and ground Max. 1 z
Resis- Between CP01 (female) (40) and ground
contact of connector) Max. 1 z
tance
Between CP01 (female) (58) and ground Max. 1 z
Resis- Between CP01 (female) (59) and CP01 (21) Min. 1 Mz
tance Between CP01 (female) (77) and CP01 (21) Min. 1 Mz
Ground fault in wiring harness 2. Disconnect connector CP01 and connect T-adapter to female side.
5
(Contact with ground circuit) Resis- Between CP01 (female) (59) and ground Min. 1 Mz
tance Between CP01 (female) (77) and ground Min. 1 Mz
6 Defective pump controller
HB215LC-2 40-303
40 Troubleshooting
Circuit diagram related to model selection abnormality (HB215LC-2)
40-304 HB215LC-2
40 Troubleshooting
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) (HB205-
DA2LKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Pump Controller)
Failure
- DA2LKA (Pump controller system)
• Pump controller determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at approximately 5 V or below for approximately 3 seconds after
failure starting switch is turned to ON position, during which pump controller outputs no current to
system operating lamp.
controller
machine pump controller memory.
• Although work equipment controller is not able to light up system operating lamp, no
Related trouble will result unless battery disconnect switch is turned to OFF position.
1

3. Disconnect connectors CP02 and L19, and connect T-adapters to each
defective contact of Between CP02 (female) (100) and L19 (female) (2) Max. 1 z
Pump controller is If no failure is found by above checks, pump controller is defective. (Since this
3 is an internal defect, troubleshooting cannot be performed).
defective.
HB215LC-2 40-305
40 Troubleshooting
40-306 HB215LC-2
40 Troubleshooting
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) (HB205-
DA2LKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (Pump Controller)
Failure
- DA2LKB (Pump controller system)
• Pump controller determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become Low level while pump controller outputs current to system
failure operating lamp.
controller
machine pump controller memory.
Related • Although work equipment controller is not able to light up system operating lamp, no
information trouble will result unless battery disconnect switch is turned to OFF position.
1
defective.
HB215LC-2 40-307
40 Troubleshooting
Failure code [DA2QKR] CAN2 Discon (Pump Con) (HB205-DA2QKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Pump Controller)

Failure
L03 DA2QKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication 2 line
failure (KOMNET/c).
Action of
• Retains information at time of occurrence of failure.
controller
• Information to be obtained from pump controller is not displayed and special functions
Problem on that need information do not work. Or update of received data is stopped (such as failure
machine codes and monitoring codes sent from the pump controller).
switch is received.
[F7FQKR], and [GA2QKR] are used for defective CAN communication by CAN2 when it
is detected by machine monitor. When all of these 7 failure codes are displayed, ground
OFF and air flow of air conditioner).
Related • This can be activated even when power supply to pump controller is OFF.
information a Since failure code [F7FQKR] will not be displayed if ID controller is not installed,
troubleshoot for 6 failure codes [D8AQKR], [DA2QKR], [DAFQKR], [DAZQKR],
[DB2QKR], and [GA2QKR].
using multimeter.
2. Disconnect fusible link F05 and connect T-adapter to female side.
1 Defective fusible link F05 Resis- Between F05 (female) (1) and (2)
Max. 1 z
tance
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in fuse
2 2. Remove fuse No. 17 in fuse box F01.
box F01
If fuse is blown, circuit probably has ground fault.
a Check ground terminal T04 for looseness and rust.
Improper power supply to 2. Disconnect connector CP01 and connect T-adapter to female side.
3 pump controller 3. Turn starting switch to ON position.
Voltage 20 to 30 V
Between CP01 (female) (4) and (5)
40-308 HB215LC-2
40 Troubleshooting

1. Turn starting switch to OFF position, and set battery disconnect
switch to OFF position.
Open circuit in wiring harness 2. Remove fuse No. 17 in fuse box F01.
3. Disconnect connectors F05 and CP01, and connect T-adapters to
Between terminal R04 and F05 (female) (1) Max. 1 z
Resis- Between F05 (female) (2) and F01-16G Max. 1 z
tance Between F01-17 and CP01 (female) (1) Max. 1 z
Between F01-17 and CP01 (female) (4) Max. 1 z
Defective CAN communication Perform checks on causes 4 to 9 in troubleshooting for failure code
5 2 system [DB2QKR].
7 Defective machine monitor
HB215LC-2 40-309
40 Troubleshooting
Circuit diagram related to pump controller power supply
40-310 HB215LC-2
40 Troubleshooting
Failure code [DA2RKR] CAN1 Discon (Pump Con) (HB205-DA2RKR-400-A-Z0-A)
Action level Failure code CAN1 Disconnection (Pump Controller)

Failure
L03 DA2RKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication line 1
failure (KOMNET/r).
• Retains current working mode.
• Retains current selection of auto-deceleration.
Action of • Retains current setting (Hi/Lo) of travel speed.
controller • Retains information at time of occurrence of failure.
• Low speed matching function does not work normally.
• Information to be obtained from pump controller is not displayed and special functions
that need information do not work. Or update of received data is stopped.
• Pump control is disabled.
• Low speed matching function is disabled.
Problem on • Swing is disabled.
machine • Hydraulic oil temperature gauge pointer disappears on machine monitor screen.
• Wiper operation is disabled.
• Washer operation is disabled.
• Flow rate of attachment oil pressure line cannot be controlled.
switch is received.
• Machine monitor uses failure codes [DB2RKR] and [GA2RKR] to indicate failures in CAN
communication over CAN 1 line. When failure code [DB2RKR] or [GA2RKR] is displayed
simultaneously on screen, there may be a ground fault, short circuit, or hot short circuit in
wiring harness (CAN communication line).
Related • CAN1 terminating resistor is located in machine monitor on operator's cab side and
information connector "B_RES" is located on engine side (CAN communication-1 circuit (KOMNET/r)
is not provided. It is led from connector "J2").
using multimeter.
• This may occur even when power is not supplied to pump controller.
Defective pump controller Perform checks on causes 1 to 4 in troubleshooting for failure code
1 power supply system [DA2QKR].
2 1 system [DB2RKR].
HB215LC-2 40-311
40 Troubleshooting
Failure code [DAF0MB] Monitor ROM Abnormality (PC400-DAF0MB-400-A-Z0-A)
Action level Failure code Monitor ROM Abnormality

Failure
– DAF0MB (Machine monitor system)
Detail of • Program of machine monitor is rewritten (program error).
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
40-312 HB215LC-2
40 Troubleshooting
Failure code [DAF0MC] Monitor Error (PC400-DAF0MC-400-A-Z0-A)
Action level Failure code Monitor Error

Failure
– DAF0MC (Machine monitor system)
Detail of
• Machine monitor malfunctions.
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
HB215LC-2 40-313
40 Troubleshooting
Failure code [DAF8KB] Camera Power Supply Short Circuit (PC200-DAF8KB-400-A-00-

A)
Action Short circuit in camera power supply
Failure code
level Failure
(Machine monitor system)
L03 DAF8KB
Details of • Output power supply voltage (rating: 8 V) from machine monitor to camera is below 6.0 V
failure or above 10 V.
• Stops output power supply voltage (rating: 8 V) to camera.
Problem on • Camera image is not displayed on monitor screen.
machine
information
Defective camera 1. Turn starting switch to OFF position.
2. Disconnect camera connector(s), and turn starting switch to ON position.
1 (internal open
Disconnect camera connectors and perform failure reproduction operation. If
circuit)
failure code disappears at this time, camera has an internal defect.
2. Disconnect connector CM04.
Defective machine 3. Connect T-adapters to male side of connector CM04.
2
monitor 4. Turn starting switch to ON position.
Voltage Between CM04 (male) (1) and ground 6 to 10 V
wiring harness 2. Disconnect connector CM04 and camera connector(s).
3 (contact with GND 3. Connect T-adapters to female side of connector CM04.
circuit) Resistance Between CM04 (female) (1) and ground Min. 1 Mz
2. Disconnect camera connector(s).
3. Insert T-adapters into connector CM04.
wiring harness
(contact with 24 V
(Disconnect camera connector(s) and check that camera is not defective in
circuit)
advance.)
Voltage Between CM04 (1) and (7) Max. 10 V
40-314 HB215LC-2
40 Troubleshooting
Circuit diagram related to camera power supply
HB215LC-2 40-315
40 Troubleshooting
Failure code [DAF9KQ] Model Selection Abnormality (HB205-DAF9KQ-400-A-Z1-A)
Action level Failure code Model Selection Abnormality

Failure
L03 DAF9KQ (Machine monitor system)
Detail of • Machine model registered in machine monitor and pump controller differs.
failure (Machine monitor or pump controller of wrong part number is installed for replacement.)
Action of
controller
Problem on • Machine does not operate normally.
machine
(Code: 02201)
a HB215LC-2
Related Model selection signal 4: OFF
information Model selection signal 5: ON
• ppAssembly part number of pump controller program can be checked with monitoring
function.
(Code: 20229)
• Assembly part number of machine monitor program can be checked with monitoring
function.
(Code: 20227)
1. Use monitoring function to display assembly part number and check
whether it is identical to that listed in Parts book.
1 Defective machine monitor Defective machine monitor
(Wrong machine model is programmed.)
1. Use monitoring function to display assembly part number and check
whether it is identical to that listed in Parts book.
Defective pump controller
40-316 HB215LC-2
40 Troubleshooting
Failure code [DAFGMC] GPS Module Error (PC400-DAFGMC-400-A-Z0-A)
Action level Failure code GPS Module Error

Failure
- DAFGMC (KOMTRAX system)
Detail of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX
failure communication modem in 50 seconds after KOMTRAX started.
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on
machine
Related • Method of reproducing failure code: Turn starting switch to ON position (at least 50
information seconds after starting switch is turned to ON position).
GPS module in machine monitor may be defective.
HB215LC-2 40-317
40 Troubleshooting
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) (HB205-DAFLKA-

400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Monitor)

Failure
― DAFLKA (Machine monitor system)
• Machine monitor determines that system operating lamp circuit is open because voltage
Detail of of output circuit remains at approximately 5 V or less for approximately 3 seconds after
failure starting switch is turned to ON position, during which machine monitor outputs no current
to system operating lamp.
controller
machine machine monitor memory.
• Although machine monitor is not able to light up system operating lamp, no trouble will
Related result unless battery disconnect switch is turned to OFF position.
1

3. Disconnect connectors CM01 and L19, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between CP02 (female) (100) and L19 (female) (2) Max. 1 z
Defective machine If no failure is found by above checks, machine monitor is defective. (Since
monitor
40-318 HB215LC-2
40 Troubleshooting
HB215LC-2 40-319
40 Troubleshooting
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) (HB205-DAFLKB-

400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (Monitor)

Failure
― DAFLKB (Machine monitor system)
• Machine monitor determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become low level while machine monitor outputs current to system
failure operating lamp.
controller
machine machine monitor memory.
Related • Although machine monitor is not able to light up system operating lamp, no trouble will
information result unless battery disconnect switch is turned to OFF position.
1
Defective machine If no failure is found by above checks, machine monitor is defective. (Since
monitor
40-320 HB215LC-2
40 Troubleshooting
Failure code [DAFQKR] CAN2 Discon (Monitor) (PC400-DAFQKR-400-A-Z0-A)
Action code Failure code CAN2 Disconnection (Monitor)

Failure
- DAFQKR (KOMTRAX system)
Detail of • KOMTRAX terminal does not recognize machine monitor through CAN communication 2
failure line.
Action of
controller
Problem on • System may not function normally.
machine
switch is received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication.
Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is
Related not displayed on machine monitor and it can be observed only through KOMTRAX
information system.
using multimeter.
Defective power supply Perform troubleshooting for "E-5" in E mode troubleshooting.
1
to machine monitor
Defective CAN Perform checks on causes 4 and after in troubleshooting for failure code
2 [DB2QKR]
communication
HB215LC-2 40-321
40 Troubleshooting
Failure code [DAZ9KQ] A/C Model Selection Abnormality (HB205-DAZ9KQ-400-A-Z1-A)
Action level Failure code Air Conditioner Model Selection Abnormality

Failure
― DAZ9KQ (Machine monitor system)
• Machine model in machine monitor program differs from that in air conditioner controller
Detail of program.
failure (Replaced machine monitor or air conditioner controller has wrong part No.)
Action of
controller
Problem on • Machine does not operate normally.
machine
(Code: 02201)
a HB215LC-2
Related
• Model code specified by air conditioner controller program cannot be checked with
monitoring function.
• Model code of machine monitor program can be checked with monitoring function.
(Code: 00500)
• Air conditioner control data (model and series) of machine monitor can be checked with
(Code: 55200)
• Air conditioner control data (model and series) can be checked with monitoring function.
(Code: 55201) (OK if control data is 01 (which means PC))
Defective machine monitor
Defective air conditioner Defective air conditioner controller
2
controller (Wrong machine model is programmed.)
40-322 HB215LC-2
40 Troubleshooting
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) (HB205-DAZQKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Air Conditioner ECU)

Failure
L01 DAZQKR (Detected by machine monitor) (Machine monitor system)
Detail of • In CAN communication 2 line (KOMNET/c), machine monitor cannot recognize air
failure conditioner controller.
Action of
controller
• Function to collect information from engine controller does not work.
Problem on (Failure codes and monitoring codes that are sent by engine controller)
machine • Air conditioner cannot be operated (air does not blow out).
• Display of air conditioner operation screen of machine monitor is not correct.
switch is received.
[F7FQKR], and [GA2QKR] are used for defective CAN communication by CAN2 when it is
detected by machine monitor. When all of these 7 failure codes are displayed, ground
Related in such case, check on air conditioner screen whether air conditioner is operable (ON/
information OFF and air flow of air conditioner).
a Since failure code [F7FQKR] will not be displayed if ID controller is not installed,
using multimeter.
1 to air conditioner a Perform troubleshooting shown in Chapter 80 "Troubleshooting of power
controller supply system".
Defective CAN 1. Turn starting switch to OFF position.

terminating resistor 2. Disconnect connectors CM02 and K02, and connect T-adapters to each
2 male side.
(Internal open or short Between K02 (male) (A) and (B) 120 ± 12 z
circuit) Resistance
Between CM02 (male) (7) and (9) 120 ± 12 z
• CAN communication line
a CAN terminating resistor of 120 z is also located in machine monitor. That
is, 2 CAN terminating resistors of 120 z are connected in parallel. When
circuit resistance is measured at connector of controller other than
machine monitor, if combined resistance is 60 z, wiring harness does not
have open circuit.
3. Disconnect related connectors and connect T-adapters to connectors to
be measured.
3 wiring harness a If short circuit is found (resistance between 2 terminals is 1 z or below),
disconnect all CAN communication connectors of every controller and
check whether short circuit occurs between wiring harnesses or inside
controller.
Between CM02 (female) (8) and (9) Approx. 120
z
Between CE03 (female) (17) and (18) Approx. 60
z
Resistance
Between CP01 (female) (45) and (64) Approx. 60
z
Between AC01 (female) (1) and (2) Approx. 60
z
HB215LC-2 40-323
40 Troubleshooting

Between CK01 (female) (10) and (11) Approx. 60
z
Between CC01 (female) (3) and (9) Approx. 60
z
Between HC02 (female) (1) and (11) Approx. 60
z
Between K02 (female) (A) and (B) Approx. 120
z
• ACC signal of starting switch (start of CAN communication is not
recognized)
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors to be measured and insert T-adapters into them.
3. Turn battery disconnect switch to ON position, and turn starting switch to
ON position.
Between AC02 (4) and (1) 20 to 30 V
Voltage
Between CK02 (3) and (1) 20 to 30 V
Between CC01 (2) and (7) 20 to 30 V
Between HC02 (17) and each of (6) and (12) 20 to 30 V
OFF position.
2. Disconnect related connectors and connect T-adapters to female side of
connectors to be measured.
Open circuit in wiring Between CM02 (female) (8) and CP01 (female)
harness (45) Max. 1 z
4 (Wire breakage or Between CM02 (female) (9) and CP01 (female)
defective contact of (64) Max. 1 z
connector) Between CM02 (female) (8) and CE03 (female)
(17) Max. 1 z
Between CM02 (female) (9) and CE03 (female)
(18) Max. 1 z
Between CM02 (female) (8) and AC01 (female) (9) Max. 1 z
Between CM02 (female) (9) and AC01 (female)
(10) Max. 1 z
Resistance Between CM02 (female) (8) and CK01 (female)
(10) Max. 1 z
Between CM02 (female) (9) and CK01 (female)
(11) Max. 1 z
Between CM02 (female) (8) and CC01 (female) (3) Max. 1 z
Between CM02 (female) (9) and CC01 (female) (9) Max. 1 z
Between CM02 (female) (8) and HC02 (female) (1) Max. 1 z
Between CM02 (female) (9) and HC02 (female)
(11) Max. 1 z
Between CE03 (female) (17) and K02 (female) (A) Max. 1 z
Between CE03 (female) (18) and K02 (female) (B) Max. 1 z
40-324 HB215LC-2
40 Troubleshooting

a If no failure (open circuit) is found by check on cause 3, measure
resistance at any one place in each case.
OFF position.
Ground fault in wiring 2. Disconnect related connectors and connect T-adapters to female side of
harness connectors to be measured.
5
(Contact with ground Between ground and any of CP01 (female) (45),
circuit) CM02 (female) (7), (8), CE03 (female) (17), and Min. 1 Mz
HC02 (female) (1)
Resistance
Between ground and any of CP01 (female) (64),
CM02 (female) (9), CE03 (female) (18), and HC02 Min. 1 Mz
(female) (11)
a If no failure (open circuit) is found by check on cause 3, measure voltage
at any one place in each case.
OFF position.
2. Insert T-adapters into connectors to be measured.
3. Turn battery disconnect switch to ON position.
Short circuit or hot short
6 circuit in wiring harness a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
so regard wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and any of CM02 (8), CP01 (45),
CK01 (10), AC01 (2), CC01 (female) (3), CE03 1 to 4 V
(17), and HC02 (female) (1)
Voltage
Between ground and any of CM02 (9), CP01 (64),
CK01 (11), AC01 (1), CC01 (female) (9), CE03 1 to 4 V
(18), and HC02 (female) (11)
• When all 7 of [D8AQKR], [DA2QKR], [DAFQKR], [DAZQKR], [DB2QKR],
[F7FQKR], and [GA2QKR] failure codes are displayed:
a Identify which controller is defective by disconnecting them one by one
from CAN communication line by repeating the following steps 1 to 3.
Defective engine 1. Turn starting switch to OFF position, and set battery disconnect switch to
controller, pump OFF position.
controller, inverter, air 2. Disconnect CAN communication connector of engine controller (connector
7 CE03), pump controller (connector CP01), inverter (connector HC02), air
conditioner unit, ID
controller, or KOMTRAX conditioner unit (connector AC01), ID controller (connector CC01), and
terminal KOMTRAX terminal (connector CK01) one by one in turn.
3. Turn battery disconnect switch to ON position, turn starting switch to ON
position, then perform troubleshooting.
4. Return to step 1. to check next connector.
Has the number of displayed failure codes If YES, disconnected
decreased from 7? controller is defective.
Defective air conditioner If no failure is found by above checks, air conditioner controller is defective.
8
Defective machine If no failure is found by preceding checks, machine monitor is defective.
9
HB215LC-2 40-325
40 Troubleshooting
Circuit diagram related to CAN communication line 2
40-326 HB215LC-2
40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con) (HB205-DB2QKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Engine Controller)

Failure
L03 DB2QKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor cannot recognize engine controller over CAN communication-2 line
failure (KOMNET/c).
Action of
controller
• Information to be obtained from engine controller is not displayed and special functions
Problem on that need information do not work. Or update of received data is stopped.
machine (Failure codes and monitoring codes that are sent by engine controller)
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2).
• ID controller is optional setting (connector CC01).
[F7FQKR], and [GA2QKR] are used for defective CAN communication by CAN2 when it
is detected by machine monitor. When all of these 7 failure codes are displayed, ground
Related OFF and air flow of air conditioner).
information
a Since failure code [F7FQKR] will not be displayed if ID controller is not installed,
using multimeter.
Defective fuse -14 or -18 in 2. Remove fuses -14 and -18 from fuse box F01.
1
fuse box F01 • When fuse is blown, engine controller may have internal short
circuit.
a If fuse is not blown, this check is not required.
2 Defective engine controller 2. Disconnect connector CE03 and connect T-adapter to male side.
Resis- Between CE03 (male) (1) and (21) Min. 10 z
tance Between CE03 (male) (11) and (31) Min. 10 z
2. Disconnect connector CE03, and connect T-adapter to female side.
Defective power supply to 3. Turn starting switch to ON position.
3 engine controller
a If any trouble is found, perform troubleshooting for failure code
[CA441].
Between CE03 (female) (1) and (21) 20 to 30 V
Voltage
Between CE03 (female) (11) and (31) 20 to 30 V
Defective CAN terminating 2. Disconnect connectors CM02 and K02, and connect T-adapters to
4 resistor each male side.
(Internal open or short circuit) Resis- Between K02 (male) (A) and (B) 120 ± 12 z
tance Between CM02 (male) (7) and (9) 120 ± 12 z
HB215LC-2 40-327
40 Troubleshooting

a CAN terminating resistor of 120 z is also located in machine
monitor. That is, 2 CAN terminating resistors of 120 z are
connected in parallel. When circuit resistance is measured at
connector of controller other than machine monitor, if combined
resistance is 60 z, wiring harness does not have open circuit.
1. Turn starting switch to OFF position, and turn battery disconnect
2. Disconnect related connectors and connect T-adapters to
connectors to be measured.
a If short circuit is found (resistance between 2 terminals is 1 z or
below), disconnect all CAN communication connectors of every
controller and check whether short circuit occurs between wiring
Open or short circuit in wiring harnesses or inside controller.
5 Approx. 120
harness Between CM02 (female) (8) and (9)
z
Between CE03 (female) (17) and (18) Approx. 60
z
z
Between AC01 (female) (1) and (2) Approx. 60
Resis- z
tance Between CK01 (female) (10) and (11) Approx. 60
z
*Between CC01 (female) (10) and (11) Approx. 60
z
z
Between K02 (female) (A) and (B) Approx. 120
z
recognized)
2. Disconnect connectors to be measured and insert T-adapters into
them.
3. Turn battery disconnect switch to ON position, and turn starting
switch to ON position.
Between CP01 (2) and each of (24), (43), and
(80) 20 to 30 V
Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
6 (Wire breakage or defective
contact of connector) *Between CC01 (2) and (7) 20 to 30 V
2. Disconnect related connectors and connect T-adapters to female
side of connectors to be measured.
Between CM02 (female) (8) and CP01
Resis- Between CM02 (female) (9) and CP01
tance
Between CM02 (female) (8) and CE03
40-328 HB215LC-2
40 Troubleshooting

Between CM02 (female) (9) and CE03
Between CM02 (female) (8) and AC01
Between CM02 (female) (9) and AC01
Between CM02 (female) (8) and CK01
Between CM02 (female) (9) and CK01
Between CM02 (female) (8) and CC01
Between CM02 (female) (9) and CC01
Between CM02 (female) (8) and HC02
Between CM02 (female) (9) and HC02
Between CE03 (female) (17) and K02
(female) (A) Max. 1 z
Between CE03 (female) (18) and K02
(female) (B) Max. 1 z

resistance at any one place in each case.
2. Disconnect related connectors and connect T-adapters to female
Ground fault in wiring harness side of connectors to be measured.
7
(Contact with ground circuit) Between ground and any of CP01 (female)
(45), CM02 (female) (7), (8), CE03 (female) Min. 1 Mz
Resis- (17), and HC02 (female) (1)
tance Between ground and any of CP01 (female)
(64), CM02 (female) (9), CE03 (female) (18), Min. 1 Mz
and HC02 (female) (11)
HB215LC-2 40-329
40 Troubleshooting

voltage at any one place in each case.
2. Insert T-adapters into connectors to be measured.
Open circuit or hot short circuit
8 a Voltage of CAN H and CAN L is 2.5 ± 1 V including during
in wiring harness
communication, so regard wiring harness as normal if measured
voltage is 1 to 4 V.
Between ground and any of CM02 (8), CK01
(10), AC01 (2), CC01 (3), CE03 (17), and 1 to 4 V
HC02 (1)
Voltage
Between ground and any of CM02 (9), CK01
(11), AC01 (1), CC01 (9), CE03 (18), and 1 to 4 V
HC02 (11)
• When all 7 of [D8AQKR], [DA2QKR], [DAFQKR], [DAZQKR],
[DB2QKR], [F7FQKR], and [GA2QKR] failure codes are displayed:
a Identify which controller is defective by disconnecting them one by
one from CAN communication line by repeating the following steps
1 to 3.
Defective engine controller, switch to OFF position.
pump controller, air 2. Disconnect CAN communication connector of engine controller
9 conditioner unit, inverter, *ID (connector CE03), pump controller (connector CP01), air
controller, or KOMTRAX conditioner unit (connector AC01), inverter (connector HC02), *ID
terminal controller (connector CC01), and KOMTRAX terminal (connector
CK01) one by one in turn.
3. Turn battery disconnect switch to ON position, turn starting switch to
ON position, then perform troubleshooting.
4. Return to step 1. to check next connector.
Has the number of displayed failure codes If YES, disconnected
decreased from 7? controller is defective.
*ID controller is optional setting.
40-330 HB215LC-2
40 Troubleshooting
HB215LC-2 40-331
40 Troubleshooting
Failure code [DB2RKR] CAN1 Discon (Engine Con) (HB205-DB2RKR-400-A-Z0-A)
Action level Failure code CAN1 Disconnection (Engine Controller)

Failure
L03 DB2RKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize engine controller over CAN communication-1 line
failure (KOMNET/r).
• Retains current working mode.
Action of • Retains current selection of auto-deceleration.
controller • Retains information at time of occurrence of failure.
• Information to be obtained from engine controller is not displayed and special functions
that need information do not work. Or update of received data is stopped.
• Engine cannot be controlled.
Problem on • Low speed matching function is disabled.
machine • Swing is disabled
• Engine speed and coolant temperature cannot be detected.
• Engine coolant and hydraulic oil temperature gauge pointers disappear on machine
monitor screen.
switch is received.
• If failure code [DB2QKR] is also displayed, engine controller is probably defective (cause
1).
• Machine monitor uses failure codes [DA2RKR] and [GA2RKR] to indicate failures in CAN
communication over CAN 1 line. When failure code [DA2RKR] or [GA2RKR] is displayed
Related simultaneously on screen, there may be a ground fault, short circuit, or hot short circuit in
information wiring harness (CAN communication line).
• CAN1 terminating resister is located in machine monitor on operator's cab side and
connector Terminal port is located on engine side (CAN communication-1 circuit
(KOMNET/r) is not provided. It is output from connector ECM J2.)
using multimeter.
Defective engine Perform checks on causes 1 to 3 in troubleshooting for failure code
1 controller system [DB2QKR].
Defective CAN 1. Turn starting switch to OFF position.
terminating resistor 2. Disconnect connectors CM02 and Terminal port, and connect T-adapters
2 to each male side.
(internal open or short Between Terminal port (male) (A) and (B) 120 ± 12 z
circuit) Resistance
Between CM02 (male) (10) and (12) 120 ± 12 z
a CAN terminating resistor of 120 z is also located in machine monitor. That
is, 2 CAN terminating resistors of 120 z are connected in parallel. When
circuit resistance is measured at connector of controller other than
machine monitor, if combined resistance is 60 z, wiring harness does not
have open circuit.
Open or short circuit in 2. Turn the battery disconnect switch to OFF position.
3 wiring harness 3. Disconnect connectors CM02, CP01, HC02, ECM J1, ECM J2 and
Terminal port, one by one, and connect T-adapters to female side.
a If a short circuit is found (resistance between 2 terminals is 1 z or below),
disconnect all CAN communication connectors of every controller and
check whether short circuit occurs in wiring harness or inside controller.
Between CM02 (female) (11) and (12) Approx. 120
z
Resistance
z
40-332 HB215LC-2
40 Troubleshooting

z
Between Terminal port (female) (A) and (B) Approx. 120
z
Between ECM J1 (female) (8) and (18) Approx. 120
z
Approx. 120
Between ECM J2 (female) (24) and (25) z
HB215LC-2 40-333
40 Troubleshooting

recognized)
OFF position.
2. Disconnect connectors CM01, CP01, HC01, and CE03, and insert T-
adapters.
ON position.
Voltage
Between CP01 (2) and each of (24), (43), and (80) 20 to 30 V
Open circuit in wiring OFF position.
harness 2. Disconnect connectors CM02, CP01, HC02, ECM J1, ECM J2, and
4 (Wire breakage or Terminal port, and connect T-adapters to each female side.
defective contact of Between CM02 (female) (11) and CP01 (female)
connector) (7) Max. 1 z
Between CM02 (female) (12) and CP01 (female)
(26) Max. 1 z
(21) Max. 1 z
(31) Max. 1 z
Resistance
Between CM02 (female) (11) and ECM J1 (female)
(8) Max. 1 z
Between CM02 (female) (12) and ECM J1 (female)
(18) Max. 1 z
Between ECM J2 (female) (24) and Terminal port
(female) (A) Max. 1 z
Between ECM J2 (female) (25) and Terminal port
(female) (B) Max. 1 z
OFF position.
2. Disconnect connectors CM02, CP01, HC02, ECM J1, ECM J2, and
Terminal port, and connect T-adapter to either female side.
Ground fault in wiring CM02 (female) (10), (11), HC02 (female) (21), and Min. 1 Mz
harness ECM J1 (female) (8)
5
(Contact with ground Between ground and ECM J2 (female) (24) or
circuit) Terminal port (female) (A) Min. 1 Mz
Resistance
CM02 (female) (12), HC02 (female) (31), and ECM Min. 1 Mz
J1 (female) (18)
Between ground and either of ECM J2 (female)
(25) and Terminal port (female) (B) Min. 1 Mz
a If no failure (open circuit) is found by check on cause 3, measure voltage

at any one place in each case.
Open circuit or hot short OFF position.
6 circuit in wiring harness 2. Disconnect either of connectors CM02, CP01, HC02, and Terminal port,
and connect T-adapter to female side.
a Measurement is not performed on ECM J1 and ECM J2.
40-334 HB215LC-2
40 Troubleshooting

a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
so regard wiring harness as normal if measured voltage is 1 to 4 V.
CM02 (female) (10), (11), HC02 (female) (21), and 1 to 4 V
Terminal port (female) (A)
Voltage
CM02 (female) (12), HC02 (female) (31), and 1 to 4 V
Terminal port (female) (B)
• If failure code [DA2RKR] is also displayed.
a Disconnect pump controller and engine controller one by one from CAN
communication line to determine which controller is defective.
Defective pump OFF position.
7 2. Disconnect pump controller (connector CP01).
controller
ON position.
Does either or both of failure codes [DA2RKR] and If YES, pump controller
[DB2RKR] disappear? is defective.
HB215LC-2 40-335
40 Troubleshooting

• If failure code [DA2RKR] is also displayed.
a Disconnect pump controller and engine controller one by one from CAN
communication line to determine which controller is defective.
Defective engine OFF position.
8
controller 2. Disconnect engine controller (connector J1).
ON position.
Does either or both of failure codes [DA2RKR] and If YES, engine controller
[DB2RKR] disappear? is defective.
9
Defective machine If no failure is found by above checks, machine monitor is defective.
10
40-336 HB215LC-2
40 Troubleshooting
HB215LC-2 40-337
40 Troubleshooting
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit (PC400-DGH2KB-400-A-Z0-A)
Action level Failure code Hydraulic Oil Temperature Sensor Short Circuit
Failure
L01 DGH2KB (Pump controller system)
Detail of • Signal voltage of hydraulic oil temperature sensor circuit is below 1 V, so pump controller
failure determines that circuit has ground fault.
controller
Problem on • Hydraulic oil temperature gauge indicates 50°C.
machine
• Signal voltage from hydraulic oil temperature sensor can be checked with monitoring
Related function.
information (Code: 04402 Hydr. Temp. Sensor Volt)
Approx. 90
10°C
kz
Defective hydraulic oil Between P22 (male) (1) and (2) Approx. 35
1 temperature sensor 30°C
Resis- a Temperature-resistance
kz
(Internal open or short circuit) characteristics of oil Approx. 6.5
tance 80°C
temperature sensor kz
Approx. 3.5
100°C
kz
Between P22 (male) (2) and ground Min. 1 Mz
Open circuit, short circuit, a If voltage is 0 V, wiring harness has open circuit, ground fault, or
2 ground fault, or hot short short circuit, and if voltage is 24 V, wiring harness has hot short
circuit in wiring harness circuit.
a Voltage of approximately 5 V is applied to temperature sensor signal
circuits through resistance in pump controller.
Voltage Between P22 (female) (1) and (2) Approx. 5 V
a Use Temperature-Resistance characteristics table for
Short circuit or ground fault in troubleshooting on cause 1 as resistance criteria.
3 wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resis- Between CP01 (female) (28) and (46) 3.5 to 90 kz
tance Between CP01 (female) (28) and ground Min. 1 Mz
4 2. Disconnect connectors CP01 and P22, and connect T-adapter to
(Contact with ground circuit) either female side.
Resis- Between ground and CP01 (female) (28) or
P22 (female) (2) Min. 1 Mz
tance
If cause is not found by above checks, pump controller is defective.
40-338 HB215LC-2
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
HB215LC-2 40-339
40 Troubleshooting
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit (HB205-DHA4KA-400-
A-Z0-A)
Action level Failure code Air Cleaner Clogging Sensor Open Circuit
Failure
L01 DHA4KA (Machine monitor system)
Detail of • Signal voltage of air cleaner clogging switch is not 1 V or less while engine is not running,
failure and machine monitor detected clogging of air cleaner (open of sensor contacts).
Action of • Displays system abnormality on machine monitor in yellow.
controller
Problem on • If machine is used as it is, engine may be damaged.
machine
• Input (ON/OFF) from air cleaner clogging switch can be checked with monitoring function
Related (Code: 04501 Monitor input 2).
Air cleaner may be clogged. Check it for clogging and then clean or replace if
1 (When system works clogged.
properly)
Defective air cleaner 2. Disconnect connector P23, and connect T-adapter to male side.
2 clogging switch (internal 3. Start engine
open circuit) Between P23 (male) (1) When air cleaner is
Resistance and (2) Max. 1 z
normal *1
harness 2. Disconnect connectors CM02 and P23, and insert T-adapters into each
defective contact of Between CM02 (female) (4) and P23 (female) (1) Max. 1 z
Resistance
connector) Between P23 (female) (2) and ground Max. 1 z
2. Insert T-adapters into connectors CM01 and CM02.
Defective machine 3. Start engine
4
monitor
Between CM02 (4) and When air cleaner is
Voltage Max. 1 V
CM01 (3) normal
• Air cleaner suction resistance
*1: Max. -3,430 Pa {-350 mmH2O}
Circuit diagram related to air cleaner clogging sensor
40-340 HB215LC-2
40 Troubleshooting
Failure code [DHPAMA] F Pump Press Sensor Abnormality (HB205-DHPAMA-400-A-Z0-

A)
Action level Failure code F pump pressure sensor abnormality

Failure
L01 DHPAMA (Pump controller system)
Detail of • Signal voltage of front pump pressure sensor circuit is 0.3 V and below or 4.5 V and
failure above.
• Controls pump taking front pump pressure to be 0 MPa {0 kg/cm2}.
controller • Low speed matching function does not work normally.
• Automatic travel speed selector function does not work.
Problem on • Straight travel performance or steering performance lowers.
machine • 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 break. Accordingly, take extreme care when checking.
• Front pump pressure can be checked with monitoring function.
(Code: 01100)
If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
2. Disconnect connector P25, and connect T-adapter to female side.
Defective 5 V sensor 3. Turn starting switch to ON position.
1 power supply 1 system
a If power supply voltage is abnormal, proceed to check on cause 3.
Power
Voltage Between P25 (female) (3) and (1) 4.5 to 5.5 V
supply
Sensor
output
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective front pump is difficult to judge whether cause of failure is defective sensor, ground
2 pressure sensor fault or hot short circuit in wiring harness. Check as below.
(internal defect) 1. Turn starting switch to OFF position.
2. Interchange connector P25 with connector P26 of rear 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 again in this failure code column, front pump
pressure sensor is defective.
a After finishing test, restore connectors.
2. Disconnect connectors CP01 and P25, and connect T-adapters to each
female side.
harness a If power supply voltage in check on cause 2 is
normal, this check is not required. Max. 1 z
3 (Wire breakage or Between CP01 (female) (18) and P25 (female) (1)
connector) Resistance Between CP01 (female) (11) and P25 (female) (2) Max. 1 z
Between CP01 (female) (6) and P25 (female) (3)
harness
HB215LC-2 40-341
40 Troubleshooting

2. Disconnect connectors C01 and P25, and connect T-adapter to either
(Contact with ground female side.
circuit) Between ground and CP01 (female) (11) or P25 Min. 1 Mz
Resistance (female) (2)
40-342 HB215LC-2
40 Troubleshooting

5 3. Connect T-adapter to female side of connector P25.
wiring harness
Voltage Between P25 (female) (2) and ground Max. 1 V
Pump controller is If no failure is found by above checks, pump controller is defective.
6
Circuit diagram related to front pump pressure sensor
HB215LC-2 40-343
40 Troubleshooting
Failure code [DHPBMA] R Pump Press Sensor Abnormality (HB205-DHPBMA-400-A-

Z0-A)
Action level Failure code R pump pressure sensor abnormality

Failure
L01 DHPBMA (Pump controller system)
Detail of • Signal voltage of rear pump pressure sensor circuit is 0.3 V and below or 4.5 V and above.
failure
• Controls pump taking rear pump pressure to be 0 MPa {0 kg/cm2}.
• Automatic travel speed selector function does not work.
Problem on • Straight travel performance or steering performance lowers.
• Rear pump pressure can be checked with monitoring function.
(Code: 01101)
If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
Defective 5 V sensor 3. Turn starting switch to ON position.
1 power supply 1 system
Power
supply
2. Connect T-adapter to connector P26.
Sensor
output
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective rear pump is difficult to judge whether cause of failure is defective sensor, ground
2 pressure sensor fault or hot short circuit in wiring harness. Check as below.
(internal defect) 1. Turn starting switch to OFF position.
2. Interchange connector P26 with connector P25 of front pump PPC
pressure sensor.
4. If E mark is not displayed again for this failure code column, rear pump
2. Disconnect connectors CP01 and P26, and connect T-adapter to each
female side.
harness a If power supply voltage in check on cause 2 is
3 (Wire breakage or Between CP01 (female) (18) and P26 (female) (1)
connector) Resistance Between CP01 (female) (11) and P26 (female) (2) Max. 1 z
Between CP01 (female) (6) and P26 (female) (3)
harness
40-344 HB215LC-2
40 Troubleshooting

2. Disconnect connectors CP01 and P26, and connect T-adapter to either
circuit) Between ground and CP01 (female) (11) or P26 Min. 1 Mz
Resistance (female) (2)
HB215LC-2 40-345
40 Troubleshooting

wiring harness
6
Circuit diagram related to rear pump pressure sensor
40-346 HB215LC-2
40 Troubleshooting
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality (HB205-
DHS3MA-400-A-Z0-A)
Action level Failure code Arm CURL PPC pressure sensor abnormality
Failure
L01 DHS3MA (Pump controller system)
Detail of • Signal voltage of arm IN PPC pressure sensor circuit is 0.3 V and below or 4.5 V and
failure above.
• Fixes arm IN PPC pressure at 0 MPa {0 kg/cm2} and continues control.
• Automatic deceleration does not cancel.
Problem on • Poor operability of arm IN
• Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200)
If failure code [DA25KP] is also displayed, perform troubleshooting for it
first.
Defective 5 V sensor power 2. Disconnect connector P04 and connect T-adapter to female side.
1 supply 1 system 3. Turn starting switch to ON position.
Between P04 (female) (3) and Power
Voltage 4.5 to 5.5 V
(1) supply
Sensor
output
a If power supply voltage is normal and sensor output voltage is
abnormal, it is difficult to judge whether cause of failure is defective
Defective arm IN PPC sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor (internal below.
defect)
2. Interchange connector P04 with connector of another 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 again for this failure code, arm IN PPC
2. Disconnect connectors CP01 and P04, and connect T-adapters to
each female side.
Open circuit in wiring harness a If power supply voltage in check on cause
3 (Wire breakage or defective 1 is normal, this check is not required. Max. 1 z
contact of connector) Resis- Between CP01 (female) (18) and P04
tance (female) (1)
Between CP01 (female) (14) and P04
HB215LC-2 40-347
40 Troubleshooting

a If power supply voltage in check on cause
1 is normal, this check is not required. Max. 1 z
Between CP01 (female) (6) and P04 (female)
(3)
Ground fault in wiring harness 2. Disconnect connectors CP01 and P04, and connect T-adapter to
tance
Hot short circuit in wiring 3. Connect T-adapter to female side of connector P04.
5
Circuit diagram related to arm IN PPC pressure sensor
40-348 HB215LC-2
40 Troubleshooting
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality (HB205-
DHS4MA-400-A-Z0-A)
Action level Failure code Bucket CURL PPC pressure sensor abnormality
Failure
Detail of • Signal voltage of bucket CURL PPC pressure sensor circuit is 0.3 V and below or 4.5 V
failure and above.
• Fixes bucket CURL PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem on • Poor operability of bucket CURL
• Bucket CURL PPC pressure can be checked with monitoring function.
(Code: 07300 Bucket Curl PPC Pressure)
first.
Power
supply
Sensor
output
Defective bucket Curl PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, bucket CURL
PPC pressure sensor is defective.
each female side.
tance (female) (1)
HB215LC-2 40-349
40 Troubleshooting

(3)
tance
5
Circuit diagram related to bucket CURL PPC pressure sensor
40-350 HB215LC-2
40 Troubleshooting
Failure code [DHS8MA] Boom Raise PPC Press Sensor

Abnormality (HB205-DHS8MA-400-A-Z0-A)
Action level Failure code Boom RAISE PPC pressure sensor abnormality
Failure
Detail of • Signal voltage of boom RAISE PPC pressure sensor circuit is 0.3 V and below or 4.5 V
failure and above.
• Fixes boom RAISE PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem on • Poor operability of boom RAISE operation
• Boom RAISE PPC pressure can be checked with monitoring function.
(Code: 07400)
first.
Power
supply 4.5 to 5.5 V
2. Insert T-adapter in connector P06.
Sensor
output
Defective boom RAISE PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, boom RAISE
each female side.
tance (female) (1)
HB215LC-2 40-351
40 Troubleshooting

(3)
tance
5
Circuit diagram related to boom raise PPC pressure sensor
40-352 HB215LC-2
40 Troubleshooting
Failure code [DHS9MA] Boom Lower PPC Press Sensor

Abnormality (HB205-DHS9MA-400-A-Z0-A)
Action level Failure code Boom LOWER PPC pressure sensor abnormality
Failure
L01 DHS9MA (pump controller system)
Detail of • Signal voltage of boom LOWER pressure sensor circuit is 0.3 V and below or 4.5 V and
failure above.
• Fixes boom LOWER PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem on • Poor operability of boom LOWER operation
• Boom LOWER PPC pressure can be checked with monitoring function.
(Code: 07500)
first.
Defective 5 V sensor power 3. Turn starting switch to ON position.
1 supply 2 system
a If power supply voltage is abnormal, go to check on cause 3 and
after.
(1) supply
Sensor
output
Defective boom LOWER PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again in this failure code column, boom
LOWER PPC pressure sensor is defective.
each female side.
Open circuit in wiring harness a If power supply voltage in check on
3 (Wire breakage or defective cause 1 is normal, this check is not
required. Max. 1 z
contact of connector) Resis-
tance Between CP01 (female) (18) and P02
(female) (1)
HB215LC-2 40-353
40 Troubleshooting

a If power supply voltage in check on
cause 1 is normal, this check is not
required. Max. 1 z
(female) (3)
tance
5
Circuit diagram related to boom LOWER PPC pressure sensor
40-354 HB215LC-2
40 Troubleshooting
Failure code [DHSAKZ] Swing RH PPC Press Sensor Abnormality (HB205-

DHSAKZ-400-A-Z0-A)
Action level Failure code Swing RH PPC pressure sensor abnormality

Failure
L03 DHSAKZ (Pump controller system)
Detail of • Signal voltage of swing RIGHT PPC pressure sensor circuit is 0.3 V and below or 4.5 V
failure and above.
• Limits the swing speed.
Problem on • Swing speed, etc. are limited.
• Swing RIGHT PPC pressure can be checked with monitoring function.
(Code: 09002)
first.
1 supply 1 system
after.
(1) supply
Sensor
output
Defective swing RIGHT PPC sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor below.
(Internal defect) 1. Turn starting switch to OFF position.
sensor.
4. If E mark is not displayed again in this failure code column, swing
RIGHT PPC pressure sensor is defective.
each female side.
tance (female) (1)
HB215LC-2 40-355
40 Troubleshooting

(3)
tance
5
Circuit diagram related to swing RIGHT PPC pressure sensor
40-356 HB215LC-2
40 Troubleshooting
Failure code [DHSBKZ] Swing LH PPC Press Sensor Abnormality (HB205-

DHSBKZ-400-A-Z0-A)
Action level Failure code Swing LH PPC pressure sensor abnormality

Failure
L03 DHSBKZ (Pump controller system)
Detail of • Signal voltage of swing LEFT PPC pressure sensor circuit is 0.3 V and below or 4.5 V and
failure above.
• Swing LEFT PPC pressure can be checked with monitoring function.
(Code: 09001 Swing Left PPC Pressure)
first.
(1) supply
Sensor
output
Defective swing LEFT PPC sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor below.
sensor.
4. If E mark is not displayed again in this failure code column, swing
LEFT PPC pressure sensor is defective.
each female side.
tance (female) (1)
HB215LC-2 40-357
40 Troubleshooting

(3)
tance
5
Circuit diagram related to swing LEFT PPC pressure sensor
40-358 HB215LC-2
40 Troubleshooting
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality (HB205-
DHSCMA-400-A-Z0-A)
Action level Failure code Arm Dump PPC pressure sensor abnormality
Failure
L01 DHSCMA (Pump controller system)
Detail of • Signal voltage of arm OUT PPC pressure sensor circuit is 0.3 V and below or 4.5 V and
failure above.
• Fixes arm OUT PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem on • Poor operability of arm OUT
Related be measured at pump controller connector.
information • Arm OUT PPC pressure can be checked with monitoring function.
(Code: 07600)
Set to arm crane mode (L).
first.
Defective 5 V sensor power 2. Disconnect connector P08, and connect T-adapter to female side.
Power
supply
Sensor
output
Defective arm OUT PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, arm OUT PPC
each female side.
a If power supply voltage in check on cause 1
3 (Wire breakage or defective is normal, this check is not required. Max. 1 z
contact of connector) Resis- Between CP01 (female) (18) and P08 (female)
tance (1)
(2) Max. 1 z
HB215LC-2 40-359
40 Troubleshooting

is normal, this check is not required. Max. 1 z
(3)
Resis- Between ground and CP01 (female) (51) or P08
Min. 1 Mz
tance (female) (2)
5
Circuit diagram related to arm DUMP (arm OUT) PPC pressure sensor
40-360 HB215LC-2
40 Troubleshooting
Failure code [DHSDMA] Bucket Dump PPC Press Sensor

Abnormality (HB205-DHSDMA-400-A-Z0-A)
Action level Failure code Bucket Dump PPC pressure sensor abnormality
Failure
L01 DHSDMA (Pump controller system)
Detail of • Signal voltage of bucket DUMP PPC pressure sensor circuit is 0.3 V and below or 4.5 V
failure and above.
• Fixes bucket DUMP PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem on • Poor operability of bucket DUMP
• Bucket DUMP PPC pressure can be checked with monitoring function.
(Code: 07301 Bucket Dump PPC Pressure)
first.
(1) supply
Sensor
output
Defective bucket DUMP PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, bucket DUMP
each female side.
tance (female) (1)
HB215LC-2 40-361
40 Troubleshooting

(3)
tance
5 harness 3. Connect T-adapter to female side of connector P05.
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
Circuit diagram related to bucket DUMP PPC pressure sensor
40-362 HB215LC-2
40 Troubleshooting
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor

Abnormality (HB205-DHSFMA-400-A-Z0-A)
Action level Failure code Travel Forward LH PPC Pressure Sensor Abnormality
Failure
L01 DHSFMA (Pump controller system)
Detail of • Signal voltage of left travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5
failure V.
• Controls machine by setting left travel FORWARD PPC pressure as 0 MPa {0 kg/cm 2}.
Problem on • Controllability of travel deteriorates.
• Left travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07102 Travel Fwd LH PPC Pressure)
first.
Defective 5 V sensor power 2. Disconnect connector P09, and connect T-adapter to female side.
(1) supply
Sensor
output
Defective left travel sensor, ground fault or hot short circuit in wiring harness. Check as
2 FORWARD PPC pressure below.
sensor (internal defect)
2. Interchange connector P09 with connector of other PPC pressure
sensor.
4. If E mark is not displayed in this failure code column, travel
FORWARD LH PPC pressure sensor is defective.
each female side.
tance (female) (1)
HB215LC-2 40-363
40 Troubleshooting

(3)
tance
harness 2. Disconnect connector P09.
(Contact with 5 V circuit and 4. Turn starting switch to ON position.
24 V circuit)
Circuit diagram related to travel PPC pressure sensor
40-364 HB215LC-2
40 Troubleshooting
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor

Abnormality (HB205-DHSGMA-400-A-Z0-A)
Action level Failure code Travel Forward RH PPC Pressure Sensor Abnormality
Failure
L01 DHSGMA (Pump controller system)
Detail of • Signal voltage of right travel FORWARD PPC pressure sensor is 0.3 V and below or 4.5 V
failure and above.
• Controls machine by setting right travel FORWARD PPC pressure as 0 MPa {0 kg/cm 2}.
• Right travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07103 Travel Fwd RH PPC Pressure)
first.
Between P11 (female) (3) and
Voltage Power supply 4.5 to 5.5 V
(1)
Defective right travel sensor, ground fault or hot short circuit in wiring harness. Check as
FORWARD PPC pressure below.
2 sensor
(Internal defect) 2. Interchange connector P11 with connector of another PPC pressure
sensor.
FORWARD RH PPC pressure sensor is defective.
each female side.
Open circuit in wiring harness is normal, this check is not required. Max. 1 z
3 (Wire breakage or defective Between CP01 (female) (18) and P11 (female)
contact of connector) Resis- (1)
tance Between CP01 (female) (72) and P11 (female)
(2) Max. 1 z
a If power supply voltage in check on cause 1 Max. 1 z

is normal, this check is not required.
HB215LC-2 40-365
40 Troubleshooting

(3)
Min. 1 Mz
tance P11 (female) (2)
5
40-366 HB215LC-2
40 Troubleshooting
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor

Abnormality (HB205-DHSHMA-400-A-Z0-A)
Action level Failure code Travel Reverse LH PPC Pressure Sensor Abnormality
Failure
L01 DHSHMA (Pump controller system)
Detail of • Signal voltage of left travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
• Controls machine by regarding left travel REVERSE PPC pressure as 0 MPa {0 kg/cm 2}.
• Left travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07104)
first.
(1) supply
Sensor
output
Defective left travel abnormal, it is difficult to judge whether cause of failure is defective
REVERSE PPC pressure sensor, ground fault or hot short circuit in wiring harness. Check as
2 sensor below.
2. Interchange connector P10 with connector of other PPC pressure
sensor.
REVERSE LH PPC pressure sensor is defective.
each female side.
tance (female) (1)
HB215LC-2 40-367
40 Troubleshooting

(3)
tance
24 V circuit)
40-368 HB215LC-2
40 Troubleshooting
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor

Abnormality (HB205-DHSJMA-400-A-Z0-A)
Action level Failure code Travel Reverse RH PPC Pressure Sensor Abnormality
Failure
L01 DHSJMA (Pump controller system)
Detail of • Signal voltage of right travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
• Controls machine by regarding right travel REVERSE PPC pressure as 0 MPa {0 kg/
Action of cm2}.
• Right travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07105 Travel Rev RH PPC Pressure)
first.
1 supply 1 system
after.
(1) supply
Sensor
output
Defective right travel abnormal, it is difficult to judge whether cause of failure is defective
REVERSE PPC pressure sensor, ground fault or hot short circuit in wiring harness. Check as
2 sensor below.
sensor.
REVERSE RH PPC pressure sensor is defective.
each female side.
tance (female) (1)
HB215LC-2 40-369
40 Troubleshooting

(3)
tance
24 V circuit)
40-370 HB215LC-2
40 Troubleshooting
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt. (HB205-
DHVAKZ-400-A-Z0-A)
Action level Failure code Hybrid Swing-R PPC Pressure Sensor Open/Short Circuit
Failure
L03 DHVAKZ (Hybrid controller systems)
Detail of • Signal voltage of hybrid swing RIGHT PPC pressure sensor circuit is 0.3 V and below or
failure 4.5 V and above.
• Limits swing speed, etc. in accordance with pump controller swing RIGHT PPC pressure.
controller is set to OFF position.
machine
Related • Voltage sensed by hybrid swing RIGHT PPC pressure sensor can be checked with
information monitoring function.
(Code: 09007)
If failure code [GAA6KP] or [GAA6KY] is also displayed, perform
2. Disconnect connector HP06 and connect T-adapter to female side.
1 supply 1 system
a If power supply voltage is abnormal, perform checks for cause 3 and
after.
Between HP06 (female) (3) and Power
(1) supply
2. Insert T-adapter into connector HP06.
Sensor
Voltage Between HP06 (2) and (1) 0.5 to 4.5 V
output
Defective hybrid swing sensor, ground fault or hot short circuit in wiring harness. Check as
2 RIGHT PPC pressure sensor below.
(internal defect)
2. Interchange connector HP06 with connector of another PPC
pressure sensor.
4. If E mark is not displayed again for this failure code, hybrid swing
RIGHT PPC pressure sensor is defective.
2. Disconnect connectors HC02 and HP06, and connect T-adapters to
each female side.
contact of connector) Resis- Between HC02 (female) (38), (39) and HP06
tance (female) (1)
Between HC02 (female) (9) and HP06 (female)
(2) Max. 1 z
HB215LC-2 40-371
40 Troubleshooting

Between HC02 (female) (25) and HP06
(female) (3)
Ground fault in wiring harness 2. Disconnect connectors HC02 and HP06, and connect T-adapter to
Resis- Between ground and HC02 (female) (9) or Min. 1 Mz
tance HP06 (female) (2)
40-372 HB215LC-2
40 Troubleshooting

2. Disconnect connector HP06.
Hot short circuit in wiring 3. Connect T-adapter to female side of connector HP06.
5
Voltage Between HP06 (female) (2) and ground Max. 1 V
If no failure is found by above checks, inverter (hybrid controller) is
Defective inverter (hybrid
controller)
performed).
Circuit diagram related to swing RIGHT PPC pressure sensor
HB215LC-2 40-373
40 Troubleshooting
Failure code [DHVAL8] HYB Swing-R PPC Pr. Sen. Signal Mismatch (HB205-
DHVAL8-400-A-Z0-A)
Action level Failure code Hybrid Swing-R PPC Pressure Sensor Signal Mismatch
Failure
L03 DHVAL8 (Hybrid controller systems)
• When motor-generator is running, difference between hybrid swing RIGHT PPC pressure
Detail of sensor and pump control swing RIGHT PPC pressure sensor values exceeds 0.49 MPa
failure {5.0 kg/cm2 }.
• Selects the minimum value of the pump controller and hybrid swing RIGHT PPC
pressures for controlling the controller.
Action of • Limits the swing speed etc.
is set to OFF position.
machine
Related • Hybrid swing RIGHT PPC pressure can be checked with monitoring function.
• Swing RIGHT PPC pressure can be checked with monitoring function.
(Code: 09002)
Perform troubleshooting for failure codes [DHVAKZ], [DHSAKZ], and [GA60MC].
40-374 HB215LC-2
40 Troubleshooting
Failure code [DHVAMA] HYB Swing-R PPC Sensor Malfunction (HB205-DHVAMA-

400-A-Z1-A)
Action level Failure code Hybrid Swing-R PPC Sensor Malfunction

Failure
L03 DHVAMA (Hybrid controller systems)
• Any 2 of failure codes [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cir., [DHVAL8]
Detail of HYB Swng-R PPC Pr. Sen. Signal Mismatch, [GA2RKR] KOMNET Datalink Timeout
failure Error, and [DHSAKZ] Swing RH PPC Press Sensor Abnormality are displayed.
• Open circuit in PPC lock signal line
• Stops control of swing motor and motor-generator.
• Turns ON swing parking brake.
Action of • Low speed matching function does not work normally.
controller • Hoist matching function does not work normally.
• Even if cause of failure disappears, machine does not become normal until starting switch
machine
• Voltage sensed by hybrid swing RIGHT PPC pressure sensor can be checked with
information • Swing RIGHT PPC pressure can be checked with monitoring function.
(Code: 09002)
• PPC lock signal can be checked with monitoring function.
(Code: 09702)
1 Perform troubleshooting for failure codes [DHVAKZ], [DHSAKZ], and [GA2RKR].
Open circuit in wiring harness 2. Disconnect connectors S14 and HC01, and connect T-adapters to
2 (Wire breakage or defective each female side.
contact of connector) Resis- Between S14 (female) (2) and HC01 (female)
(15) Max. 1 z
tance
HB215LC-2 40-375
40 Troubleshooting
Circuit diagram related to hybrid swing RIGHT PPC pressure sensor
40-376 HB215LC-2
40 Troubleshooting
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen. Opn/Short Cir. (HB205-
DHVBKZ-400-A-Z0-A)
Action level Failure code Hybrid Swing-L PPC Pressure Sensor Open/Short Circuit
Failure
L03 DHVBKZ (Hybrid controller systems)
Detail of • Signal voltage of hybrid swing LEFT PPC pressure sensor circuit is 0.3 V and below or
failure 4.5 V and above.
• Limits operation and swing speed in accordance with pump controller swing LEFT PPC
Action of pressure.
machine
Related • Voltage sensed by hybrid swing LEFT PPC pressure sensor can be checked with
information monitoring function.
(Code: 09006)
If failure code [GAA6KP] or [GAA6KY] is also displayed, perform
Defective 5 V sensor power
supply system
a If power supply voltage is abnormal, perform checks for cause 3 and
after.
Power
Voltage Between HP04 (female) (3) and (1) 4.5 to 5.5 V
supply
2. Insert T-adapter into connector HP04.
Sensor
Voltage Between HP04 (2) and (1) 0.5 to 4.5 V
output
Defective hybrid swing LEFT sensor, ground fault or hot short circuit in wiring harness. Check as
2 PPC pressure sensor below.
(internal defect)
2. Interchange connector HP04 with connector of another PPC
pressure sensor.
4. If E mark is not displayed again in this failure code column, hybrid
swing LEFT PPC pressure sensor is defective.
each female side.
Open circuit in wiring harness a If power supply voltage in check on cause 1
contact of connector) Resis- Between HC02 (female) (38), (39) and HP04
tance (female) (1)
HB215LC-2 40-377
40 Troubleshooting

(female) (3)
Ground fault in wiring 2. Disconnect connectors HC02 and HP04, and connect T-adapter to
4 harness either female side.
(Contact with ground circuit) Resis- Between ground and HC02 (female) (19) or
HP04 (female) (2) Min. 1 Mz
tance
2. Disconnect connector HP04.
Hot short circuit in wiring 3. Connect T-adapter to female side of connector HP04.
5
Voltage Between HP04 (female) (2) and ground Max. 1 V
If no failure is found by above checks, inverter (hybrid controller) is
controller)
performed).
Circuit diagram related to swing LEFT PPC pressure sensor
40-378 HB215LC-2
40 Troubleshooting
Failure code [DHVBL8] HYB Swing-L PPC Pr. Sen. Signal Mismatch (HB205-
DHVBL8-400-A-Z0-A)
Action level Failure code Hybrid Swing-L PPC Pressure Sensor Signal Mismatch
Failure
L03 DHVBL8 (Hybrid controller systems)
• When motor-generator is running, difference between hybrid swing LEFT PPC pressure
Detail of sensor and pump control swing LEFT PPC pressure sensor values exceeds 0.49 MPa
failure {5.0 kg/cm2 }.
• Selects the lower of the pump controller and hybrid swing LEFT PPC pressures for
control.
Action of • Limits the swing speed etc.
machine
Related • Hybrid swing LEFT PPC pressure can be checked with monitoring function.
• Swing LEFT PPC pressure can be checked with monitoring function.
(Code: 09001)
Perform troubleshooting for failure codes [DHVBKZ], [DHSBKZ], and [GA60MC].
HB215LC-2 40-379
40 Troubleshooting
Failure code [DHVBMA] HYB Swing-L PPC Sensor Malfunction (HB205-DHVBMA-

400-A-Z1-A)
Action level Failure code Hybrid Swing-L PPC Sensor Malfunction

Failure
L03 DHVBMA (Hybrid controller systems)
• Any 2 of failure codes [DHVBKZ] HYB Swng-L PPC Pr. Sen. Opn/Short Cir., [DHVBL8]
Detail of HYB Swng-L PPC Pr. Sen. Signal Mismatch, [GA2RKR] KOMNET Datalink Timeout
failure Error, and [DHSBKZ] Swing LH PPC Press Sensor Abnormality are displayed.
• Open circuit in PPC lock signal line
• Stops control of swing motor and motor-generator.
• Turns ON swing parking brake.
machine
• Voltage sensed by hybrid swing LEFT PPC pressure sensor can be checked with
information • Swing LEFT PPC pressure can be checked with monitoring function.
(Code: 09001)
• PPC lock signal can be checked with monitoring function.
(Code: 09702)
1 Perform troubleshooting for failure codes [DHVBKZ] and [DHSBKZ].
Open circuit in wiring harness 2. Disconnect connectors S14 and HC01, and connect T-adapters to
contact of connector) Resis- Between S14 (female) (2) and HC01 (female)
(15) Max. 1 z
tance
40-380 HB215LC-2
40 Troubleshooting
Circuit diagram related to hybrid swing LEFT PPC pressure sensor
HB215LC-2 40-381
40 Troubleshooting
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality (HB205-

DKR0MA-400-A-Z0-A)
Action level Failure code F Pump Swash Plate Sensor Abnormality

Failure
L01 DKR0MA (Pump controller system)
Detail of • Signal voltage of F pump swash plate sensor circuit is below 0.5 V or above 4.5 V.
failure
machine
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely,
sensor will break. Accordingly, take extreme care when checking.
information • Input voltage from front pump swash plate sensor can be checked with monitoring
function.
(Code: 01138 F pump swash plate sensor voltage)
first.
1 supply 1 system
after.
Between P27 (female) (A) and Power
(B) supply
Between P27 (male) (A) and (B) Approx. 6
kz
Approx. 6
Resis- Between P27 (male) (B) and (C) kz
tance Approx. 170
Between P27 (male) (A) and (C)
z
Defective F pump swash plate Voltage Between P27 (C) and (B) Sensor
Approx. 3 V
sensor output
2
3. Starting engine
a Shifts the pump swash plate angle toward the minimum position
with control lever in neutral.
Sensor Approx. 1.4
Voltage Between P27 (C) and (B)
output V
a If sensor power supply voltage is normal and sensor output voltage
is abnormal, it is difficult to judge whether cause of failure is
defective sensor, ground fault or hot short circuit in wiring harness.
Check as below.
2. Interchange connector P27 with connector P28.
40-382 HB215LC-2
40 Troubleshooting

4. If E mark is not displayed again for this failure code column, F pump
swash plate sensor is defective.
each female side.
a If sensor power supply voltage in check on
required. Max. 1 z
Open circuit in wiring harness Between CP01 (female) (6) and P27 (female)
3 (Wire breakage or defective (A)
tance
required. Max. 1 z
(female) (B)
(female) (C) Max. 1 z

P27 (female) (C) Min. 1 Mz
tance
5
Voltage Between P27 (female) (C) and ground Max. 1 V
HB215LC-2 40-383
40 Troubleshooting
Circuit diagram related to F and R pump swash plate sensor
40-384 HB215LC-2
40 Troubleshooting
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality (HB205-

DKR1MA-400-A-Z0-A)
Action level Failure code R pump swash plate sensor abnormality

Failure
L01 DKR1MA (Pump controller system)
Detail of • Signal voltage of R pump swash plate sensor circuit is 0.5 V and below or 4.5 V and
failure above.
machine
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely,
sensor will break. Accordingly, take extreme care when checking.
information • Input voltage from rear pump swash plate sensor can be checked with monitoring
function.
(Code: 01140 R pump swash plate sensor voltage)
first.
1 supply 1 system
a If sensor power supply voltage is abnormal, proceed to check on
cause 3.
Between P28 (female) (A) and Power
(B) supply
Between P28 (male) (A) and (B) Approx. 6
kz
Approx. 6
Resis- Between P28 (male) (B) and (C) kz
tance Approx. 170
Between P28 (male) (A) and (C)
z
Defective R pump swash Sensor
Voltage Between P28 (C) and (B) Approx. 3 V
plate sensor output
2
3. Starting engine
a Shifts the pump swash plate angle toward the minimum position with
control lever in neutral.
Sensor Approx. 1.4
Voltage Between P28 (C) and (B)
output V
a If sensor power supply voltage is normal and sensor output voltage
is abnormal, it is difficult to judge whether cause of failure is
defective sensor, ground fault or hot short circuit in wiring harness.
Check as below.
2. Interchange connector P28 with connector P27.
HB215LC-2 40-385
40 Troubleshooting

4. If E mark is not displayed again for this failure code column, R pump
swash plate sensor is defective.
each female side.
required. Max. 1 z
3 (Wire breakage or defective (A)
tance
required. Max. 1 z
(B)
(C) Max. 1 z

P28 (female) (C) Min. 1 Mz
tance
5 harness 3. Connect T-adapter to female side of connector P28.
Voltage Between P28 (female) (C) and ground Max. 1 V
40-386 HB215LC-2
40 Troubleshooting
Circuit diagram related to F and R pump swash plate sensor
HB215LC-2 40-387
40 Troubleshooting
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality (PC220_10-

DR21KX-400-A-00-A)
Action Camera 2 image reverse drive malfunction
Failure code
level Failure
L01 DR21KX
Details of • Output voltage of camera 2 image reverse drive line (pin 6 of connector CM04) differs
failure from command voltage output from machine monitor.
Action of • Does not display image of camera 2.
controller
Problem on • Image of camera 2 is not displayed.
machine
• When output voltage of camera 2 image reverse drive line (pin 6 of connect or CM04) is 0
V, original image is sent. When it is 8 V, mirror image is sent (since power supply voltage
Related of camera is 8 V, 8 V is used as command voltage to send mirror image).
information • Since two or more connector A46 may be provided, you must check connector A41 to
identify which camera is assigned to camera 2.
Open circuit in 2. Disconnect connectors CM04 and A46, and connect T-adapters to each female
wiring harness side.
1 (wire breakage or Between CM04 (female) (6) and A46
Between CM04 (female) (8) and A46

wiring harness 2. Disconnect connectors CM04 and A46, and connect T-adapters to either
2 (contact with GND female side.
circuit) Between ground and CM04 (female) (6)
Resistance or A46 (female) (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector A46 and connect T-adapters to female side.
wiring harness 3. Turn starting switch to ON position.
3
(contact with 24 V a Check that camera 2 is set for original images.
circuit) Between A46 (female) (3) and (4), or
Voltage Max. 1 V
between A46 (female) (3) and ground
Short circuit in 2. Disconnect connector CM04 and connect T-adapters to female side.
4 wiring harness Between CM04 (female) (6) and each
Resistance pin other than (6) Min. 1 Mz
If no failure is found by above checks, camera 2 is defective. (Since this is an
5 Defective camera 2 internal defect, troubleshooting cannot be performed.)
Defective machine If no failure is found by above checks, machine monitor is defective. (Since this is
6 an internal defect, troubleshooting cannot be performed.)
monitor
40-388 HB215LC-2
40 Troubleshooting
Circuit diagram related to camera
HB215LC-2 40-389
40 Troubleshooting
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality (PC220_10-

DR31KX-400-A-00-A)
Action Camera 3 image reverse drive malfunction
Failure code
level Failure
L01 DR31KX
Details of • Output voltage of camera 3 image reverse drive line (pin 7 of connector CM04) differs
failure from command voltage output from machine monitor.
Action of • Does not display image of camera 3.
controller
Problem on • Image of camera 3 is not displayed.
machine
• When output voltage of camera 3 image reverse drive line (pin 7 of connect or CM04) is 0
V, original image is sent. When it is 8 V, mirror image is sent (since power supply voltage
Related of camera is 8 V, 8 V is used as command voltage to send mirror image).
information • Since two or more connector A46 may be provided, you must check connector A42 to
identify which camera is assigned to camera 3.
Open circuit in 2. Disconnect connectors CM04 and A46, and connect T-adapters to each female
wiring harness side.
1 (wire breakage or Between CM04 (female) (7) and A46
Between CM04 (female) (8) and A46

wiring harness 2. Disconnect connectors CM04 and A46, and connect T-adapters to either
2 (contact with GND female side.
circuit) Between ground and CM04 (female) (7)
Resistance or A46 (female) (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector A46 and connect T-adapters to female side.
wiring harness 3. Turn starting switch to ON position.
3
(contact with 24 V a Check that camera 3 is set for original images.
circuit) Between A46 (female) (3) and (4) or
Voltage Max. 1 V
ground
Short circuit in 2. Disconnect connector CM04 and connect T-adapter to female side.
4 wiring harness Between CM04 (female) (7) and each
Resistance pin other than (7) Min. 1 Mz
If no failure is found by above checks, camera 3 is defective. (Since this is an
5 Defective camera 3 internal defect, troubleshooting cannot be performed.)
monitor
40-390 HB215LC-2
40 Troubleshooting
Circuit diagram related to camera
HB215LC-2 40-391
40 Troubleshooting
Failure code [DV20KB] Travel Alarm Short Circuit (HB205-DV20KB-400-A-Z0-A)
Action level Failure code Travel Alarm Short Circuit

Failure
L01 DV20KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives travel alarm circuit.
failure
• Stops driving travel alarm circuit.
Problem on
• Travel alarm does not sound.
machine
2. Disconnect connector M14, and connect T-adapter to female side.
4. Perform troubleshooting by operating the travel lever.
Defective travel alarm k Never enter under the machine when operating travel lever.
1
(Internal defect)
a If the following voltage is normal but travel alarm does not sound, travel
alarm is defective.
Travel lever: Neutral Max. 1 V
Between M14 (female)
Voltage Travel lever: When
(1) and (2) 20 to 30 V
operated
harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either
2 female side.
Between CP02 (female) (107) and ground, or M14
circuit) Resistance (female) (1) and ground Min. 1 Mz

2. Insert T-adapter into connector M14.
4. Perform troubleshooting by operating the travel lever.
Pump controller is
3
defective. k Never enter under the machine when operating travel lever.
Travel lever: Neutral Max. 1 V
Voltage Between M14 (1) and (2) Travel lever: When
operated 20 to 30 V
40-392 HB215LC-2
40 Troubleshooting
Circuit diagram related to travel alarm
HB215LC-2 40-393
40 Troubleshooting
Failure code [DW43KA] Travel Speed Sol Open Circuit (HB205-DW43KA-400-A-Z0-A)
Action level Failure code Travel Speed Solenoid Open Circuit

Failure
L01 DW43KA (Pump controller system)
Detail of • On energizing travel speed shifting solenoid, an abnormal current flowed in the circuit.
failure
Action of • None in particular (Since no current flows, solenoid is not energized.)
Problem on • "Hi" travel speed is slow. (Although "Hi" is displayed on machine monitor, actual travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is "ON", sensor status
Related displayed on monitoring screen is "ON" even if solenoid is not energized due to short
information circuit.)
(Code: 02300)
Defective travel speed 1. Turn starting switch to OFF position.
1 selector solenoid 2. Disconnect connector V04, and connect T-adapter to male side.
(Internal open circuit) Resistance Between V04 (male) (1) and (2) 20 to 60 z
2. Disconnect connector V04 and connect T-adapter to female side.
Open circuit, short circuit, 3. Turn starting switch to ON position.
ground fault, hot short circuit
of wiring harness, or defective a Shake the wiring harness by hand while measuring the voltage. If
2
transmission controller the voltage drops to approximately 0 V during shaking, wiring
harness is open at this point.
Voltage Between V04 (female) (1) and (2) 1 to 4.5 V
Between CP02 (female) (93) and each of
Resistance (115), (117), and (120) 20 to 60 z
Open circuit in wiring harness a If no failure is found by above checks, this check is not required.
3 (Wire breakage or defective 1. Turn starting switch to OFF position.
contact of connector) 2. Disconnect connectors CP02 and V04, and connect T-adapter to
each female side.
Between CP02 (female) (93) and V04
Resistance
Between V04 (female) (2) and each of
CP02 (female) (115), (117), and (120) Max. 1 z
40-394 HB215LC-2
40 Troubleshooting
Circuit diagram related to travel speed solenoid
HB215LC-2 40-395
40 Troubleshooting
Failure code [DW43KB] Travel Speed Sol Short Circuit (HB205-DW43KB-400-A-Z0-A)
Action level Failure code Travel Speed Solenoid Short Circuit

Failure
L01 DW43KB (Pump controller system)
• Abnormal current flows when pump controller drives travel speed selector solenoid, so
Detail of
pump controller determines that short circuit exists in travel speed selector solenoid
failure
circuit.
• Stops driving travel speed selector solenoid.
Problem on • "Hi" travel speed is slow. (Although "Hi" is displayed on machine monitor, actual travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
Related displayed on monitoring screen is "ON" even if solenoid is not energized due to short
information circuit.)
(Code: 02300)
Defective travel speed 1. Turn starting switch to OFF position.
selector solenoid 2. Disconnect connector V04, and connect T-adapter to male side.
1
(Internal short circuit or Between V04 (male) (1) and (2) 20 to 60 z
ground fault) Resistance
Between V04 (male) (1) and ground Min. 1 Mz
Short circuit or ground fault in
2 Between CP02 (female) (93) and each of
wiring harness 20 to 60 z
Resistance (115), (117), and (120)
Between CP02 (female) (93) and ground Min. 1 Mz
a If no abnormality is found in check on cause 2, this check is not
required.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
3 2. Disconnect connectors CP02 and V04, and connect T-adapter to
either female side.
Between ground and CP02 (female) (93) or
Resistance V04 (female) (1) Min. 1 Mz
40-396 HB215LC-2
40 Troubleshooting
HB215LC-2 40-397
40 Troubleshooting
Failure code [DW45KA] Swing Brake Sol Open Circuit (HB205-DW45KA-400-A-Z0-A)
Action level Failure code Swing Brake Solenoid Open Circuit

Failure
L03 DW45KA (Hybrid controller systems)
• Controller output voltage to solenoid is above standard value when pump controller does
Detail of not drive swing parking brake solenoid, so pump controller determines that open circuit
failure exists in swing parking brake solenoid circuit.
• None in particular (Since no current flows, solenoid is not energized. That is, swing
Action of parking brake is applied.)
Problem on • Upper structure does not swing (swing parking brake is not released).
machine
• When solenoid and wiring harness are normal, swing operation is possible if swing lock
switch is turned OFF and swing parking brake cancel switch is set to RELEASE position.
(Note that swing parking brake is applied when starting switch is in OFF position.)
• Keep the swing lock switch in OFF position and the swing parking brake cancel switch in
the NORMAL position during troubleshooting.
• The brake is disengaged when current flows through swing parking brake solenoid while
the engine is running.
Related • Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
information monitoring function. (As long as controller's command to solenoid is "ON", sensor status
displayed on monitoring screen is "ON" even if solenoid is not energized due to open
circuit.)
(Code: 09700)
• Power for swing parking brake solenoid is supplied from pin (8) of inverter (hybrid
controller) connector HC01 or fuse No.1 in fuse box F01.
Defective No. 1 (upper right) If fuse is blown, see failure code [DW45KB].
1
fuse in fuse box F01
Defective swing parking brake 2. Disconnect connector V03, and connect T-adapters to male side.
2
solenoid
Resistance Between V03 (male) (1) and (2) 20 to 60 z
3 of wiring harness, or defective a Shake the wiring harness by hand while measuring the voltage. If
hybrid controller the voltage drops to approximately 0 V during shaking, wiring
Voltage Between V03 (female) (1) and (2) 1 to 4.5V
2. Remove diode arrays D01 and D03, and connect T-adapters to each
male side.
Defective diode array D01 or a Measure it with diode range of multimeter.
4
D03 Between D01 (male) (3) (+) and (7) (-) No continuity
Between D01 (male) (7) (+) and (3) (-) Continuity
Continuity
Between D03 (male) (5) (+) and (1) (-) No continuity
2. Remove diode D01.
3. Disconnect connector HC01, and connect T-adapter to female side.
Open circuit in wiring harness a Swing lock switch: OFF
5 (Wire breakage or defective Between HC01 (female) (8) and D01
Resistance
Between D01 (female) (3) and HC01
(female) (13) or ground 20 to 60 z
a If no failure is found by above checks, this check is not required.
40-398 HB215LC-2
40 Troubleshooting

2. Disconnect connectors D01, HC01, and V03, and connect T-
Between D01 (female) (3) and V03 (female)
(1) Max. 1 z
Resistance
Between V03 (female) (2) and HC01
(female) (13) or ground Max. 1 z
If cause is not found by above checks, inverter (hybrid controller) is
Defective inverter (hybrid defective.
6 controller)
HB215LC-2 40-399
40 Troubleshooting
Circuit diagram related to swing parking brake solenoid
40-400 HB215LC-2
40 Troubleshooting
Failure code [DW45KB] Swing Brake Sol Short Circuit (HB205-DW45KB-400-A-Z0-A)
Action level Failure code Swing Brake Solenoid Short Circuit

Failure
L03 DW45KB (Hybrid controller systems)
Detail of • Abnormal current flows when pump controller drives swing parking brake solenoid, so
failure pump controller determines that short circuit exists in swing parking brake solenoid circuit.
• Stops driving swing parking brake solenoid.
machine
• When solenoid and wiring harness are normal, swing operation is possible if swing lock
switch is turned OFF and swing parking brake cancel switch is set to RELEASE position.
(Note that swing parking brake is applied when starting switch is in OFF position.)
• Keep the swing lock switch in OFF position and the swing parking brake cancel switch in
the NORMAL position during troubleshooting.
• The brake is disengaged when current flows through swing parking brake solenoid while
the engine is running.
Related
• Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
information
displayed on monitoring screen is "ON" even if solenoid is not energized due to short
circuit.)
(Code: 09700)
• Power for swing parking brake solenoid is supplied from pin (8) of hybrid controller
connector HC01 or fuse No.1 in fuse box F01.
Defective No. 1 (upper right) Even if fuse is blown, perform troubleshooting according to following
1 steps to identify cause.
fuse in fuse box F01
Defective swing parking brake 2. Disconnect connector V03, and connect T-adapter to male side.
2
2. Remove diode arrays D01 and D03, and connect T-adapter to each
male side.
a Measure it with diode range of multimeter.
Defective diode array D01 or No
3 Between D01 (male) (3) (+) and (7) (-)
D03 continuity
Continuity
No
Between D03 (male) (1) (+) and (5) (-)
continuity
2. Remove fuse No.1 (upper right, 5 A) in fuse box F01 and diode
Ground fault in wiring harness D01.
4 3. Disconnect connectors HC01, D01, and V03.
(Contact with ground circuit) 4. Connect T-adapters to female side of connectors HC01 and D01.
Resis- Between HC01 (female) (8) and ground Min. 1 Mz
tance Between D01 (female) (3) and ground Min. 1 Mz
HB215LC-2 40-401
40 Troubleshooting

2. Remove fuse No.1 (upper right, 5 A) in fuse box F01 and diode
D01.
5 Short circuit in wiring harness 3. Disconnect connector HC01.
4. Connect T-adapters to female side of connectors D01 and HC01.
Resis- Between D01 (female) (3) and HC01 (female)
(13) or ground 20 to 60 z
tance
40-402 HB215LC-2
40 Troubleshooting
HB215LC-2 40-403
40 Troubleshooting
Failure code [DW45KK] Swing Brake Sol. Valve Low Sup. Voltage (HB205-
DW45KK-400-A-Z0-A)
Action level Failure code Swing Brake Solenoid Valve Low Supply Voltage
Failure
L03 DW45KK (Hybrid controller systems)
Detail of • Low voltage is detected in driving power supply circuit of swing parking brake solenoid
failure which is the of the hybrid controller.
machine
• When solenoid and wiring harness are normal, swing operation is possible if swing
parking brake cancel switch is set to RELEASE position. (Note that swing parking brake
cancel does not operate when starting switch is in OFF position.)
• Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
• Controller's command voltage (ON/OFF) to swing parking brake solenoid valve can be
checked with monitoring function.
(Code: 02300)
Ground fault in pump
controller swing parking brake If failure code [GAA2KB] is also displayed, perform troubleshooting for it
1
solenoid valve output first.
Abnormality in pump If failure code [DW22KK] is also displayed, perform troubleshooting for it
2 controller load power supply first.
Open circuit in wiring harness 2. Disconnect connectors CP02 and HC01, and connect T-adapters to
contact of connector) Resis- Between CP02 (101) and HC01 (21)
Max. 1 z
tance
If no failure is found by above checks, pump controller or hybrid
Defective pump controller or controller is defective.
4 defective hybrid controller
40-404 HB215LC-2
40 Troubleshooting
Circuit diagram related to hybrid controller (inverter)
HB215LC-2 40-405
40 Troubleshooting
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. (HB205-DW45KY-400-A-
Z0-A)
Action level Failure code Swing Brake Solenoid Valve Power Short Circuit
Failure
L03 DW45KY (Hybrid controller systems)
Detail of not drive swing parking brake solenoid, so pump controller determines that short circuit
failure exists in swing parking brake solenoid circuit.
Problem on • Swing parking brake does not operate when current abnormally flows through swing
machine parking brake solenoid.
cancel does not operate, or swing parking brake is kept engaged when starting switch is
in OFF position.)
• Keep swing lock switch in OFF position during troubleshooting.
• The brake is disengaged when current flows through swing parking brake solenoid.
Related (Work equipment should be lowered because swing parking brake may not operate.)
information • Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
(Code: 09700)
• Power for swing parking brake solenoid is supplied from pin (8) of inverter (hybrid
controller) connector HC01 or fuse No.1 in fuse box F01.
2. Disconnect connectors HC01, D01 and V03, and connect T-adapter
Hot short circuit in wiring
1
harness a Ignore failure codes displayed on machine monitor.
Between ground and HC01 (female) (8) or D01
Voltage Max. 1 V
(female) (7)
Between ground and D01 (female) (3) or V03
Voltage Max. 1 V
(female) (1)
If no failure is found by above checks, inverter (hybrid controller) may be
controller)
performed.)
40-406 HB215LC-2
40 Troubleshooting
HB215LC-2 40-407
40 Troubleshooting
Failure code [DW91KA] Travel Junction Sol Open Circuit (HB205-DW91KA-400-A-Z0-A)
Action level Failure code Travel Junction Solenoid Open Circuit

Failure
L01 DW91KA (Pump controller system)
Detail of not drive travel junction solenoid, so pump controller determines that open circuit exists in
failure travel junction solenoid circuit.
Problem on • Machine does not turn during travel.
machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with
displayed on monitoring screen is "ON" even if solenoid is not energized due to open
Related circuit.)
• Travel junction circuit is made when solenoid is de-energized.
• Method of reproducing failure code: Start engine and turn machine with right and left
travel levers.
Defective travel junction 1. Turn starting switch to OFF position.
solenoid 2. Disconnect connector V05, and connect T-adapter to male side.
1
Resis- Between V05 (male) (1) and (2)
(Internal open circuit) 20 to 60 z
tance
pump controller the voltage drops to approximately 0 V during shaking, wiring
Open or short circuit in wiring 2. Disconnect connector CP02 and connect T-adapter to female side.
3
harness Resis- Between CP02 (female) (85) and each of
(115), (117), and (120) 20 to 60 z
tance
Open circuit in wiring harness 2. Disconnect connectors CP02 and V05, and connect T-adapters to
contact of connector) Between CP02 (female) (85) and V05 (female)
Max. 1 z
Resis- (1)
tance Between V05 (female) (2) and each of CP02
(female) (115), (117), and (120) Max. 1 z
40-408 HB215LC-2
40 Troubleshooting
Circuit diagram related to travel interconnection valve solenoid
HB215LC-2 40-409
40 Troubleshooting
Failure code [DW91KB] Travel Junction Sol Short Circuit (HB205-DW91KB-400-A-Z0-A)
Action level Failure code Travel Junction Solenoid Short Circuit

Failure
L01 DW91KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives travel junction solenoid, so pump
failure controller determines that short circuit exists in travel junction solenoid circuit.
• Stops driving travel junction solenoid.
Problem on • Machine does not turn during travel.
machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with
displayed on monitoring screen is "ON" even if solenoid is not energized due to short
Related circuit.)
• Travel junction circuit is made when solenoid is de-energized.
• Method of reproducing failure code: Start engine and turn machine with right and left
travel levers.
Defective travel junction 1. Turn starting switch to OFF position.
1
(Internal short circuit or ground Resis- Between V05 (male) (1) and (2) 20 to 60 z
fault) tance Between V05 (male) (1) and ground Min. 1 Mz
wiring harness Resis- (115), (117), and (120) 20 to 60 z
tance
V05 (female) (1) Min. 1 Mz
tance
Hot short circuit in wiring 2. Disconnect connector V05 and connect T-adapter to female side.
harness
Voltage Between V05 (female) (1) and ground Max. 4.5 V
40-410 HB215LC-2
40 Troubleshooting
Circuit diagram related to travel interconnection valve solenoid
HB215LC-2 40-411
40 Troubleshooting
Failure code [DWA2KA] Attachment Sol Open Circuit (HB205-DWA2KA-400-A-Z0-A)
Action level Failure code Attachment Solenoid Open Circuit

Failure
L03 DWA2KA (Pump controller system)
Detail of • When output to attachment return selector solenoid is OFF, The open circuit is detected
failure due to exceeding the standard value of controller output terminal voltage.
Problem on • Attachment return circuit does not change to 1-way circuit.
machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (As long as controller's command to solenoid is "ON", sensor
status displayed on monitoring screen is "ON" even if solenoid is not energized due to
Related open circuit.)
• Method of reproducing failure code: Turn starting switch to ON position and set machine
in working mode other than breaker mode (B).
Defective attachment 1. Turn starting switch to OFF position.
1 return selector solenoid 2. Disconnect connector V06, and connect T-adapter to male side.
(internal open circuit) Resistance Between V06 (male) (1) and (2) 20 to 60 z
Open circuit, short 2. Disconnect connector V06 and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, wiring harness is open
pump controller at this point.
Open circuit or ground
3 Between CP02 (female) (86) and each of CP02
fault in wiring harness 20 to 60 z
Resistance (female) (115), (117), (120)
harness 2. Disconnect connectors CP02 and V06, and connect T-adapters to each
defective contact of Between CP02 (female) (86) and V06 (female) (1) Max. 1 z
connector) Resistance Between V06 (female) (2) and CP02 (female) (115),
(117), (120) Max. 1 z
defective.
40-412 HB215LC-2
40 Troubleshooting
Circuit diagram related to ATT single/multiple selector solenoid
HB215LC-2 40-413
40 Troubleshooting
Failure code [DWA2KB] Attachment Sol Short Circuit (HB205-DWA2KB-400-A-Z0-A)
Action level Failure code Attachment singular and plural selector solenoid short
Failure circuit
L03 DWA2KB (Pump controller system)
• Abnormal current flows when pump controller drives attachment return selector solenoid,
Detail of
so pump controller determines that short circuit exists in attachment return selector
failure
solenoid circuit.
• Stops driving attachment return selector solenoid.
Problem on • Attachment return circuit does not change to 1-way circuit.
machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (As long as controller's command to solenoid is "ON", sensor
status displayed on monitoring screen is "ON" even if solenoid is not energized due to
Related short circuit.)
• Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B).
Defective attachment return 2. Disconnect connector V06, and connect T-adapter to male side.
1 selector solenoid (internal
short circuit or ground fault) Between V06 (male) (1) and (2) 20 to 60 z
Resistance
Open circuit or ground fault in 2. Disconnect connector CP02 and connect T-adapter to female side.
2 wiring harness Between CP02 (female) (86) and each of

Between ground and CP02 (female) (86) or
Resistance V06 (female) (1) Min. 1 Mz

Hot short circuit in wiring 2. Disconnect connector V06 and connect T-adapter to female side.
harness
40-414 HB215LC-2
40 Troubleshooting
Circuit diagram related to ATT single/multiple selector solenoid
HB215LC-2 40-415
40 Troubleshooting
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit (HB205-DWK0KA-400-A-Z0-A)
Action level Failure code 2-Stage Relief Solenoid Open Circuit

Failure
L01 DWK0KA (Pump controller system)
Detail of • Controller output voltage to solenoid is above standard value when pump controller does
failure not drive 2-stage relief solenoid, so pump controller determines that open circuit exists.
controller • If cause of failure disappears by itself, machine becomes normal.
Problem on • Traveling force is weak (main relief valve is not switched to high pressure setting)
machine • One-touch power maximizing function does not operate.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is ON, sensor state
displayed on monitoring screen is ON even if solenoid is not energized due to open
circuit.)
information • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
• Controller detects open circuit when controller does not drive solenoid
Defective 2-stage relief 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector V02, and connect T-adapter to male side.
Open or short circuit in wiring a If resistance is 1 Mz or higher, wiring harness has open circuit. If
3
harness resistance is 1 z or below, wiring harness has short circuit.

contact of connector) Between CP02 (female) (109) and V02
Resistance
40-416 HB215LC-2
40 Troubleshooting
Circuit diagram related to 2-stage relief solenoid
HB215LC-2 40-417
40 Troubleshooting
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit (HB205-DWK0KB-400-A-Z0-A)
Action level Failure code 2-Stage Relief Solenoid Short Circuit

Failure
L01 DWK0KB (Pump controller system)
Detail of • When driving 2-stage relief solenoid, abnormal current flows and short circuit is detected.
failure
• Shuts off power supply to 2-stage relief solenoid.
Problem on • Traveling force is weak (main relief valve is not switched to high pressure setting)
machine • One-touch power maximizing function does not operate.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with

monitoring function. (As long as controller's command to solenoid is ON, sensor state
displayed on monitoring screen is ON even if solenoid is not energized due to short
circuit.)
• Controller detects open circuit when controller does not drive solenoid

1
Ground fault in wiring harness 2. Disconnect connectors CP02 and V02, and connect T-adapter to
2 female side of V02.
tance
2. Disconnect connectors CP02 and V02, and connect T-adapter to
3 Short circuit in wiring harness female side of V02.
Resis- Between V02 (female) (1) and (2)
Min. 1 Mz
tance
2. Disconnect connector V02.
Hot short circuit in wiring 3. Connect T-adapter to female side of V02.
4
Resis- Between V02 (female) (1) and ground
Max. 4.5 V
tance
40-418 HB215LC-2
40 Troubleshooting
HB215LC-2 40-419
40 Troubleshooting
Failure code [DWK2KA] Variable Back Press Sol Open Circuit (HB205-DWK2KA-400-
A-Z0-A)
Action level Failure code Variable Back Pressure Solenoid Open Circuit
Failure
L01 DWK2KA (Pump controller system)
Detail of • When output to variable back pressure solenoid is ON, no current flows in the circuit, so
failure the open circuit is detected.
Problem on • Back pressure valve set pressure cannot be changed.
machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is ON, sensor status
displayed on monitoring screen is ON even if solenoid is not energized due to open
Related circuit.)
• When controller's command to solenoid is ON, back pressure valve set pressure
decreases.
Defective variable back 1. Turn starting switch to OFF position.
1 pressure solenoid 2. Disconnect connector V25, and connect T-adapter to male side.
Open circuit, short circuit, 2. Disconnect connector V25 and connect T-adapter to female side.
ground fault, hot short circuit 3. Turn starting switch to ON position.
pump controller the voltage becomes 0 V while shaking, wiring harness is open.
Voltage Between V25 (female) (1) and (2) Min. 20 V
Resistance CP02 (female) (115), (117), (120) 20 to 60 z

Resistance
40-420 HB215LC-2
40 Troubleshooting
Circuit diagram related to variable back pressure solenoid
HB215LC-2 40-421
40 Troubleshooting
Failure code [DWK2KB] Variable Back Press Sol Short Circuit (HB205-DWK2KB-
400-A-Z0-A)
Action level Failure code Variable Back Pressure Solenoid Short Circuit
Failure
L01 DWK2KB (Pump controller system)
• Abnormal current flows when pump controller drives variable back pressure solenoid, so
Detail of
pump controller determines that short circuit exists in variable back pressure solenoid
failure
circuit.
• Stops driving variable back pressure solenoid.
Problem on • Back pressure valve set pressure cannot be changed.
machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked with
Related circuit.)
• When controller's command to solenoid is ON, back pressure valve set pressure is
decreased.
Defective variable back 1. Turn starting switch to OFF position.
pressure solenoid 2. Disconnect connector V25, and connect T-adapter to male side.
1

Between ground and CP02 (female) (113)
Resistance or V25 (female) (1) Min. 1 Mz

2. Disconnect connector V25.
Hot short circuit in wiring 3. Connect T-adapter to female side of connector V25.
4
Resistance Between V25 (female) (1) and ground Max. 4.5 V
40-422 HB215LC-2
40 Troubleshooting
Circuit diagram related to variable back pressure solenoid
HB215LC-2 40-423
40 Troubleshooting
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit (HB205-DXA8KA-400-A-Z0-A)
Action level Failure code PC-EPC (F) Solenoid Open Circuit

Failure
L03 DXA8KA (Pump controller system)
Detail of • No current flows when pump controller drives PC-EPC (F) solenoid, so pump controller
failure determines that open circuit exists in PC-EPC (F) solenoid circuit.
Problem on • If pump load increases, engine speed decreases largely and engine may stop.
machine
• When solenoid and wiring harness are normal, engine can be prevented from stopping by
setting emergency pump drive switch to ON position.
Related • Drive current of PC-EPC (F) solenoid can be checked with monitoring function.
Incorrect operation of
1 Set emergency pump drive switch at its normal position (lower side).
emergency pump drive switch
Defective PC-EPC (F) 1. Turn starting switch to OFF position.
2
tance
2. Disconnect connector V11, and connect T-adapter to female side.
2. Disconnect connector S25 and connect T-adapter to male side.
Switch position:
Max. 1 z
Defective emergency pump Between S25 (male) Normal
drive (3) and (2) Switch position:
4 Min. 1 Mz
Resis- Emergency
tance Switch position:
Max. 1 z
Between S25 (male) Normal
(6) and (5) Switch position:
Emergency Min. 1 Mz

5
Open or short circuit in wiring a Check that emergency pump drive switch is at normal position
harness (lower side).
Resis- Between CP02 (female) (96) and each of
(115), (117), and (120) 3 to 14 z
tance
40-424 HB215LC-2
40 Troubleshooting

2. Disconnect connectors CP02, S25 and V11, and connect T-
Open circuit in wiring harness adapters to each female side.
Between CP02 (female) (96) and S25 (female)
(3) Max. 1 z
Resis- Between S25 (female) (2) and V11 (female) (1) Max. 1 z
tance Between S25 (female) (6) and each of CP02
(female) (115), (117), (120) Max. 1 z
Between S25 (female) (5) and V11 (female) (2) Max. 1 z
Circuit diagram related to PC-EPC solenoid
HB215LC-2 40-425
40 Troubleshooting
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit (HB205-DXA8KB-400-A-Z0-A)
Action level Failure code PC-EPC (F) Solenoid Short Circuit

Failure
L03 DXA8KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives PC-EPC (F) solenoid, so pump
failure controller determines that short circuit exists in PC-EPC (F) solenoid circuit.
• Stops output to PC-EPC (F) solenoid.
machine
Related • Drive current of PC-EPC (F) solenoid can be checked with monitoring function.
Defective PC-EPC (F) 1. Turn starting switch to OFF position.
1
(Internal short circuit or Resis- Between V11 (male) (1) and (2) 3 to 14 z
ground fault) tance Between V11 (male) (1) and ground Min. 1 Mz
Defective emergency pump
drive switch (internal short Between S25 (male) (5) and
2 Min. 1 Mz
circuit or ground fault) Resis- each of (2) and (3) Switch position:
tance Between ground and each of Normal
S25 (male) (2) and (3) Min. 1 Mz

Short circuit or ground fault in a Check that emergency pump drive switch is at normal position
3 wiring harness (lower side).
Between CP02 (female) (96) and each of (115),
Resis- (117), and (120) 3 to 14 z
tance
2. Disconnect connectors CP02, S25 and V11, and connect T-adapter
Ground fault in wiring harness to any female side.
4
(Contact with ground circuit) Between ground and CP02 (female) (96) or S25
Min. 1 Mz
Resis- (female) (3)
tance Between ground and S25 (female) (5) or V11
(female) (2) Min. 1 Mz
40-426 HB215LC-2
40 Troubleshooting
HB215LC-2 40-427
40 Troubleshooting
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit (HB205-DXA9KA-400-A-Z0-A)
Action level Failure code PC-EPC (R) Solenoid Open Circuit

Failure
L03 DXA9KA (Pump controller system)
Detail of • No current flows when pump controller drives PC-EPC (R) solenoid, so pump controller
failure determines that open circuit exists in PC-EPC (R) solenoid circuit.
machine
Related • Drive current of PC-EPC (R) solenoid can be checked with monitoring function.
Incorrect operation of
1 Set emergency pump drive switch at its normal position (lower side).
emergency pump drive switch
Defective PC-EPC (R) 1. Turn starting switch to OFF position.
solenoid 2. Disconnect connector V12 and connect T-adapter to male side.
2
tance
Switch position:
Max. 1 z
Defective emergency pump Between S25 (male) Normal
drive (3) and (2) Switch position:
4 Min. 1 Mz
Resis- Emergency
tance Switch position:
Max. 1 z
Between S25 (male) Normal
(6) and (5) Switch position:
Emergency Min. 1 Mz

5
Open or short circuit in wiring a Check that emergency pump drive switch is at normal position
harness (lower side).
Resis- Between CP02 (female) (104) and each of
(115), (117), and (120) 3 to 14 z
tance
40-428 HB215LC-2
40 Troubleshooting

2. Disconnect connectors CP02, S25 and V12, and connect T-
Open circuit in wiring harness Between CP02 (female) (104) and S25
6 (Wire breakage or defective (female) (9) Max. 1 z
contact of connector) Between S25 (female) (8) and V12 (female) (1) Max. 1 z
Resis-
Between S25 (female) (12) and each of CP02
tance
(female) (115), (117), (120) Max. 1 z
Between S25 (female) (11) and V12 (female)
(2) Max. 1 z
HB215LC-2 40-429
40 Troubleshooting
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit (HB205-DXA9KB-400-A-Z0-A)
Action level Failure code PC-EPC (R) Solenoid Short Circuit

Failure
L03 DXA9KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives PC-EPC (R) solenoid, so pump
failure controller determines that short circuit exists in PC-EPC (R) solenoid circuit.
• Stops output to PC-EPC (R) solenoid.
machine
Related • Drive current of PC-EPC (R) solenoid can be checked with monitoring function.
Defective PC-EPC (R) 1. Turn starting switch to OFF position.
1
Defective emergency pump
drive switch (internal short Between S25 (male) (5) and each
2 Switch Min. 1 Mz
circuit or ground fault) Resis- of (2) and (3)
position:
tance Between ground and each of S25
Normal Min. 1 Mz
(male) (2) and (3)
Short circuit or ground fault in a Check that emergency pump drive switch is at normal position
3 wiring harness (lower side).
Resis- (115), (117), and (120) 3 to 14 z
tance
2. Disconnect connectors CP02, S25 and V12, and connect T-adapter
Ground fault in wiring harness to any female side.
4
(Contact with ground circuit) Between ground and CP02 (female) (104) or
Min. 1 Mz
Resis- S25 (female) (3)
tance Between ground and S25 (female) (5) or V12
40-430 HB215LC-2
40 Troubleshooting
HB215LC-2 40-431
40 Troubleshooting
Failure code [DXE0KA] LS-EPC Sol Open Circuit (HB205-DXE0KA-400-A-Z0-A)
Action level Failure code LS-EPC Solenoid Open Circuit

Failure
L01 DXE0KA (Pump controller system)
Detail of • No current flows when pump controller drives LS-EPC solenoid, so pump controller
failure determines that open circuit exists in LS-EPC solenoid circuit.
Problem on • Travel speed is high when travel speed selection is Lo. and Mi.
machine • Operation speed of work equipment is high in fine control mode (L).
• Drive current of LS-EPC solenoid can be checked with monitoring function.
Defective LS-EPC solenoid 2. Disconnect connector V19, and connect T-adapter to male side.
1
(Internal open circuit) Resis- Between V19 (male) (1) and (2)
3 to 14 z
tance
3
(115), (117), and (120) 3 to 14 z
tance
contact of connector) Resis- Between CP02 (female) (88) and V19 (female)
(1) Max. 1 z
tance
Resis- Between V19 (female) (2) and each of CP02
(female) (115), (117), (120) Max. 1 z
tance
40-432 HB215LC-2
40 Troubleshooting
Circuit diagram related to LS-EPC solenoid
HB215LC-2 40-433
40 Troubleshooting
Failure code [DXE0KB] LS-EPC Sol Short Circuit (HB205-DXE0KB-400-A-Z0-A)
Action level Failure code LS-EPC Solenoid Short Circuit

Failure
L01 DXE0KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives LS-EPC solenoid, so pump controller
failure determines that short circuit exists in LS-EPC solenoid circuit.
• Stops output to LS-EPC solenoid.
Problem on • Travel speed is high when travel speed selection is Lo. and Mi.
machine • Operation speed of work equipment is high in fine control mode (L).
• Drive current of LS-EPC solenoid can be checked with monitoring function.
Defective LS-EPC solenoid 1. Turn starting switch to OFF position.

1 (Internal short circuit or ground
fault) Resis- Between V19 (male) (1) and (2) 3 to 14 z
tance
tance
40-434 HB215LC-2
40 Troubleshooting
Circuit diagram related to LS-EPC solenoid
HB215LC-2 40-435
40 Troubleshooting
Failure code [DXE4KA] Attachment Flow EPC Open Circuit (HB205-DXE4KA-400-A-00-

A)
Action level Failure code Open circuit in attachment flow throttle EPC
Failure
- DXE4KA (Pump controller system)
• No current flows when pump controller drives attachment flow rate adjustment (service
Detail of current) EPC solenoid, so pump controller determines that open circuit exists in
failure attachment flow rate adjustment (service current) EPC solenoid circuit.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
information • Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B)
Defective attachment flow rate 1. Turn starting switch to OFF position.
adjustment (service current) 2. Disconnect connector V30, and connect T-adapter to male side.
1 EPC solenoid (Internal open Resis- Between V30 (male) (1) and (2)
circuit) 3 to 14 z
tance
3
(115), (117), and (120) 3 to 14 z
tance
Max. 1 z
Resis- (1)
(female) (115), (117), (120) Max. 1 z
40-436 HB215LC-2
40 Troubleshooting
Circuit diagram related to service flow throttle EPC
HB215LC-2 40-437
40 Troubleshooting
Failure code [DXE4KB] Attachment Flow EPC Short Circuit (HB205-DXE4KB-400-A-00-

A)
Action level Failure code Open circuit in attachment flow throttle EPC
Failure
― DXE4KB (Pump controller system)
• Abnormal current flows when pump controller drives attachment flow rate (service
Detail of current) EPC solenoid, so pump controller determines that short circuit exists in
failure attachment flow rate adjustment (service current) EPC solenoid circuit.
• Stops driving attachment flow rate adjustment EPC solenoid.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
information • Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B).
Defective attachment flow rate 1. Turn starting switch to OFF position.
adjustment (service current) 2. Disconnect connector V30, and connect T-adapter to male side.
1 EPC solenoid (internal short Resis- Between V30 (male) (1) and (2) 3 to 14 z
circuit or ground fault) tance Between V30 (male) (1) and ground Min. 1 Mz
tance
tance
40-438 HB215LC-2
40 Troubleshooting
Circuit diagram related to service flow throttle EPC
HB215LC-2 40-439
40 Troubleshooting
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit (HB205-DXE5KA-400-A-Z0-

A)
Action level Failure code Merge-divider Main Solenoid Open Circuit

Failure
• No current flows when pump controller drives merge-divider (main) EPC solenoid, so
Detail of
pump controller determines that open circuit exists in merge-divider (main) EPC solenoid
failure
circuit.
• Stops output command to merge-divider main solenoid and merge-divider LS solenoid to
Action of put pump in merging condition constantly.
Problem on • Single operation speed of work equipment is high in fine control mode (L).
machine • Machine does not turn easily during travel.
• Drive current to merge-divider main EPC solenoid can be checked with monitoring
Related function.
Defective merge-divider main 1. Turn starting switch to OFF position.

EPC solenoid (internal open 2. Disconnect connector V23, and connect T-adapter to male side.
1
circuit) Resis- Between V23 (male) (1) and (2)
3 to 14 z
tance
3
(115), (117), and (120) 3 to 14 z
tance
Max. 1 z
Resis- (female) (1)
(female) (115), (117), (120) Max. 1 z
40-440 HB215LC-2
40 Troubleshooting
Circuit diagram related to pump merge-divider main solenoid
HB215LC-2 40-441
40 Troubleshooting
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit (HB205-DXE5KB-400-A-Z0-

A)
Action level Failure code Merge-divider Main Solenoid Short Circuit

Failure
• Abnormal current flows when pump controller drives merge-divider (main) EPC solenoid,
Detail of
so pump controller determines that short circuit exists in merge-divider (main) EPC
failure
solenoid circuit.
• Stops output command to merge-divider main solenoid and merge-divider LS solenoid to
• Drive current to merge-divider main EPC solenoid can be checked with monitoring
Related function.
information (Code: 08000 Merge-divide Sol Current Main)
Defective merge-divider main 2. Disconnect connector V23, and connect T-adapter to male side.
1 EPC solenoid (internal short
circuit or ground fault) Resis- Between V23 (male) (1) and (2) 3 to 14 z
tance
tance
40-442 HB215LC-2
40 Troubleshooting
Circuit diagram related to pump merge-divider main solenoid
HB215LC-2 40-443
40 Troubleshooting
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit (HB205-DXE6KA-400-A-Z0-A)
Action level Failure code Merge-divider LS Solenoid Open Circuit

Failure
Detail of • No current flows when pump controller drives merge-divider (LS) EPC solenoid, so pump
failure controller determines that open circuit exists in merge-divider (LS) EPC solenoid circuit.
• Stops output command to merge-divider main solenoid and merge-divider SL solenoid to
• Drive current to merge-divider (LS) EPC solenoid can be checked with monitoring
Related function.
Defective merge-divider (LS) 1. Turn starting switch to OFF position.

EPC solenoid (internal open 2. Disconnect connector V24, and connect T-adapter to male side.
1
circuit) Resis- Between V24 (male) (1) and (2)
3 to 14 z
tance
3
(115), (117), and (120) 3 to 14 z
tance
Max. 1 z
Resis- (1)
(female) (115), (117), (120) Max. 1 z
40-444 HB215LC-2
40 Troubleshooting
Circuit diagram related to merge-divider LS solenoid
HB215LC-2 40-445
40 Troubleshooting
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit (HB205-DXE6KB-400-A-Z0-A)
Action level Failure code Merge-divider LS Solenoid Short Circuit

Failure
• Abnormal current flows when pump controller drives merge-divider (LS) EPC solenoid, so
Detail of
pump controller determines that short circuit exists in merge-divider (LS) EPC solenoid
failure
circuit.
• Stops output command to merge-divider main solenoid and merge-divider SL solenoid to
Defective merge-divider (LS) 2. Disconnect connector V24, and connect T-adapter to male side.
1 EPC solenoid (internal short
circuit or ground fault) Resis- Between V24 (male) (1) and (2) 3 to 14 z
tance
V24 (female) (1) and ground Min. 1 Mz
tance
40-446 HB215LC-2
40 Troubleshooting
Circuit diagram related to merge-divider LS solenoid
HB215LC-2 40-447
40 Troubleshooting
Failure code [DY20KA] Wiper Working Abnormality (HB205-DY20KA-400-A-Z0-A)
Action level Failure code Wiper Working Abnormality

Failure
― DY20KA (Pump controller system)
Detail of • When windshield wiper works, W signal that indicates that wiper motor reaches working
failure area upper end position is not input.
Action of • Stops working output to wiper motor.
Problem on • Wiper motor does not work.
machine
• Signal input (ON/OFF) of W contact signal that indicates wiper working area end can be
(Code: 02204)
• Method of reproducing failure code: Turn starting switch to ON position and set wiper
switch to INT or ON position.
2. Disconnect connector M05 and connect T-adapter to female side.
Wiper position:
Working area upper Max. 1 z
Defective wiper motor Between M05 (female) end
1
(Internal open circuit) (6) and (5) Wiper position: Other
Resistance than working area Min. 1 Mz
upper end
Between M05 (female) Wiper position: Whole
(1) and (3) range Max. 20 z

2. Disconnect connectors CP01 and CP02, and connect T-adapters to
each female side.
Wiper position:
Working area upper Max. 1 z
Between CP01
Open or short circuit in wiring end
2 (female) (56) and
harness Wiper position: Other
ground
Resistance than working area Min. 1 Mz
upper end
Between CP02
Wiper position: Whole
(female) (114) and
range Max. 20 z
(119)
aIf 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 side of connectors CP01 and CP02
Open circuit in wiring harness and male side of M05.
Between CP01 (female) (56) and M05 (male)
(6) Max. 1 z
Between M05 (male) (5) and ground (T01) Max. 1 z
Resistance Between CP02 (female) (114) and M05 (male)
(1) Max. 1 z
(3) Max. 1 z
40-448 HB215LC-2
40 Troubleshooting
Circuit diagram related to wiper
HB215LC-2 40-449
40 Troubleshooting
Failure code [DY20MA] Wiper Parking Abnormality (HB205-DY20MA-400-A-Z0-A)
Action level Failure code Wiper Parking Abnormality

Failure
― DY20MA (Pump controller system)
Detail of • When windshield wiper rests, P signal that indicates that wiper motor is at rest area
failure position is not input.
Action of • Stops output for resting to wiper motor.
Problem on • Wiper does not rest.
machine
• Condition of P contact signal of wiper resting area can be checked with monitoring
function.
(Code: 02204)
• Method of reproducing failure code: Turn starting switch to ON position and set wiper
switch to INT/ONoOFF position.
Wiper position: Rest
Defective wiper motor Max. 1 z
Between M05 (female) area
1
(Internal open circuit) (4) and (5) Wiper position:
Resistance Working area Min. 1 Mz
Between M05 (female) Wiper position: Whole
(1) and (3) range Max. 20 z

2. Disconnect connectors CP01 and CP02, and connect T-adapter to
each female side.
Wiper position: Rest
Between CP01 Max. 1 z
Open or short circuit in wiring area
2 (female) (75) and
harness Wiper position:
ground Min. 1 Mz
Resistance Working area
Between CP02
Wiper position: Whole
(female) (114) and
range Max. 20 z
(119)
aIf 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 side of connectors CP01 and CP02
Open circuit in wiring harness and male side of M05.
(4) Max. 1 z
Between M05 (male) (5) and ground (T01) Max. 1 z
Resistance Between CP02 (female) (114) and M05 (male)
(1) Max. 1 z
(3) Max. 1 z
40-450 HB215LC-2
40 Troubleshooting
HB215LC-2 40-451
40 Troubleshooting
Failure code [DY2CKB] Washer Drive Short Circuit (HB205-DY2CKB-400-A-Z0-A)
Action level Failure code Washer Drive Short Circuit

Failure
― DY2CKB (Pump controller system)
Detail of • When outputting current to window washer motor, abnormal current flows and short circuit
failure is detected.
• Stops output to washer motor.
Problem on • Window washer does not operate.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position and turn washer
information switch to ON position.
Defective fuse No. 4 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on
1 cause 5.)
box F01
Defective washer motor 2. Disconnect connector M06 and connect T-adapter to male side.
2 (Internal open circuit or ground Between M06 (male) (1) and (2) 5 to 20 z
fault) Resis-
Between M06 (male) (1) and ground, or
tance Min. 1 Mz
between M06 (male) (2) and ground
2. Disconnect connector D02 and connect T-adapter to male side.
Defective assembled-type
3 diode D02 a Measure it with diode range of multimeter.
(Internal short circuit) Between D02 (male) (6) (+) and (2) (-) Continuity
Continuity No
continuity
Open or short circuit in wiring 3. Turn starting switch to ON position.
4
harness
a Ignore failure codes displayed on machine monitor.
Voltage Between CP01 (female) (3) and ground 20 to 30 V
2. Disconnect fuse No. 4 of fuse box F01.
Ground fault in wiring harness 3. Disconnect connectors M06, CP01, and D02, and connect T-
5 adapter to any one of female sides.
Between ground and any one of F01 (4), M06
Min. 1 Mz
Resis- (female) (2), or D02 (female) (2)
tance Between ground and any one of CP01 (female)
(3), M06 (female) (1), or D02 (female) (6) Min. 1 Mz

2. Disconnect connectors CP01 and M06, and connect T-adapter to
Hot short circuit in wiring female side of CP01.
6 harness 3. Remove fuse No. 4.
a Ignore failure codes displayed on machine monitor.
Voltage Between CP01 (female) (3) and ground Max. 1 V
40-452 HB215LC-2
40 Troubleshooting
Circuit diagram related to window washer motor
HB215LC-2 40-453
40 Troubleshooting
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit (HB205-DY2DKB-400-A-Z0-A)
Action level Failure code Wiper Drive (Forward) Short Circuit

Failure
― DY2DKB (Pump controller system)
Detail of • When power to normal rotation side of wiper motor drive is supplied, short circuit was
failure detected because of abnormal current flown to the circuit.
• Stops output to wiper motor drive normal rotation side.
Problem on • Windshield wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and set wiper
Defective wiper motor 1. Turn starting switch to OFF position.

fault) Resis- Between M05 (female) (3) and (1) Max. 20 z
tance Between M05 (female) (3) and ground Min. 1 Mz
2. Disconnect connectors CP02 and M05 and connect T-adapter to
2 Short circuit in wiring harness either harness side.
Resis- Between CP02 (female) (119) and (114), or
between M05 (male) (1) and (3) Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connectors CP02 and M05 and connect T-adapter to
3 either harness side.
Resis- Between CP02 (female) (119) and ground, or
between M05 (male) (3) and ground Min. 1 Mz
tance
• Reference
4 Pump controller is defective. 3. Turn starting switch to ON position.
4. Turn wiper switch ON and OFF, and troubleshoot.
Wiper
Between M05 (3) and switch: Max. 3 V
Voltage OFF
(5)
Wiper Pulse below 3 V io
switch: ON above 20 V
40-454 HB215LC-2
40 Troubleshooting
HB215LC-2 40-455
40 Troubleshooting
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit (HB205-DY2EKB-400-A-Z0-A)
Action level Failure code Wiper Drive (Reverse) Short Circuit

Failure
― DY2EKB (Pump controller system)
Detail of • When driving reverse side of wiper motor drive circuit, short circuit was detected because
failure of abnormal current flown to the circuit.
• Stops output to wiper motor drive reverse side.
Problem on • Windshield wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and set wiper

fault) Resis- Between M05 (female) (1) and (3) Max. 20 z
tance Between M05 (female) (1) and ground Min. 1 Mz
2. Disconnect connectors CP02 and M05 and connect T-adapter to
2 Short circuit in wiring harness either harness side.
Resis- Between CP02 (female) (119) and (114), or
between M05 (male) (1) and (3) Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connectors CP02 and M05 and connect T-adapter to
3 either harness side.
Resis- Between CP02 (female) (114) and ground, or
between M05 (male) (1) and ground Min. 1 Mz
tance
• Reference
4 Pump controller is defective. 3. Turn starting switch to ON position.
4. Turn wiper switch ON and OFF, and troubleshoot.
Wiper
Between M05 (1) and switch: Max. 3 V
Voltage OFF
(5)
Wiper Pulse below 3 V io
switch: ON above 20 V
40-456 HB215LC-2
40 Troubleshooting
HB215LC-2 40-457
40 Troubleshooting
Failure code [GA****] Precautions related to hybrid components and

troubleshooting of high voltage parts
Precautions related to hybrid equipment
k Before performing the testing and adjusting related to hybrid equipment, understand the following
items fully.
1. Only qualified person can perform removal of hybrid equipment (motor-generator, capacitor, inverter,
electric swing motor) and high-voltage wires.
2. Even qualified person must not disassemble the equipments listed above for quality assurance reasons.
3. Replace hybrid equipment and high-voltage wires (orange conduit windings) as units.
4. Before handling hybrid equipment, make sure to discharge the capacitors first.
(For the details, see Testing and adjusting, "Discharge of capacitor electric charge" in "Special functions of
machine monitor".)
a However, capacitors can be discharged by using the machine monitor only when the hybrid system is
normal.
a If any of the GA**** failure codes listed in the following page is displayed to indicate abnormality of the
hybrid system, discharging cannot be conducted even when discharging instructions are displayed on the
machine monitor and operated as instructed. (Conditions of consuming capacitor electric charge is not
satisfied.) Therefore, use generator: 796-426-1800, which is a dedicated device for discharging
capacitors.
a Even if the capacitor charge ratio is [0%], the capacitor voltage is not necessarily to be completely 0 V.
With the nature of a capacitor, the voltage tends to recover after discharging. Accordingly, take care when
disconnecting the power cable connector.
a As described below, do not operate the key switch after the discharging is completed, since this will result
in recharging of the capacitor.
• Do not turn the key switch ON before the engine completely stops after the key switch has been turned
OFF.
• The key switch must be turned ON when the engine is completely stopped after the key switch has
been turned OFF the last time.
The items with the mark above relate to handling of hybrid equipment. Before performing work,
understand 00-200 Foreword, Safety, Basic information, "Handling hybrid equipment and high-voltage wires".
a For the monitoring items applicable to troubleshooting of hybrid equipment, see the list for failure code
[GA——] (separate sheet 1).
a For the check sheet to record the diagnostic test results of abnormal hybrid equipment, see separate
sheet 2 for failure code [GA——].
k Discharge the capacitor by using a discharging tool (generator): 796-426-1800 in advance.
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
complete. Do not work with bare hands. Be sure to insulate your hands before work.
a When HB01 (capacitor part) is removed, cover the connector halves (on the harness and capacitor) with a
plastic bag or the like to prevent entry of foreign material.
a Troubleshooting shall be performed with the engine stopped.
a Do not connect the multimeter directly to the capacitor side connector (female side of HB01).
40-458 HB215LC-2
40 Troubleshooting
1. Capacitor charge LED

1) Both right and left LEDs are lit: High voltage is being output
2) Only right LED is lit: Charged with high voltage
3) Both right and left LEDs are OFF: Charge voltage is 30 V or below
• If failure is suspected in high voltage parts as a result of troubleshooting by failure code, perform
troubleshooting according to common troubleshooting 1. to 7. on and after the next next page.
HB215LC-2 40-459
40 Troubleshooting
Errors that do not allow discharging with the machine monitor
Errors related to the high voltage circuit Errors related to the motor-generator and swing
motor
Failure Failure
Error name Error name
code code
[GA00NS] Hybrid Equipment Overheat [GA13KP] Low HYB Control. Sen. Power Sup.
[GA01KA] Power Cable Interlock Open Circuit [GA19KR] Generator Motor Driver Sub-CPU
Communication Failure
Generator Motor Driver IGBT 0
[GA02KZ] DC Line Open & Short Circuit [GA25MA]
Abnormality
HW source voltage high error in DC Generator Motor Driver IGBT 1
[GA04KG] [GA26MA]
line before boosting Abnormality
SW output voltage drop in DC line
[GA05KP] [GA60KZ] Generator Motor Open/Short Circuit
before boosting
DC voltage sensor open/short circuit
[GA06KZ] [GA60MC] Generator Motor Failure
before boosting
HW source voltage high error in DC Generator Motor Phase-A Current
[GA08KG] [GA62KY]
line after boosting Sensor Power Short Circuit
SW output voltage drop in DC line Generator Motor Phase-A Current
[GA09KP] [GA62MA]
after boosting Sensor Malfunction
DC voltage sensor open/short circuit Generator Motor Phase-B Current
[GA0AKZ] [GA63KY]
after boosting Sensor Power Short Circuit
[GA10MA] Hybrid Controller Malfunction [GA63MA] Generator Motor Phase-B Current
Sensor Malfunction
[GA10MC] Hybrid Controller Error [GA64KY] Generator Motor Phase-C Current
Sensor Power Short Circuit
[GA12NK] Hybrid Controller Power Supply Not [GA64MA] Generator Motor Phase-C Current
Turned ON Sensor Malfunction
Generator Motor Driver Excitation
[GA18MC] [GAA6KP] Low HYB Control. Sen. Power 2 Sup.
Power Supply Failure
[GA1SFS] Contactor Locked
[GA1SMC] Contactor Failure
[GA1VMC] Capacitor Contactor Failure
40-460 HB215LC-2
40 Troubleshooting
High voltage equipment, power cable, and connectors layout drawing
1. Capacitor enclosure
2. Inverter enclosure
3. High-voltage wiring (electric swing motor)
4. High-voltage wiring (capacitor)
A: Motor-generator
B: Electric control unit
C: Electric swing motor
HB215LC-2 40-461
40 Troubleshooting
a Connector GM01 is located at the bottom of the motor-generator (A) housing.

Precautions for connecting the power cable
a The power cable connector is asymmetrical and has different upper and lower sides. The marks (I, II, III or
IIII) on the power cable side and body side must be matched.
40-462 HB215LC-2
40 Troubleshooting
a Marks on the engine motor-generator (connectors: GM02 and GM03) are as follows:
• Motor-generator side connector (orientation marked with dots)
• Harness side connector (orientation marked with lines)
HB215LC-2 40-463
40 Troubleshooting
Common troubleshooting for high voltage parts

• Common troubleshooting flow
40-464 HB215LC-2
40 Troubleshooting
HB215LC-2 40-465
40 Troubleshooting
1. Troubleshooting of capacitor
If failure is suspected in the capacitor as a result of troubleshooting by failure code, perform troubleshooting
as follows.
2. Disconnect inverter power cable connector HC06.
(Leave capacitor side connector HB01 connected)
a Wipe off the capacitor enclosure.
a If the measured value is not stable, take a reading at one minute later.
a It is recommended to use a megohmmeter for measurement.
Between HC06 (DC+)(male): Red probe of
tester Resis-
Min. 10 Mz
and capacitor enclosure: Black probe of tance
Deterioration of insulation tester
1 in capacitor system Between HC06 (DC+)(male): Black probe
of tester Resis-
Min. 10 Mz
and capacitor enclosure: Red probe of tance
tester
Between HC06 (DC-)(male): Red probe of
tester Resis-
Min. 10 Mz
and capacitor enclosure: Black probe of tance
tester
Between HC06 (DC-)(male): Black probe
of tester Resis-
Min. 10 Mz
and capacitor enclosure: Red probe of tance
tester
If no failure is found by check on cause 1, other high voltage part may be defective.
Move on to troubleshooting of other suspicious high voltage parts.
If any failure is found, perform 5. Troubleshooting capacitor power cable. If no failure is found, replace the
capacitor.
40-466 HB215LC-2
40 Troubleshooting
2. Troubleshooting of electric swing motor

If failure is suspected in the electric swing motor as a result of troubleshooting by failure code, perform
troubleshooting as follows.
2. Disconnect inverter power cable connector HC05.
a The swing motor has coil resistance.
Open circuit at between Between HC05 (U) (male) and HC05 (V) Resis-
1 (male) Max. 1 z
swing motor phases. tance
Between HC05 (V) (male) and HC05 (W) Resis-
(male) Max. 1 z
tance
Between HC05 (W) (male) and HC05 (U) Resis-
(male) Max. 1 z
tance
2. Disconnect inverter power cable connector HC05 and capacitor power
cable connector HB01.
a Wipe off the inverter enclosure.
Deterioration of insulation a Taking a measurement at any one of phases U, V or W is enough.
2 in swing motor system
Between HC05 (U) (male): Red probe of
tester Resis-
Min. 10 Mz
and inverter enclosure (ground): Black tance
probe of tester
Between HC05 (U) (male): Black probe of
tester Resis-
Min. 10 Mz
and inverter enclosure (ground): Red probe tance
of tester
If no failure is found by checks on causes 1 and 2, other high voltage part may be defective.
If any failure is found, perform 6. Troubleshooting electric swing motor power cable. If no failure is found,
replace the electric swing motor.
HB215LC-2 40-467
40 Troubleshooting
Circuit diagram related to high voltage system
Note 1: I*, II*, III*, and IIII* indicate the number of marks.
Note 2: Mark* means the number of marks is 1 to 3.
40-468 HB215LC-2
40 Troubleshooting
Note 3: When mating a connector, match the number of marks and the marked side of the body and harness
connectors (harness connectors are asymmetrical and have different upper and lower sides).
Note 4: Marks on the engine motor-generator are as follows:
HB215LC-2 40-469
40 Troubleshooting
3. Troubleshooting of motor-generator
If failure is suspected in the motor-generator as a result of troubleshooting by failure code, perform
2. Disconnect inverter power cable connectors HC03 and HC04.
a The motor-generator has motor coil resistance.
Open circuit at between Between HC03 (A1) (male) and HC04 (A2) Resis-
1 (male) Max. 1 z
motor-generator phases. tance
Between HC03 (B1) (male) and HC04 (B2) Resis-
(male) Max. 1 z
tance
Between HC03 (C1) (male) and HC04 (C2) Resis-
(male) Max. 1 z
tance
2. Disconnect inverter power cable connectors HC03 and HC04.
a Taking measurement at either of connectors HC03 and HC04 is
enough.
Short circuit at between Between HC03 (A1) (male) and HC03 (B1) Resis-
2 motor-generator phases. Min. 10 Mz
(male) tance
Between HC03 (B1) (male) and HC03 (C1) Resis-
(male) Min. 10 Mz
tance
Between HC03 (C1) (male) and HC03 (A1) Resis-
(male) Min. 10 Mz
tance
40-470 HB215LC-2
40 Troubleshooting

2. Disconnect inverter power cable connectors HC03 and HC04, and
capacitor power cable connector HB01.
a Taking measurement at either of connectors HC03 and HC04 is
enough.
Between HC03 (A1) (male): Red probe of
tester Resis-
Min. 10 Mz
probe of tester
Between HC03 (A1) (male): Black probe of
tester Resis-
Min. 10 Mz
Deterioration of insulation and inverter enclosure (ground): Red probe tance
3 in motor-generator system of tester
Between HC03 (B1) (male): Red probe of
tester Resis-
Min. 10 Mz
probe of tester
Between HC03 (B1) (male): Black probe of
tester Resis-
Min. 10 Mz
of tester
Between HC03 (C1) (male): Red probe of
tester Resis-
Min. 10 Mz
probe of tester
Between HC03 (C1) (male): Black probe of
tester Resis-
Min. 10 Mz
of tester
If no failure is found by checks on causes 1 to 3, other high voltage part may be defective.
If any failure is found, perform 7. Troubleshooting motor-generator power cable. If no failure is found, replace
the motor-generator.
HB215LC-2 40-471
40 Troubleshooting
40-472 HB215LC-2
40 Troubleshooting
HB215LC-2 40-473
40 Troubleshooting
4. Troubleshooting of inverter
If failure is suspected in the inverter as a result of troubleshooting by failure code, perform troubleshooting as
follows.
2. Disconnect inverter power cable connectors HC03 to HC06, and
capacitor power cable connector HB01.
Between HC06 (DC+) (female): Red probe
Resis-
Deterioration of insulation of tester and inverter enclosure: Black tance
Min. 10 Mz
1 probe of tester
in inverter
Between HC06 (DC+) (female): Black
probe of tester and inverter enclosure: Red Resis- Min. 10 Mz
probe of tester tance
Between HC06 (DC-) (female): Red probe
of tester and inverter enclosure: Black Resis-
Min. 10 Mz
Between HC06 (DC-) (female): Black
probe of tester and inverter enclosure: Red Resis- Min. 10 Mz
If no failure is found by check on cause 1, other high voltage part may be defective.
Replace the inverter if abnormal.
40-474 HB215LC-2
40 Troubleshooting
HB215LC-2 40-475
40 Troubleshooting
40-476 HB215LC-2
40 Troubleshooting
5. Troubleshooting of capacitor power cable

If failure is suspected in the capacitor power cable as a result of troubleshooting by failure code, perform
1 Open circuit in power cable Between HC06 (DC+) (male) and HB01 Resis-
(DC+) (male) Max. 1 z
tance
Between HC06 (DC-) (male) and HB01 Resis-
(DC-) (male) Max. 1 z
tance
Internal short circuit in 2. Disconnect inverter power cable connector HC06 and capacitor power
2 power cable cable connector HB01.
Between HC06 (DC+) (male) and HC06 Resis-
(DC-) (male) Min. 10 Mz
tance
a Wipe off metal parts of cable housing.
Between HC06 (DC+) (male): Red probe of
Resis-
Deterioration of insulation tester and cable housing metal (part P): tance
Min. 10 Mz
3 in power cable Black probe of tester
Between HC06 (DC+) (male): Black probe
of tester and cable housing metal (part P): Resis-
Min. 10 Mz
Red probe of tester tance
Between HC06 (DC-) (male): Red probe of
tester and cable housing metal (part P): Resis-
Min. 10 Mz
Black probe of tester tance
Between HC06 (DC-) (male): Black probe
of tester and cable housing metal (part P): Resis-
Min. 10 Mz
If any failure is found by checks on causes 1 to 3, replace the capacitor power cable.
HB215LC-2 40-477
40 Troubleshooting
40-478 HB215LC-2
40 Troubleshooting
HB215LC-2 40-479
40 Troubleshooting
6. Troubleshooting of electric swing motor power cable

If failure is suspected in the electric swing motor power cable as a result of troubleshooting by failure code,
perform troubleshooting as follows.
*: (Leave capacitor side connector HB01 disconnected) is applicable when connector HB01 is already
disconnected.
2. Disconnect inverter power cable connector HC05 and swing motor
power cable connector PM02.
(Leave capacitor side connector HB01 disconnected)*
Between HC05 (U) (male) and PM02 (U) Resis-
1 Open circuit in power cable
(male) Max. 1 z
tance
Between HC05 (V) (male) and PM02 (V) Resis-
(male) Max. 1 z
tance
Between HC05 (W) (male) and PM02 (W) Resis-
(male) Max. 1 z
tance
Internal short circuit in Between HC05 (U) (male) and HC05 (V) Resis-
2 power cable (male) Min. 10 Mz
tance
Between HC05 (V) (male) and HC05 (W) Resis-
(male) Min. 10 Mz
tance
Between HC05 (W) (male) and HC05 (U) Resis-
(male) Min. 10 Mz
tance
Between HC05 (U) (male): Red probe of
Min. 10 Mz
Between HC05 (U) (male): Black probe of
Deterioration of insulation tester and cable housing metal (part P): Resis-
3 in power cable Min. 10 Mz
Between HC05 (V) (male): Red probe of
Min. 10 Mz
Between HC05 (V) (male): Black probe of
Min. 10 Mz
Between HC05 (W) (male): Red probe of
Min. 10 Mz
Between HC05 (W) (male): Black probe of
Min. 10 Mz
If any failure is found by checks on causes 1 to 3, replace the swing motor power cable.
40-480 HB215LC-2
40 Troubleshooting
HB215LC-2 40-481
40 Troubleshooting
40-482 HB215LC-2
40 Troubleshooting
7. Troubleshooting of motor-generator power cable

If failure is suspected in the motor-generator power cable as a result of troubleshooting by failure code,
perform troubleshooting as follows.
*: (Leave capacitor side connector HB01 disconnected) is applicable when connector HB01 is already
disconnected.
motor-generator power cable connectors GM02 and GM03.
Between HC03 (A1) (male) and GM02 (A1) Resis-
(male) Max. 1 z
tance
Between HC03 (B1) (male) and GM02 (B1) Resis-
(male) Max. 1 z
tance
1 Open circuit in power cable
Between HC03 (C1) (male) and GM02 (C1) Resis-
(male) Max. 1 z
tance
Between HC04 (A2) (male) and GM03 (A2) Resis-
(male) Max. 1 z
tance
Between HC04 (B2) (male) and GM03 (B2) Resis-
(male) Max. 1 z
tance
Between HC04 (C2) (male) and GM03 (C2) Resis-
(male) Max. 1 z
tance
Between HC03 (A1) (male) and HC03 (B1) Resis-
(male) Min. 10 Mz
tance
(male) Min. 10 Mz
Internal short circuit in tance
2 power cable Between HC03 (C1) (male) and HC03 (A1) Resis-
(male) Min. 10 Mz
tance
Between HC04 (A2) (male) and HC04 (B2) Resis-
(male) Min. 10 Mz
tance
(male) Min. 10 Mz
tance
Between HC04 (C2) (male) and HC04 (A2) Resis-
(male) Min. 10 Mz
tance
HB215LC-2 40-483
40 Troubleshooting

Min. 10 Mz
Min. 10 Mz
Min. 10 Mz
Min. 10 Mz
Deterioration of insulation tester and cable housing metal (part P): Resis-
3 in power cable Min. 10 Mz
Min. 10 Mz
Min. 10 Mz
Min. 10 Mz
Min. 10 Mz
Min. 10 Mz
Min. 10 Mz
Min. 10 Mz
If any failure is found by checks on causes 1 to 3, replace the defective motor-generator power cable.
40-484 HB215LC-2
40 Troubleshooting
HB215LC-2 40-485
40 Troubleshooting
40-486 HB215LC-2
40 Troubleshooting
Failure code [GA——] Table and check sheet of monitoring items on

hybrid components (HB205-GABBBb-400-A-Z1-A)
List of monitoring items on hybrid components for troubleshooting
(Separate sheet 1)
Motor- Electric Unit Re-
Monitoring item Inver- Capa- Monitoring item
No. Code gen- swing mar-
ter citor Range
erator motor ks
Swing Right PPC
1 09008 MPa
Pressure #2
Swing Left PPC Pressure
2 09009 MPa
#2
Swing-Left PPC Sensor2
3 Voltage 09006 mV
Swing-Right PPC
4 09007 mV
Sensor2 Volt.
DC Current, High-Voltage
5 09200 V V V
Side
6 Capacitor Voltage 09300 V
Booster Volt., Low-Volt.
7 09400 V
Side
Capacitor Base
8 Temperature 09304 °C
Capacitor Bus Bar
Capacitor Cell
Booster IGBT Base
Booster IGBT Junc.
Booster Inductor
Swing Motor Coil
Swing Motor U IGBT
15 Base Temp. 09504 °C
Swing Motor V IGBT Base
16 Temp. 09505 °C
Swing Motor W IGBT
17 Base Temp. 09506 °C
Generator Motor
Gen. Motor IGBT Base
19 Temp. #0 09607 °C
20 Temp. #1 09608 °C
Swing Motor IGBT Junc.
21 Temp. 09507 °C
HB215LC-2 40-487
40 Troubleshooting

ter citor Range
erator motor ks
Booster Is Not ON,
Started OFF
22 HYB Controller Caution 09703 Hybrid system stop ON,
input OFF
HYB Swing Brake ON,
23 HYB Controller Solenoid 09700
OFF
Battery relay drive ON,
24 HYB Controller Output 09705 (HYB controller) OFF
Generator Motor Rev.
25 Speed 09602 r/min
26 Generator Motor Torque 09603 Nm
27 Gen. Motor Axial Output 09604 kW
Gen. Motor Target Rev.
29 Gen. Motor Target Torque 09606 Nm
30 Capacitor Target Voltage 09303 V
31 Capacitor Current 09307 A
32 Swing Lever Stroke 42103 ％
33 Boom Lever Stroke 42104 ％
34 Arm Lever Stroke 42105 ％
35 Bucket Lever Stroke 42106 ％
Gen. Speed ON,
Control OFF
Gen. Torque ON,
Control OFF
Hybrid controller control ON,
36 output 09701 Gen. Servo ON
OFF
Swing Motor Servo ON,
ON OFF
Low-Speed ON,
Matching ON OFF
Key SW ON,
(HYB controller) OFF
Hybrid system stop ON,
input OFF
37 Hybrid controller SW input 09702 Swing Lock Lever ON,
OFF
Swing Release Sw ON,
OFF
Swing Brake Sw. ON,
OFF
38 Swing Motor Rev. Speed 09102 r/min
39 Swing Motor Torque 09103 Nm
40 Swing Motor Axial Output 09104 kW
Swing Motor Target Rev.
Swing Motor Torque Limit
42 09106 Nm
Value
Bad Insulating Sensor
43 Voltage 09900 mV
40-488 HB215LC-2
40 Troubleshooting

ter citor Range
erator motor ks
Assembly part number
44 20255
(HYB controller)
Serial No.
45 20417
(HYB controller)
Program part number
46 20256
(HYB controller)
Program Version
47 20257
(HYB controller)
Program part number
48 20269
(HYB controller, swing)
Program Version
49 20270
(HYB controller, swing)
Program part number
50 (HYB controller, 20271
generator)
Program Version
51 (HYB controller, 20272
generator)
HB215LC-2 40-489
40 Troubleshooting
Hybrid equipment abnormality check sheet
(Separate sheet 2)
Model HB215LC-2 Work No.
Model and serial No. ＃ Date inspected/ /
Engine SAA4D107E-2 Service meter h
Engine serial No. ＃ Name of worker
A: Failure
Not
Go- ac-
B: Visual check
od cep-
ted
Wiring damage
1
Connector out of place
2
Not
C: Check with machine monitor (abnormality record, monitoring) Go- ac-
od cep-
ted
Check of error or failure code/ / / /
3
Check of monitoring information
Condi- Not
Mea-
tions for Go- ac-
Item indicated Code Unit Reference value sured
inspec- od cep-
value
tion ted
Engine Speed 01002 r/min 600 to 2,200
Throttle Position 31701 ％ 0 to 100
Capacitor Voltage 09300 V 150 to 300
Booster Volt., Low-Volt.
09400 V 150 to 300
Side
Capacitor Base
Temperature 09304 °C -30 to 65
Capacitor Bus Bar
09305 °C -30 to 65
4 Temperature
Capacitor Cell
Booster IGBT Base
Booster IGBT Junc.
Temperature 09404 -30 to 100
Booster Inductor
Swing Motor Coil
Swing Motor U IGBT Base
Temp. 09504 °C -30 to 85
40-490 HB215LC-2
40 Troubleshooting
Condi- Not
Mea-
tions for Go- ac-
Item indicated Code Unit Reference value sured
inspec- od cep-
value
tion ted
Swing Motor V IGBT Base
Temp. 09505 °C -30 to 85
Swing Motor W IGBT
Base Temp. 09506 °C -30 to 85
Temp. #0 09607 °C -30 to 180
Temp. #1 09608 °C -30 to 70
Swing Motor IGBT Junc.
Temp. 09507 °C -30 to 135
HYB Controller Solenoid 09700 ―
Generator Motor Rev. Same as engine
Speed 09602 r/min speed
Gen. Motor Target Rev.
09605 r/min 600 to 2,500
Speed
Capacitor Target Voltage 09303 V 185 to 298
-100 to 100
Swing Lever Stroke 42103 ％ (0 when lever is in
neutral)
-100 to 100
Boom Lever Stroke 42104 ％ (0 when lever is in
neutral)
-100 to 100
4 Arm Lever Stroke 42105 ％ (0 when lever is in
neutral)
-100 to 100
Bucket Lever Stroke 42106 ％ (0 when lever is in
neutral)
Hybrid controller control
09701 ―
output
Hybrid controller SW input 09702 ―
Swing Motor Rev. Speed 09102 r/min ± 8311
Swing Motor Target Rev.
Speed 09105 r/min ± 8311
Starting
switch
ON,
Bad Insulating Sensor
09900 before mV to 4650
Voltage
starting
the
engine
Assembly part number
20255 ― —
(HYB controller)
Serial No.
20417 ―
(HYB controller)
Program part number
20256 ―
(HYB controller)
Program Version
20257 ―
(HYB controller)
HB215LC-2 40-491
40 Troubleshooting
Failure code [GA00NS] HYB Equipment Overheat (HB380-GA00NS-400-A-Z0-A)
k Discharge capacitors first by using discharging tool (generator) 796-426-1800.
k Be careful not to get burned.
Action level Failure code Hybrid Equipment Overheat

Failure
L02 GA00NS (Hybrid controller system)
• Any of the hybrid equipment is overheated beyond the system stop temperature as shown
below.
Detail of • Swing motor coil: 160 °C, motor-generator: 190 °C, booster transformer in inverter: 130 °
failure C, booster IGBT junction: 135 °C, booster IGBT base: 100 °C, swing motor IGBT junction:
135 °C, generator driver IGBT base: 100 °C
• Stops swing motor and motor-generator control. Engages swing parking brake.
• Low speed matching function does not operate.
Action of • Hoist matching function does not operate.
Problem on • Swing and low speed matching impossible.
machine
Related
information
1 Defective hybrid equipment If another failure code is displayed, perform troubleshooting for it first.
Defective hybrid cooling
2 Perform troubleshooting for Y-8 to Y-11 in Y mode.
system circuit
40-492 HB215LC-2
40 Troubleshooting
Failure code [GA01KA] Power Cable Interlock Open Circuit (HB205-GA01KA-400-A-Z0-

A)
Action level Failure code Power Cable Interlock Open Circuit

Failure
L03 GA01KA (Hybrid controller systems)
• The power cable connector to the inverter and motor-generator, capacitor or electric swing
motor are disconnected.
Detail of • The cover for the power cable connector to the inverter, motor-generator or swing motor is
failure detached.
• A power cable connector is connected with the wrong side up (harness side connector is
turned 180° from its correct position).
• Stops motor-generator control, turns swing parking brake ON.
• Stops swing motor control.
Related • If failure code [GA1VFS] is also displayed, power cable connector HC06 may be loose, or
information connected 180° wrong.
Power cable
1 connector Visually check power cable connector for disconnection.
disconnected
Improper mating or
2 failure of power Visually check power cable connector for proper mating.
cable connector
Power cable
3 connector cover Visually check if power cable connector cover is detached.
detached
Improper 1. Check if mark (4 lines) on power cable connector HC06 and mark (4 lines) on
connection of body side are at the same side (whether the harness side connector is turned
4
power cable 180° wrong or not).
connector 2. Check power cable connector HC06 for loosening.
Open circuit in 1. Turn starting switch to OFF position.
motor-generator,
swing motor or a Troubleshoot when all power cable connectors are connected except HC02.
5 wiring harness
Resis-
(internal open Between HC02 (female) (14) and (24) Max. 1 z
circuit) tance
Open circuit in a If no failure is found by check on cause 4, this check is not required.
motor-generator 1. Turn starting switch to OFF position.
6 2. Disconnect connector GM01, and connect T-adapter to male side.
(Internal open
circuit) Resis- Between GM01 (male) (7) and (8)
Max. 1 z
tance
swing motor 1. Turn starting switch to OFF position.
7 (internal open 2. Disconnect connector PM01, and connect T-adapter to male side.
circuit) Resis- Between PM01 (male) (9) and (10)
Max. 1 z
tance
8
wiring harness 1. Turn starting switch to OFF position.
HB215LC-2 40-493
40 Troubleshooting
2. Disconnect connectors HC02, PM01 and GM01, and connect T-adapters to

each female side.
(Internal open Between HC02 (female) (14) and PM01 (female) (10) Max. 1 \
circuit) Resis- Between PM01 (female) (9) and GM01 (female) (8)
Max. 1 \
tance
Between GM01 (female) (7) and HC02 (female) (24) Max. 1 \
wiring harness 2. Disconnect connector HC02 and connect T-adapter to female side.
9 (contact with Resis- Between ground and HC02 (female) (14) or (24)
ground circuit) Min. 1 M\
tance
Hot short circuit in 2. Disconnect connector HC02 and connect T-adapter to female side.
Voltage Between ground and HC02 (female) (14) or (24) Max. 1 V
Defective inverter If no failure is found by checks on causes 1 to 9, inverter (hybrid controller) may be
11 (hybrid controller) defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to power cable interlock
40-494 HB215LC-2
40 Troubleshooting
Failure code [GA01KB] Power Cable Interlock Short Circuit (HB205-GA01KB-400-A-Z0-

A)
Action level Failure code Short circuit in power cable interlock circuit
Failure
L03 GA01KB (Hybrid controller systems)
• The power cable connector to the inverter and motor-generator, capacitor or electric swing
motor is disconnected.
Detail of • The cover for the power cable connector to the inverter, motor-generator or swing motor is
failure detached.
• A power cable connector is connected with the wrong side up (harness side connector is
turned 180° from its correct position).
machine
Related • If failure code [GA1VFS] is also displayed, power cable connector HC06 may be loose, or
information connected 180° wrong.
Power cable
1 connector Visually check power cable connector for disconnection.
disconnected
Improper mating or
2 failure of power Visually check power cable connector for proper mating.
cable connector
Power cable
3 connector cover Visually check if power cable connector cover is detached.
detached
Improper 1. Check if mark (4 lines) on power cable connector HC06 and mark (4 lines) on
connection of body side are at the same side (whether the harness side connector is turned
4
power cable 180° wrong or not).
connector 2. Check power cable connector HC06 for loosening.
motor-generator,
swing motor or a Troubleshoot with all power cable connectors other than HC02 are connected.
5 wiring harness
Resis-
(internal open Between HC02 (female) (14) and (24) Max. 1 z
circuit) tance
motor-generator 1. Turn starting switch to OFF position.
6 2. Disconnect connector GM01, and connect T-adapter to male side.
(Internal open
circuit) Resis- Between GM01 (male) (7) and (8)
Max. 1 z
tance
swing motor 1. Turn starting switch to OFF position.
7 (internal open 2. Disconnect connector PM01, and connect T-adapter to male side.
circuit) Resis- Between PM01 (male) (9) and (10)
Max. 1 z
tance
HB215LC-2 40-495
40 Troubleshooting

C If no failure is found by check on cause 4, this check is not required.
wiring harness 2. Disconnect connectors HC02, PM01 and GM01, and connect T-adapters to
8 each female side.
(Internal open
circuit) Between HC02 (female) (14) and PM01 (female) (10) Max. 1 \
Resis- Between PM01 (female) (9) and GM01 (female) (8)
Max. 1 \
tance
Between GM01 (female) (7) and HC02 (female) (24) Max. 1 \
9 (contact with Resis- Between ground and HC02 (female) (14) or (24)
ground circuit) Min. 1 M\
tance
Hot short circuit in 2. Disconnect connector HC02 and connect T-adapter to female side.
Voltage Between ground and HC02 (female) (14) or (24) Max. 1 V
Defective inverter If no failure is found by checks on causes 1 to 9, inverter (hybrid controller) may be
11 (hybrid controller) defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to power cable interlock
40-496 HB215LC-2
40 Troubleshooting
Failure code [GA02KZ] DC Line Open & Short Circuit (HB380-GA02KZ-400-A-Z0-A)
Action level Failure code DC Line Open & Short Circuit

Failure
L04 GA02KZ (Hybrid controller system)
Detail of • Deteriorated insulation of cable between capacitor and inverter.
failure
Problem on • Upper structure does not swing.
machine • Low speed matching impossible.
information
Insulation between
1 hybrid equipment • Visually check cables for broken insulations and other defects.
chassis ground.
Defective high-
2 voltage parts in • Perform checks 1. to 7. in common troubleshooting of high-voltage parts.
hybrid components
HB215LC-2 40-497
40 Troubleshooting
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster (HB205-GA04KG-

400-A-Z0-A)
Action level Failure code Abnormal DC HW Voltage Before Booster

Failure
L03 GA04KG (Hybrid controller systems)
Detail of • Hardware detects a capacitor voltage of 401 V or above.
failure
• Turn swing motor, motor-generator control stop, swing parking brake ON.
Action of • Hoist matching function does not work normally.
• Capacitor voltage can be checked with monitoring function.
information • Method of reproducing failure code: Turn starting switch to ON position or start engine.
Perform 1. of Failure code [GA****] Common troubleshooting for high voltage
1 Defective capacitor
parts.
Defective capacitor Perform 5. of Failure code [GA****] Common troubleshooting for high voltage
2 power cable parts.
Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
40-498 HB215LC-2
40 Troubleshooting
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster (HB205-GA05KG-

400-A-Z0-A)
Action level Failure code Abnormal DC Switch Voltage Before Booster

Failure
Detail of • Software detects a capacitor voltage of 340 V or above.
failure
parts.
Defective inverter
(hybrid controller)
HB215LC-2 40-499
40 Troubleshooting
Failurecode[GA05KP]LowDCSWOutputVolt.Bef.Booster
k Dischargethecapacitorbyusingadischargingtool(generator):796-426-1800inadvance.
Action level Failure code Low DC Switch Output Voltage Before Booster
Failure
L03 GA05KP (Hybrid controller systems)
Detail of • Software detects a capacitor voltage of 100 V or below.
failure
• Turn swing motor, motor-generator control stop, swing parking brake to ON.

Defective
connection of
Visually check that harness connectors (HB01, HC06) are connected normally
1 capacitor power
and connection surfaces are free from dirt.
cable and power
Connect and disconnect connector, and check if failure is solved.
cable connector
Defective
2 connection of
harness connector
harness 2. Disconnect connectors HB01 and HC06, and connect T-adapters to each
defective contact of Resis- Between HB01 (male) cable housing metal (Portion P)
Max. 1 Ω
connector) tance and HC06 (male) cable housing metal (Portion P)
parts.
5
power cable parts.
Defective inverter
(hybrid controller)
40-500 HB215LC-2
40 Troubleshooting
Circuit diagram related to high voltage parts
HB215LC-2
40 Troubleshooting
HB215LC-2
40 Troubleshooting
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster (HB380-GA06KZ-

400-A-Z0-A)
Action level Failure code DC Voltage Sensor Open/Short Circuit Before Booster
Failure
Detail of • Abnormal capacitor voltage sensor in inverter.
failure
Defective inverter
(hybrid controller)
HB215LC-2 40-501
40 Troubleshooting
Failure code [GA08KG] Abnorm. DC HW Volt. After Booster (HB205-GA08KG-400-A-Z0-

A)
Action level Failure code Abnormal DC HW Voltage After Booster

Failure
Detail of • Hardware detects abnormally high output voltage to power train.
failure
• Power train voltage can be checked with monitoring function.
Defective motor-
1 generator
Defective swing
2
motor Perform 1 to 7 of common troubleshooting for high voltage parts.
Defective inverter
3 (hybrid controller)
40-502 HB215LC-2
40 Troubleshooting
Failure code [GA09KG] Abnorm. DC SW Volt. After Booster (HB205-GA09KG-400-A-Z0-

A)
Action level Failure code Abnormal DC Switch Voltage After Booster

Failure
Detail of • Software detects abnormally high output voltage to power train.
failure
Defective motor-
1 generator
Defective swing
2
motor Perform 1 to 7 of common troubleshooting for high voltage parts.
Defective inverter
3 (hybrid controller)
HB215LC-2 40-503
40 Troubleshooting
Failure code [GA09KP] Low DC SW Output Volt. After Booster (HB205-GA09KP-400-

A-Z0-A)
Action level Failure code Abnormal DC Switch Voltage After Booster

Failure
Detail of • Software detects abnormally low output voltage to power train.
failure
Defective inverter
(hybrid controller)
40-504 HB215LC-2
40 Troubleshooting
Failure code [GA0AKZ] DC Vlt. Sen. Op./Shrt Cir. Aft. Booster (HB205-GA0AKZ-400-
A-Z0-A)
Action level Failure code DC voltage sensor open/short circuit after boosting
Failure
L03 GA0AKZ (Hybrid controller systems)
Detail of • Abnormality of power train voltage sensor in inverter is detected.
failure
Defective inverter
(hybrid controller)
HB215LC-2 40-505
40 Troubleshooting
Failure code [GA0BKZ] AC Line Open & Short Circuit (HB380-GA0BKZ-400-A-Z0-A)
Action level Failure code AC Line Open & Short Circuit

Failure
L04 GA0BKZ (Hybrid controller system)
Detail of • Deteriorated insulation of cables between swing motor or motor-generator and inverter.
failure
Action of • Low speed matching function does not operate.
controller • Hoist matching function does not operate.
• If cause of failure disappears, machine becomes normal by itself.
Related • Method of reproducing failure code: Start engine and then turn key to OFF position.
information
Insulation between
1 hybrid equipment • Visually check cables for broken insulations and other defects.
chassis ground.
Defective high-
2 voltage parts in • Perform checks 1. to 7. in common troubleshooting of high-voltage parts.
hybrid components
40-506 HB215LC-2
40 Troubleshooting
Failure code [GA10MA] HYB Controller Malfunction (HB205-GA10MA-400-A-Z0-A)
Action level Failure code Malfunction of hybrid controller

Failure
L04 GA10MA (Hybrid controller systems)
Detail of • Malfunction of hybrid controller
failure
Action of
controller
Problem on • Inverter (hybrid controller) does not operate normally.
machine
information
Defective power supply to Perform checks on causes 1 to 4 in troubleshooting for failure code
1 hybrid controller [GA2QKR].
2 1 system [DB2RKR].
Defective inverter (hybrid defective.
3 controller)
HB215LC-2 40-507
40 Troubleshooting
Failure code [GA10MC] HYB Controller Error (HB205-GA10MC-400-A-Z0-A)
Action level Failure code Malfunction of hybrid controller

Failure
- GA10MC (Hybrid controller systems)
Detail of • Malfunction of inverter (hybrid controller)
failure
Action of
controller
Problem on • Inverter (hybrid controller) does not operate normally.
machine
information
Malfunction of inverter (hybrid
1 If the machine behaves normally, there is no need of replacement.
controller)
40-508 HB215LC-2
40 Troubleshooting
Failure code [GA12NK] High-Voltage Line Start-up Failure (HB205-GA12NK-400-A-Z0-A)
Action level Failure code Hybrid Controller Power Supply Not Turned ON
Failure
L03 GA12NK (Hybrid controller systems)
Detail of • Electrical system in inverter is not activated.
failure
Related • Method of reproducing failure code: Turn starting switch to ON position or start engine.
information
parts.
Defective motor- Perform 3. of Failure code [GA****] Common troubleshooting for high voltage
2 generator parts.
Defective Perform 7. of Failure code [GA****] Common troubleshooting for high voltage
4 generator power parts.
cable
Defective motor-
5 generator speed Perform checks on causes 1 to 3 for failure code [GA60MC].
sensor harness
Defective inverter
(hybrid controller)
HB215LC-2 40-509
40 Troubleshooting
Failure code [GA13KP] Low HYB Control. Sen. Power Sup. (HB205-GA13KP-400-A-Z0-
A)
Action level Failure code Low HYB Control. Sen. Power Sup.
Failure
Detail of • Voltage of 5 V sensor power supply output circuit is 2.5 V or below.
failure
• Stops output of power from 5 V sensor power supply output.
• Hoist matching function does not work normally.
Action of • Stops swing motor control.
controller • Turns ON swing parking brake.
information
3 (contact with Resis- Between HC02 (female) (7) and ground
ground circuit) Min. 1 Mz
tance
Defective inverter If no failure is found by above checks, inverter (hybrid controller) may be defective.
4 (hybrid controller) (Since this is an internal defect, troubleshooting cannot be performed.)
40-510 HB215LC-2
40 Troubleshooting
Failure code [GA13KY] HYB Control. Sen. Power Short Cir (HB205-GA13KY-400-A-Z0-A)
Action level Failure code Hybrid Controller Sensor Power Supply Short Circuit
Failure
L03 GA13KY (Hybrid controller systems)
Detail of • Voltage of 5 V sensor power supply output circuit is above 6.0 V.
failure
machine
information
a To measure voltage before controller stops outputting of power.
1 wiring harness 2. Disconnect connector HC02 and connect T-adapter to female side.
3. Turn starting switch ON (with connector HC02 disconnected).
Between HC02 (female) (7) and ground Voltage 4.5 to 5.5 V
HB215LC-2 40-511
40 Troubleshooting
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir (HB380-
GA15KZ-400-A-Z0-A)
Action level Failure code Hybrid Controller Bad Insulation Sensor Open/Short Circuit
Failure
Detail of • The sensor which detects deterioration of insulation between hybrid equipment and
failure chassis ground is abnormal
controller
Problem on • Electric leakage cannot be detected
machine
information Then turn key to OFF position.
Defective high-
Perform checks 1. to 7. in common troubleshooting of high-voltage parts for failure
1 voltage parts in
code [GA****].
hybrid equipment
40-512 HB215LC-2
40 Troubleshooting
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure (HB205-GA17KR-400-

A-Z0-A)
Action level Failure code Generator Motor Driver Communication Failure

Failure
L03 GA17KR (Hybrid controller systems)
Detail of • The motor-generator controller detects internal communication error 2 in the inverter.
failure
• Motor-generator control is stopped.
Action of • Limits the swing speed.
machine
information
Defective inverter
(hybrid controller)
HB215LC-2 40-513
40 Troubleshooting
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded (HB380-GA17MB-400-A-Z0-A)
Action level Failure code Generator Motor Driver Function Degraded

Failure
― GA17MB (Hybrid controller system)
Detail of • Motor-generator controller detects internal communication error 1 in inverter.
failure
• None in particular
Problem on • None in particular
machine
information
Defective inverter
(hybrid controller)
40-514 HB215LC-2
40 Troubleshooting
Failure code [GA18MC] Gen. Mo.Dr. Excite. Pow. Sup. Failure (HB205-GA18MC-400-
A-Z0-A)
Action level Failure code Generator Motor Driver Excitation Power Supply Failure
Failure
L03 GA18MC (Hybrid controller systems)
Detail of • Electrical system in inverter is not activated.
failure
information
Perform 3. of Failure code [GA****] Common troubleshooting for high
1 Defective motor-generator
voltage parts.
Defective generator power Perform 7. of Failure code [GA****] Common troubleshooting for high
2 voltage parts.
cable
Defective motor-generator
3 Perform checks on causes 1 to 3 for failure code [GA60MC].
speed sensor harness
controller)
HB215LC-2 40-515
40 Troubleshooting
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure (HB205-
GA19KR-400-A-Z0-A)
Action level Failure code Generator Motor Driver Sub-CPU Communication Failure
Failure
L01 GA19KR (Hybrid controller systems)
Detail of • Communication failure is detected in sub-CPU of motor-generator driver.
failure
machine
information
controller)
40-516 HB215LC-2
40 Troubleshooting
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. (HB205-
GA19KT-400-A-Z0-A)
Action level Failure code Internal Abnormal Generator Motor Driver Sub-CPU
Failure Controller
L03 GA19KT
(Hybrid controller systems)
Detail of • The motor-generator controller detects internal communication error 3 in the inverter.
failure
Action of • Limits the swing speed.
machine
information
controller)
HB215LC-2 40-517
40 Troubleshooting
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction (HB205-GA1BMA-
400-A-Z0-A)
Action level Failure code Generator Motor Driver DC Voltage Sensor Malfunction
Failure
L01 GA1BMA (Hybrid controller systems)
Detail of • Malfunction of motor-generator driver DC voltage sensor is detected.
failure
Problem on
machine
information
controller)
40-518 HB215LC-2
40 Troubleshooting
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure (HB380-GA1FR-

400-A-Z0-A)
Action level Failure code Swing Motor Driver Communication Failure

Failure
L03 GA1FKR (Hybrid controller system)
Detail of • Swing motor controller detects internal communication error 2 in inverter.
failure
information
controller)
HB215LC-2 40-519
40 Troubleshooting
Failure code [GA1FMA] Abnormal Swing Motor Driver (HB380-GA1FMA-400-A-Z0-A)
Action level Failure code Abnormal Swing Motor Driver

Failure
L03 GA1FMA (Hybrid controller system)
Detail of • Abnormality detected in swing motor inverter output circuit.
failure
information
Perform check 2. in common troubleshooting of high-voltage parts for
1 Defective swing motor
failure code [GA****].
Defective swing motor power Perform check 6. in common troubleshooting of high-voltage parts for
2 failure code [GA****].
cable
controller)
40-520 HB215LC-2
40 Troubleshooting
Failure code [GA1GKR] Swg Mot. Driver Sub-CPU Comm. Failure (HB380-
GA1GKR-400-A-Z0-A)
Action level Failure code Swing Motor Driver Sub-CPU Communication Failure
Failure
L03 GA1GKR (Hybrid controller system)
Detail of • Communication error detected in sub-CPU of swing motor driver.
failure
information
controller)
HB215LC-2 40-521
40 Troubleshooting
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal (HB380-
GA1GKT-400-A-Z0-A)
Action level Failure code Swing Motor Driver Sub-CPU Controller Abnormal
Failure
L03 GA1GKT (Hybrid controller system)
failure
information
controller)
40-522 HB215LC-2
40 Troubleshooting
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded (HB380-
GA1GMB-400-A-Z0-A)
Action level Failure code Swing Motor Driver Sub-CPU Function Degraded
Failure
― GA1GMB (Hybrid controller system)
failure
• None in particular
machine
information
controller)
HB215LC-2 40-523
40 Troubleshooting
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir (HB380-
GA1HKZ-400-A-Z0-A)
Action level Failure code Swing Motor Driver Phase-U Temperature Sensor Open/
Failure Short Circuit
L03 GA1HKZ
(Hybrid controller system)
Detail of • Abnormal temperature sensor in phase-U output circuit of swing motor inverter.
failure
• Limits swing speed, etc.
Action of • If cause of failure disappears when the swing lever is in NEUTRAL position, machine
controller becomes normal by itself.
Problem on • Swing speed is limited.
machine
• Swing motor coil temperature can be checked with monitoring function.
controller)
40-524 HB215LC-2
40 Troubleshooting
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir (HB380-
GA1JKZ-400-A-Z0-A)
Action level Failure code Swing Motor Driver Phase-V Temperature Sensor Open/
L03 GA1JKZ
Detail of • Abnormal temperature sensor in phase-V output circuit of swing motor inverter.
failure
machine
controller)
HB215LC-2 40-525
40 Troubleshooting
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir (HB380-
GA1KKZ-400-A-Z0-A)
Action level Failure code Swing Motor Driver Phase-W Temperature Sensor Open/
L03 GA1KKZ
Detail of • Abnormal temperature sensor in phase-W output circuit of swing motor inverter.
failure
machine
controller)
40-526 HB215LC-2
40 Troubleshooting
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens. Opn/Shrt Cir (HB380-
GA1LKZ-400-A-Z0-A)
Action level Failure code Swing Motor Driver Current Sensor Open/Short Circuit
Failure
L03 GA1LKZ (Hybrid controller system)
Detail of • Open or short circuit in current sensor of swing motor inverter.
failure
information
controller)
HB215LC-2 40-527
40 Troubleshooting
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen. Opn/Shrt Cir. (HB380-GA1MKZ-
400-A-Z0-A)
Action level Failure code Swing Motor Driver DC Voltage Sensor Open/Short Circuit
Failure
L03 GA1MKZ (Hybrid controller system)
Detail of • Abnormal DC voltage sensor in swing motor inverter.
failure
information
controller)
40-528 HB215LC-2
40 Troubleshooting
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat (HB380-GA1NNS-400-A-Z0-

A)
Action level Failure code Swing Motor Driver IGBT Overheat

Failure
― GA1NNS (Hybrid controller system)
Detail of • Estimated junction temperature of swing motor driver IGBT in inverter exceeds 134 °C.
failure
machine
information
Excessive charge and
1 Check if swing and swing stopping has been performed too frequently.
discharge of capacitors
Malfunction of hybrid system Check coolant level in hybrid system cooling circuit, radiator fins for
2 cooling circuit clogging, and operation of water pump.
controller)
HB215LC-2 40-529
40 Troubleshooting
Failure code [GA1SFS] Contactor Locked (HB380-GA1SFS-400-A-Z0-A)
Action level Failure code Contactor Locked

Failure
L03 GA1SFS (Hybrid controller system)
Detail of
• Contactors are fused in inverter.
failure
information
controller)
40-530 HB215LC-2
40 Troubleshooting
Failure code [GA1SMC] Contactor Failure (HB380-GA1SMC-400-A-Z0-A)
Action level Failure code Contactor Failure

Failure
L03 GA1SMC] (Hybrid controller system)
Detail of
• Contactors in inverter cannot be connected.
failure
• Capacitor voltage and booster low side voltage can be checked with monitoring function.
Related (Code: 09300, 09400)
controller)
HB215LC-2 40-531
40 Troubleshooting
Failurecode[GA1TKP]CapacitorLowOutputVoltage
Action level Failure code Capacitor Low Output Voltage

Failure
L03 GA1TKP (Hybrid controller system)
Detail of • Capacitor voltage is below 190 V.
failure

Defective
connection of
1 capacitor power
cable and power
cable connector
Defective
2 connection of
harness connector
harness 2. Disconnect connectors HB01 and HC06, and connect T-adapters to each
defective contact of Resis- Between HB01 (male) cable housing metal (Portion P)
connector) Max. 1 Ω
tance and HC06 (male) cable housing metal (Portion P)
parts.
5
power cable parts.
Defective inverter
(hybrid controller)
40-532 HB215LC-2
40 Troubleshooting
HB215LC-2
40 Troubleshooting
HB215LC-2
40 Troubleshooting
Failure code [GA1TNS] Capacitor Overheat (HB205-GA1TNS-400-A-Z0-A)
Action level Failure code Capacitor Overheat

Failure
- GA1TNS (Hybrid controller systems)
Detail of • Capacitor cell center temperature exceeds 65°C.
failure
• Limits the swing speed etc.
Action of • If the swing lever is in NEUTRAL and the cause of failure disappears, machine becomes
controller normal by itself.
machine
• Capacitor cell center temperature and capacitor base temperature can be checked with
Related (Code: 09306, 09304)
information • Capacitor cell center temperature is an estimated value, which is calculated from
capacitor base temperature.
Excessive charging and Check if excessive swing and swing stop operations have been
1 discharging of capacitor performed.
Internal short circuit in 2. Disconnect connector HP01, and connect T-adapter to male side.
2 capacitor base temperature
sensor • Capacitor base temperature sensor Resis- 0.1 to 500
Between HP01 (male) (4) and (8) tance kz
2. Disconnect connectors HC02 and HP01, and connect T-adapter to
Ground fault in wiring harness either female side.
3
(Contact with ground circuit) • Capacitor base temperature sensor
Between ground and HC02 (female) (27) or Resis-
Min. 1 Mz
HP01 (female) (4) tance
See Testing and adjusting, "Measuring hybrid system coolant
4 Defective water pump
pressure".
Referring to Y mode "Y-11 Capacitor overheats", check hybrid system
Malfunction of hybrid system
5 radiator coolant level, clogging of radiator fins, operation of water
cooling circuit
pump, etc.
• Perform 1. of Failure code [GA****] Common troubleshooting for
high voltage parts.
HB215LC-2 40-533
40 Troubleshooting
Circuit diagram related to capacitor overheating
40-534 HB215LC-2
40 Troubleshooting
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/short Cir. (HB205-GA1UKZ-

400-A-Z0-A)
Action level Failure code Capacitor Temperature Sensor Open/Short Circuit

Failure
L01 GA1UKZ (Hybrid controller systems)
Detail of • Difference between capacitor base temperature and capacitor bus bar temperature is
failure 54.4 °C or more
controller
Problem on
machine
• Capacitor base temperature and capacitor bus bar temperature can be checked with
information (Code: 09304, code: 09305)
Defective capacitor base 2. Disconnect connector HP01, and connect T-adapter to male side.
1 temperature sensor 0.1 to 500
(internal open or short circuit) Resis- Between HP01 (male) (4) and (12) kz
tance Between HP01 (male) (4) and ground Min. 1 Mz
Defective capacitor bus bar 2. Disconnect connector HP01, and connect T-adapter to male side.
2 temperature sensor (internal 0.1 to 500
open or short circuit) Resis- Between HP01 (male) (5) and (12) kz
tance Between HP01 (male) (5) and ground Min. 1 Mz
2. Disconnect connectors HC01 and HP01 and connect T-adapters to
each female side.
Between HC01 (female) (7) and HP01 (female)
Open circuit in wiring harness (1) Max. 1 z
3 (wire breakage or defective Between HC01 (female) (23) and HP01
Max. 1 z
contact of connector) Resis- (female) (12)
tance Between HC01 (female) (27) and HP01

Hot short circuit in wiring • Capacitor base temperature sensor
4 Between ground and HC02 (female) (27) or Max. 5.5 V
harness
HP01 (female) (4)
Voltage
• Capacitor bus bar temperature sensor
Between ground and HC02 (female) (37) or Max. 5.5 V
HP01 (female) (5)
cooling circuit
pump, etc.
• Perform 1. of Failure code [GA****] Common troubleshooting for
high voltage parts.
If no failure is found by above checks, inverter (hybrid controller) may
7 be defective. (Since this is an internal defect, troubleshooting cannot be
controller)
performed.)
HB215LC-2 40-535
40 Troubleshooting
Circuit diagram related to capacitor temperature sensor
40-536 HB215LC-2
40 Troubleshooting
Failure code [GA1VFS] Capacitor Contactor Locked (HB205-GA1VFS-400-A-Z0-A)
Action level Failure code Capacitor Contactor Locked

Failure
L03 GA1VFS (Hybrid controller systems)
• Contactor is fused inside capacitor
Detail of • A power cable connector is connected with the wrong side up (harness side connector is
failure turned 180° from its correct position).
machine
• If failure code [GA01KA] is also displayed, power cable connector HC06 may be loose, or
Related connected 180° wrong.
information • Capacitor voltage can be checked with monitoring function.
(Code: 09300)
1. Check if mark (4 lines) on power cable connector HC06 and mark (4
Improper connection of power lines) on body side are at the same side (whether the harness side
1
cable connector connector is turned 180° wrong or not).
2. Check power cable connector HC06 for loosening.
Hot short circuit in wiring 3. Turn starting switch to ON position.
2
harness
Between HP01 (female) (6) and ground Max. 1 V
Voltage
Between HP01 (female) (7) and ground Max. 1 V
When the power supply is OFF, check the capacitor LED window
3 Defective capacitor before discharging (capacitor voltage 30 V or above). If both LEDs are
lit, capacitor is defective.
controller)
Circuit diagram related to capacitor contactor
HB215LC-2 40-537
40 Troubleshooting
40-538 HB215LC-2
40 Troubleshooting
Failure code [GA1VMC] Capacitor Contactor Failure (HB380-GA1VMC-400-A-Z0-A)
Action level Failure code Capacitor Contactor Failure

Failure
L03 GA1VMC (Hybrid controller system)
Detail of • Contactors in capacitor cannot be connected.
failure
information
Open circuit in wiring harness each female side.
1 (Wire breakage or defective Between HC01 (female) (3) and HP01 (female)
Max. 1 z
contact of connector) Resis- (6)
tance Between HC01 (female) (9) and HP01 (female)
(7) Max. 1 z
Defective inverter (hybrid Since this is an internal defect, troubleshooting cannot be performed.
3 controller)
Circuit diagram related to capacitor contactor
HB215LC-2 40-539
40 Troubleshooting
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. (HB205-
GA1XKZ-400-A-Z0-A)
Action level Failure code Booster Inductor Temperature Sensor Open/Short Circuit
Failure
L01 GA1XKZ (Hybrid controller systems)
Detail of • Abnormality of booster inductor temperature sensor in inverter is detected.
failure
controller
Problem on
machine
• Booster inductor temperature can be checked with monitoring function.
(Code: 09402)
• If any of failure codes [GA00NS], [GA1NNS], [GA1YNS], [GA1ZNS], [GA22NS],
[GA25NS] or [GA26NS] is also displayed to indicate overheating inside inverter, there
Related may be an abnormality in hybrid system cooling circuit.
information • When inductor temperature checked with monitoring function is normal (equal to as or
higher than ambient temperature, within 16°C to 190°C), there may be an abnormality in
hybrid system cooling circuit.
• When low pressure sensor shown in step 4 of cause 1 is installed, the water pump
pressure for hybrid system can be checked as a service pressure (water pump pressure
for hybrid system) with monitoring function. (Code: 01142 (MPa))
1. Check coolant level in hybrid
radiator Coolant Above sight gauge
• Visually check through sight level
gauge.
2. Clogging in hybrid radiator fins
3. Check operation of water pump
• Feel the pump vibration.
Malfunction of hybrid system 4. Check coolant flow (pressure
1 cooling circuit measurement)
• Remove the plug from elbow of
swing motor coolant inlet. 10 MPa (0.2 kg/cm2) or
Connect a low pressure sensor above (monitor
to measure the pressure after Pressure reading) when battery
turning key switch ON. voltage is 20 V or
above
a See Testing and adjusting,
"Measuring hybrid system
coolant pressure".
controller)
*: Pressure reading on monitor / 500 = actual pressure (converted pressure)
Example: 20 MPa (monitor display)
20 MPa / 500 = 0.04 MPa = 0.4 kg/cm2 (converted pressure)
40-540 HB215LC-2
40 Troubleshooting
Failure code [GA1YNS] Booster Inductor Overheat (HB205-GA1YNS-400-A-Z0-A)
Action level Failure code Booster Inductor Overheat

Failure
- GA1YNS (Hybrid controller systems)
Detail of • Booster inductor temperature in inverter exceeds 125°C.
failure
machine
• Booster inductor temperature can be checked with monitoring function.
Excessive charging and
1 Check if excessive swing and swing stop operations have been made.
discharging of capacitor
cooling circuit
pump, etc.
controller)
HB215LC-2 40-541
40 Troubleshooting
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. (HB205-
GA1ZKZ-400-A-Z0-A)
Action level Failure code Booster IGBT Temperature Sensor Open/Short Circuit
Failure
L03 GA1ZKZ (Hybrid controller systems)
Detail of • Abnormality of booster IGBT temperature sensor in inverter is detected.
failure
machine
• Booster IGBT base temperature can be checked with monitoring function.
controller)
40-542 HB215LC-2
40 Troubleshooting
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat (HB205-GA1ZNS-400-A-

Z0-A)
Action level Failure code Booster IGBT Temperature Sensor Overheat

Failure
- GA1ZNS (Hybrid controller systems)
Detail of • Booster IGBT temperature in inverter exceeds 80°C.
failure
machine
• Booster IGBT base temperature can be checked with monitoring function.
cooling circuit
pump, etc.
controller)
HB215LC-2 40-543
40 Troubleshooting
Failure code [GA22NS] Booster IGBT Junction Overheat (HB380-GA22NS-400-A-Z0-A)
Action level Failure code Booster IGBT Junction Overheat

Failure
― GA22NS (Hybrid controller system)
Detail of • Estimated junction temperature of booster IGBT in inverter exceeds 130 °C.
failure
machine
• Booster IGBT junction temperature can be checked with monitoring function.
Referring to Y mode "Y-11 Capacitor becomes hot", check coolant level
2 in hybrid system cooling circuit, radiator fins for clogging, and operation
cooling circuit
of water pump.
controller)
40-544 HB215LC-2
40 Troubleshooting
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sen.0 Opn/Short Cir. (HB205-
GA23KZ-400-A-Z0-A)
Action level Failure code Generator Motor Driver Temperature Sensor 0 Open/Short
Failure Circuit
L01 GA23KZ
Detail of • Open circuit or short circuit is detected in motor-generator driver temperature sensor 0.
failure
controller
Problem on
machine
information
controller)
HB215LC-2 40-545
40 Troubleshooting
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sen.1 Opn/Short Cir. (HB205-
GA24KZ-400-A-Z0-A)
Action level Failure code Generator Motor Driver Temperature Sensor 1 Open/Short
Failure Circuit
L01 GA24KZ
Detail of • Open circuit or short circuit is detected in motor-generator driver temperature sensor 1.
failure
controller
Problem on
machine
information
controller)
40-546 HB215LC-2
40 Troubleshooting
Failure code [GA25MA] Gen. Motor Driver IGBT 0 Abnormality (HB380-GA25MA-

400-A-Z0-A)
Action level Failure code Generator Motor Driver IGBT 0 Abnormality

Failure
L03 GA25MA (Hybrid controller system)
Detail of • Abnormality of motor-generator driver IGBT 0 is detected.
failure
information
Defective generator power Perform check 7. in common troubleshooting of high-voltage parts for
cable
controller)
HB215LC-2 40-547
40 Troubleshooting
Failure code [GA25NS] Gen. Motor Driver IGBT 0 Overheat (HB380-GA25NS-400-A-Z0-A)
Action level Failure code Generator Motor Driver IGBT 0 Overheat

Failure
Detail of • Motor-generator driver IGBT temperature exceeds 95 °C.
failure
machine
information
controller)
40-548 HB215LC-2
40 Troubleshooting
Failure code [GA26MA] Gen. Motor Driver IGBT 1 Abnormality (HB380-GA26MA-

400-A-Z0-A)
Action level Failure code Generator Motor Driver IGBT 1 Abnormality

Failure
Detail of • Abnormality of motor-generator driver IGBT 1 is detected.
failure
information
Defective generator power Perform check 7. in common troubleshooting of high-voltage parts for
cable
controller)
HB215LC-2 40-549
40 Troubleshooting
Failure code [GA26NS] Gen. Motor Driver IGBT 1 Overheat (HB380-GA26NS-400-A-Z0-A)
Action level Failure code Generator Motor Driver IGBT 1 Overheat

Failure
Detail of • Motor-generator driver IGBT temperature exceeds 95 °C.
failure
machine
information
controller)
40-550 HB215LC-2
40 Troubleshooting
Failure code [GA27KZ] DC Cur. Sens. Bef. Booster Opn/Short Cir (HB205-
GA27KZ-400-A-Z0-A)
Action level Failure code DC Current Sensor Before Booster Open/Short Circuit
Failure
L01 GA27KZ (Hybrid controller systems)
Detail of • Open circuit or short circuit is detected in DC current sensor before booster.
failure
controller
Problem on
machine
• Failure code [GA1TNS] may be displayed.
Related • Capacitor current can be checked with monitoring function.
controller)
HB215LC-2 40-551
40 Troubleshooting
Failure code [GA2QKR] CAN2 Discon (Hyb Con) (HB205-GA2QKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Hybrid Controller)

Failure
L03 GA2QKR (Hybrid controller systems)
Detail of • Machine monitor cannot communicate with inverter (hybrid controller) over CAN
failure communication 2 line (KOMNET/c).
Action of • Retains information at time of occurrence of failure.
• Information to be obtained from inverter (hybrid controller) is not displayed and special
Problem on functions that need information do not work. Or update of received data is stopped (such
machine as failure codes and monitoring codes sent from the inverter).
switch is received.
Related • Since each controller and machine monitor are connected directly to the battery, they are
information supplied with power even after starting switch is turned OFF.
using multimeter.
2. Disconnect fusible link F05 and connect T-adapter to female side.
Defective fusible Resis- Between F05 (female) (1) and (2)
1 Max. 1 z
link F05 tance
a If fusible link is blown, circuit may have ground fault.
Defective fuse No.
2 2. Remove fuse No. 17 in fuse box F01.
17 in fuse box F01
If fuse is blown, circuit probably has ground fault.
Defective power 1. Turn starting switch to OFF position.
3 supply to hybrid 2. Disconnect connector HC01 and connect T-adapter to female side.
controller 3. Turn starting switch to ON position.
Between HC01 (female) (5) and (17) 20 to 30 V
Voltage
Between HC01 (female) (11) and (23) 20 to 30 V
1. Turn starting switch to OFF position, and set battery disconnect switch to OFF
Open circuit in position.
wiring harness 2. Remove fuse No. 17 in fuse box F01.
3. Disconnect connectors F05 and HC01, and connect T-adapters to each female
4 (Wire breakage or side.
connector)
Between terminal R04 and F05 (female) (1) Max. 1 z
Resis- Between F05 (female) (2) and F01-16G Max. 1 z
tance Between F01-17 and HC01 (female) (5) Max. 1 z
Between F01-17 and HC01 (female) (11) Max. 1 z
Defective power
Perform checks on causes 4 to 9 in troubleshooting for failure code [DB2QKR]
5 supply to engine
first.
controller
Defective inverter If no failure is found by above checks, hybrid controller may be defective. (Since
6 (hybrid controller) this is an internal defect, troubleshooting cannot be performed.)
40-552 HB215LC-2
40 Troubleshooting
Circuit diagram related to hybrid controller (inverter)
HB215LC-2 40-553
40 Troubleshooting
Failure code [GA2RKR] CAN1 Discon (Hyb Con) (HB205-GA2RKR-400-A-Z0-A)
Action level Failure code CAN1 Disconnection (Hybrid Controller)

Failure
L04 GA2RKR (Hybrid controller systems)
Detail of • Machine monitor cannot communicate with inverter (hybrid controller) over CAN
failure communication 1 line (KOMNET/r).
• Turns swing motor, motor-generator control stop, swing parking brake ON.
controller • If the swing lever is in NEUTRAL and the cause of failure disappears, machine becomes
normal by itself.
• Swing is disabled.
machine • Information to be obtained from inverter (hybrid controller) is not displayed and special
functions that need information do not work. Or update of received data is stopped.
switch is received.
Related • Since each controller and machine monitor are connected directly to the battery, they are
information supplied with power even after starting switch is turned OFF.
using multimeter.
Defective power
1 supply to inverter Perform checks on causes 1 to 4 for failure code [GA2QKR]
(hybrid controller)
Defective power
Perform checks on causes 4 to 9 in troubleshooting for failure code [DB2QKR]
2 supply to engine
first.
controller
Defective inverter If no failure is found by above checks, hybrid controller may be defective. (Since
3 (hybrid controller) this is an internal defect, troubleshooting cannot be performed.)
40-554 HB215LC-2
40 Troubleshooting
Failure code [GA60KZ] Generator Motor Open/Short Circuit (HB205-GA60KZ-400-A-Z0-

A)
Action level Failure code Generator Motor Open/Short Circuit

Failure
Detail of • Open circuit or short circuit is detected in all phases (A, B, and C) of motor-generator.
failure
information
Defective power cable Perform 7. of Failure code [GA****] Common troubleshooting for high
1 between motor-generator and voltage parts.
inverter
voltage parts.
controller)
HB215LC-2 40-555
40 Troubleshooting
Failure code [GA60MC] Generator Motor Failure (HB205-GA60MC-400-A-Z0-A)
Action level Failure code Generator Motor Failure

Failure
L03 GA60MC (Hybrid controller systems)
Detail of • Difference between motor-generator speed and engine speed is 200 rpm or more.
failure
controller normal.
Problem on • Upper structure does not swing (when open or short circuit exists).
machine
• Motor-generator speed and engine speed can be checked with monitoring function.
(Code: 09602, 01002)
Related • For the replacement procedure of motor-generator speed sensor, see Failure code
information [GA60N1].
2. Disconnect connectors HC02 and GM01, and connect T-adapters
to each female side.
Open circuit in wiring harness Between HC02 (female) (4) and GM01
contact of connector) Resis- Between HC02 (female) (7) and GM01
tance
Between HC02 (female) (33) and GM01

Ground fault in wiring harness 2. Disconnect connectors HC02 and GM01, and connect T-adapter to
Resis- Between ground and HC02 (female) (4) or
GM01 (female) (2) Min. 1 Mz
tance
Hot short circuit in wiring 2. Disconnect GM01, and connect T-adapter to female side.
harness
Voltage Between GM01 (female) (2) and ground Max. 1 V
4 Defective motor-generator Since this is an internal defect, troubleshooting cannot be performed.
controller)
40-556 HB215LC-2
40 Troubleshooting
Circuit diagram related to motor-generator speed sensor
HB215LC-2 40-557
40 Troubleshooting
Failure code [GA60N1] Generator Motor Overrun (HB205-GA60N1-400-A-Z0-A)
Action level Failure code Generator Motor Overrun

Failure
— GA60N1 (Hybrid controller systems)
Detail of • Overrun of motor-generator is detected.
failure
Problem on
machine
information
Perform troubleshooting for failure code [GA60MC].
40-558 HB215LC-2
40 Troubleshooting
Failure code [GA61KZ] Gen. Motor Temp. Sens. Opn/Short Cir. (HB205-GA61KZ-
400-A-Z0-A)
Action level Failure code Generator Motor Temperature Sensor Open/Short Circuit
Failure
Detail of • Open circuit or short circuit is detected in motor-generator temperature sensor
failure
controller
Problem on
machine
• For the replacement procedure of motor-generator temperature sensor, see Failure code
[GA61NS].
information • Motor-generator temperature can be checked with monitoring function.
(Code: 09600)
2. Disconnect connector GM01, and connect T-adapter to male side.
Approx.
-40°C
4200 kz
Approx.
10°C
210 kz
Defective motor-generator Approx.
1 25°C
temperature sensor 100 kz
Resis- Between GM01 (male) (4) and (5) Approx. 50
tance 40°C
kz
Approx.
90°C
7.7 kz
Approx.
200°C
440 z
Between GM01 (male) (4) and ground Min. 1 Mz
2. Disconnect connector HC02 and connect T-adapter to female side.
Open or short circuit in wiring Between HC02 (female) (28) and (17)
2
harness Resis- a Use temperature sensor resistance 500 z to
tance characteristics table for check on cause 1 5000 kz
as resistance criteria.
Open circuit in wiring harness 2. Disconnect connectors HC02 and GM01, and connect T-adapters
3 (Wire breakage or defective to each female side.
contact of connector) Between HC02 (female) (28) and GM01
Max. 1 z
Resis- (female) (4)
tance Between HC02 (female) (17) and GM01

tance
Hot short circuit in wiring 2. Disconnect connector GM01, and connect T-adapter to female side.
5
Voltage Between GM01 (female) (4) and ground Max. 5.5 V
6 Perform troubleshooting for failure code [GA1NNS].
cooling circuit
HB215LC-2 40-559
40 Troubleshooting

8 controller)
Circuit diagram related to motor-generator temperature sensor
40-560 HB215LC-2
40 Troubleshooting
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat (HB205-

GA61NS-400-A-Z0-A)
Action level Failure code Generator Motor Temperature Sensor Overheat

Failure
GA61NS (Hybrid controller systems)
Detail of • Motor-generator temperature exceeds 180°C.
failure
machine
information • See "Y-9" in troubleshooting for hybrid systems (Y mode).
2 Perform checks on cause 2 for failure code [GA1NNS].
cooling circuit
tance
5 controller)
• Reference
a When motor-generator temperature sensor needs replacement, the motor-generator housing must be
replaced (see Disassembly and assembly).
HB215LC-2 40-561
40 Troubleshooting
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir (HB205-
GA62KY-400-A-Z0-A)
Action level Failure code Generator Motor Phase-A Current Sensor Power Short
Failure Circuit
L01 GA62KY
Detail of • Overcurrent is detected in phase A of motor-generator.
failure
Problem on
machine
information
voltage parts.
inverter
controller)
40-562 HB215LC-2
40 Troubleshooting
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir (HB205-GA62KZ-
400-A-Z0-A)
Action level Failure code Generator Motor Phase-A Current Sensor Open/Short
Failure Circuit
L01 GA62KZ
Detail of • Open circuit or short circuit is detected in phase A of motor-generator.
failure
Problem on
machine
information
inverter
voltage parts.
controller)
HB215LC-2 40-563
40 Troubleshooting
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction (HB380-
GA62MA-400-A-Z0-A)
Action level Failure code Generator Motor Phase-A Current Sensor Malfunction
Failure
Detail of • Malfunction of motor-generator phase-A current sensor is detected.
failure
information
controller)
40-564 HB215LC-2
40 Troubleshooting
Failure code [GA62MC] Gen. Mot. Ph-A Cur. Sen. Defect Op. (HB205-GA62MC-400-A-
Z0-A)
Action level Failure code Generator Motor Phase-A Current Sensor Defective
Failure Operation
L01 GA62MC
Detail of • Malfunction of motor-generator phase-A current sensor is detected.
failure
Problem on
machine
information
controller)
HB215LC-2 40-565
40 Troubleshooting
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir (HB205-
GA63KY-400-A-Z0-A)
Action level Failure code Generator Motor Phase-B Current Sensor Power Short
Failure Circuit
L01 GA63KY
Detail of • Overcurrent is detected in phase B of motor-generator.
failure
Problem on
machine
information
voltage parts.
inverter
controller)
40-566 HB215LC-2
40 Troubleshooting
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir (HB205-GA63KZ-
400-A-Z0-A)
Action level Failure code Generator Motor Phase-B Current Sensor Open/Short
Failure Circuit
L01 GA63KZ
Detail of • Open circuit or short circuit is detected in phase B of motor-generator.
failure
Problem on
machine
information
inverter
voltage parts.
controller)
HB215LC-2 40-567
40 Troubleshooting
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction (HB380-
GA63MA-400-A-Z0-A)
Action level Failure code Generator Motor Phase-B Current Sensor Malfunction
Failure
Detail of • Malfunction of motor-generator phase-B current sensor is detected.
failure
information
controller)
40-568 HB215LC-2
40 Troubleshooting
Failure code [GA63MC] Gen. Mot. Ph-B Cur. Sen. Defect Op. (HB205-GA63MC-400-A-
Z0-A)
Action level Failure code Generator Motor Phase-B Current Sensor Defective
Failure Operation
L01 GA63MC
Detail of • Malfunction of motor-generator phase-B current sensor is detected.
failure
Problem on
machine
information
controller)
HB215LC-2 40-569
40 Troubleshooting
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir (HB205-
GA64KY-400-A-Z0-A)
Action level Failure code Generator Motor Phase-C Current Sensor Power Short
Failure Circuit
L01 GA64KY
Detail of • Overcurrent is detected in phase C of motor-generator.
failure
Problem on
machine
information
voltage parts.
inverter
controller)
40-570 HB215LC-2
40 Troubleshooting
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir (HB205-GA64KZ-
400-A-Z0-A)
Action level Failure code Generator Motor Phase-C Current Sensor Open/Short
Failure Circuit
L01 GA64KZ
Detail of • Open circuit or short circuit is detected in phase C of motor-generator.
failure
Problem on
machine
information
inverter
voltage parts.
controller)
HB215LC-2 40-571
40 Troubleshooting
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction (HB205-
GA64MA-400-A-Z0-A)
Action level Failure code Generator Motor Phase-C Current Sensor Malfunction
Failure
L03 GA64MA (Hybrid controller systems)
Detail of • Malfunction of motor-generator phase-C current sensor is detected.
failure
information
controller)
40-572 HB215LC-2
40 Troubleshooting
Failure code [GA64MC] Gen. Mot. Ph-C Cur. Sen. Defect Op. (HB205-GA64MC-400-A-
Z0-A)
Action level Failure code Generator Motor Phase-C Current Sensor Defective
Failure Operation
L01 GA64MC
Detail of • Malfunction of motor-generator phase-C current sensor is detected.
failure
Problem on
machine
information
controller)
HB215LC-2 40-573
40 Troubleshooting
Failure code [GA70KB] HYB Swing Motor Short Circuit (HB380-GA70KB-400-A-Z0-A)
Action level Failure code Hybrid Swing Motor Short Circuit

Failure
L03 GA70KB (Hybrid controller system)
Detail of • Short circuit in swing motor.
failure
information
Defective power cable Perform check 6. in common troubleshooting of high-voltage parts for
2 between swing motor and failure code [GA****].
inverter
controller)
40-574 HB215LC-2
40 Troubleshooting
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion (HB205-
GA70MD-400-A-Z0-A)
Action level Failure code Hybrid Swing Motor Defective Stirring Motion
Failure
L03 GA70MD (Hybrid controller systems)
Detail of • Error of swing motor speed measured with inverter is detected.
failure
information
Hybrid swing motor resolver If failure code [GA72MA] is also displayed, perform troubleshooting for
1
malfunction it first.
controller)
HB215LC-2 40-575
40 Troubleshooting
Failure code [GA70NS] HYB Swing Motor Overheat (HB205-GA70NS-400-A-Z0-A)
Action level Failure code Hybrid Swing Motor Overheat

Failure
- GA70NS (Hybrid controller systems)
Detail of • Swing motor temperature exceeds 140°C.
failure
machine
• See "Y-8" in troubleshooting for hybrid systems (Y mode).
Ground fault in wiring harness 2. Disconnect connectors HC02 and PM01, and connect T-adapter to
PM01 (female) (7) Min. 1 Mz
tance
Malfunction of hybrid system Check hybrid system radiator coolant level, clogging of radiator fins,
3 cooling circuit and operation of water pump.
5 controller)
Circuit diagram related to hybrid swing motor temperature sensor
40-576 HB215LC-2
40 Troubleshooting
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. (HB205-
GA71KZ-400-A-Z0-A)
Action level Failure code Hybrid Swing Motor Temperature Sensor Open/Short
Failure Circuit
L01 GA71KZ
Detail of • Abnormality of swing motor temperature sensor is detected.
failure
controller
Problem on
machine
2. Disconnect connector PM01, and connect T-adapter to male side.
Approx.
-40°C
4200 kz
Approx.
10°C
210 kz
Defective swing motor Approx.
1 25°C
temperature sensor 100 kz
Resis- Between PM01 (male) (7) and (8) Approx. 50
tance 40°C
kz
Approx.
90°C
7.7 kz
Approx.
200°C
440 z
Between PM01 (male) (7) and ground Min. 1 Mz
2. Disconnect connector HC02 and connect T-adapter to female side.
Open or short circuit in wiring Between HC02 (female) (18) and (17)
2
harness Resis- a Use temperature sensor resistance 500 z to
tance characteristics table for check on cause 1 5000 kz
as resistance criteria.
Open circuit in wiring harness 2. Disconnect connectors HC02 and PM01, and connect T-adapters to
contact of connector) Between HC02 (female) (18) and PM01
Max. 1 z
Resis- (female) (7)
tance Between HC02 (female) (17) and PM01

Ground fault in wiring harness 2. Disconnect connectors HC02 and PM01, and connect T-adapter to
tance
Hot short circuit in wiring 2. Disconnect connector PM01, and connect T-adapter to female side.
harness
Voltage Between PM01 (female) (7) and ground Max. 5.5 V
6 Defective swing motor Since this is an internal defect, troubleshooting cannot be performed.
HB215LC-2 40-577
40 Troubleshooting

7 controller)
Circuit diagram related to hybrid swing motor temperature sensor
40-578 HB215LC-2
40 Troubleshooting
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction
Action level Failure code Hybrid Swing Motor Resolver Malfunction

Failure
Detail of • Malfunction of swing motor resolver is detected.
failure
information
2. Disconnect connectors HC02 and PM01, and connect T-adapters to
each female side.
Between HC02 (female) (5) and PM01 (female)
(1) Max. 1 z
Between HC02 (female) (6) and PM01 (female)
Open circuit in wiring harness (3) Max. 1 z
1 (Wire breakage or defective Between HC02 (female) (15) and PM01
Max. 1 z
contact of connector) Resis- (female) (2)
tance Between HC02 (female) (16) and PM01
Between HC02 (female) (26) and PM01
Between HC02 (female) (36) and PM01

2. Disconnect connectors HC02 and PM01, and connect T-adapter to
either female side.
Between ground and HC02 (female) (5) or
2 Between ground and HC02 (female) (15) or
(Contact with ground circuit) Min. 1 Mz
Resis- PM01 (female) (2)
tance Between ground and HC02 (female) (16) or
4 controller)
HB215LC-2 40-579
40 Troubleshooting
Circuit diagram related to swing motor resolver for hybrid controller
40-580 HB215LC-2
40 Troubleshooting
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op. (HB380-GA72MC-
400-A-Z0-A)
Action level Failure code Hybrid Swing Motor Resolver Defective Operation
Failure
L03 GA72MC (Hybrid controller system)
Detail of • Malfunction of swing motor resolver is detected.
failure
information
Perform troubleshooting for failure code [GA72MA].
HB215LC-2 40-581
40 Troubleshooting
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. (HB380-
GA81KZ-400-A-Z0-A)
Action level Failure code Swing Motor Power Cable Open/Short Circuit
Failure
Detail of • Open or short circuit in power cable for swing motor.
failure
information
Defective power cable Perform check 6. in common troubleshooting of high-voltage parts for
2 between swing motor and failure code [GA****].
inverter
controller)
40-582 HB215LC-2
40 Troubleshooting
Failure code [GAA0KB] HYB Con. Battery Relay Drive Short Cir. (HB205-GAA0KB-
400-A-Z0-A)
Action level Failure code Hybrid Controller Battery Relay Drive Short Circuit
Failure
L01 GAA0KB (Hybrid controller systems)
Detail of • Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
failure
• Stops 24 V output to battery relay primary circuit (coil side).
Problem on • Each controller may fail in writing of data into its ROM (non-volatile memory).
machine
• Output state (ON/OFF) to battery relay can be checked with monitoring function.
information • Method of reproducing failure code: Turn starting switch to ONoOFF position. Wait for
0.5 seconds.
Battery relay drive short circuit If failure code [D110KB] is also displayed, perform troubleshooting for it
1
(Internal short circuit) first.
defective.
• Reference
2 2. Insert T-adapter into connector HC01.
controller)
4. Measure voltage within 0.5 second after turning staring switch to
OFF position from ON position.
Voltage Between HC01 (14) and ground 20 to 30 V
HB215LC-2 40-583
40 Troubleshooting
Circuit diagram related to battery relay
40-584 HB215LC-2
40 Troubleshooting
Failure code [GAA2KB] Swing Brake Sol. Supply Line Short Cir. (HB205-GAA2KB-
400-A-Z0-A)
Action level Failure code Swing Brake Solenoid Supply Line Short Circuit
Failure
L03 GAA2KB (Pump controller system)
Detail of • Pump controller determines that short circuit exists in swing parking brake solenoid circuit
failure when pump controller drives swing parking brake solenoid.
machine
cancel does not operate when engine is not running.)
• Keep the swing lock switch in OFF position and the emergency stop switch in OFF
position during troubleshooting.
Related • The brake is disengaged when current flows through swing parking brake solenoid.
information • Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
circuit.)
(Code: 02300)
2. Disconnect connectors CP02 and HC01, and connect T-adapters
Ground fault in wiring harness female side of HC01.
1
(Contact with ground circuit) 3. Turn starting switch to ON position.
Between HC01 (female) (21) and ground Resis-
Min. 1 Mz
tance
Defective inverter (hybrid 2. Disconnect connector HC01, and connect T-adapter to male side.
2 controller) Between HC01 (male) (21) and HC01 (male) Resis-
(13) Min. 1 kz
tance
If no failure is found by above checks, pump controller may be
3 Defective pump controller defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
HB215LC-2 40-585
40 Troubleshooting
40-586 HB215LC-2
40 Troubleshooting
Failurecode[GAA6KP]LowHYBControl.Sen.Power2Sup.
k Dischargethecapacitorbyusingadischargingtool(generator):796-426-1800inadvance.
Action level Failure code Low Hybrid Control Sensor Power 2 Supply
Failure
L03 GAA6KP (Hybrid controller systems)
Detail of • Voltage of 5 V sensor power supply output 2 circuit is 2.5 V or below.
failure
• Hoist matching function does not work normally.
Action of • Stops swing motor control.
controller • Turns ON swing parking brake.
information
2. Disconnect connectors of the following sensors one by one and turn starting
switch ON each time.
Defective hybrid a If this failure code goes out, disconnected sensor is defective.
1 pressure sensor 3. Each time troubleshooting is finished, return to step 1.
(internal defect) Sensor Connector
Swing RIGHT PPC pressure sensor HP06
Swing LEFT PPC pressure sensor HP04
2. Disconnect connectors HC02, HP04, and HP06.
Ground fault in 3. Connect T-adapter to female side of connector HC02.
wiring harness
2
(contact with ground Between HC02 (female) (25) and ground Resistance Min. 1 Mz
circuit) Between HC02 (female) (25) and HC02 (female) (38) Resistance Min. 1 Mz
Between HC02 (female) (25) and HC02 (female) (39) Resistance Min. 1 Mz
Loose mounting bolt Power cable connector HC05 mounting bolts (2 pcs.) Tightening 8.8 to 10.8Nm
3 of electric swing on inverter side torque {0.9 to 1.1kgm}
motor power cable Power cable connector PM02 mounting bolts (2 pcs.) Tightening 8.8 to 10.8Nm
on swing motor side torque {0.9 to 1.1kgm}
2. Disconnect connectors HC05 and PM02.
Defective shielded a Wipe off dirt from metallic portions of cable housing.
cable of electric a There are 3 shielded cables in power cable between HC05 and PM02. If any
4
swing motor power of them is normal, troubleshooting cannot be performed since this is internal
cable effect.
Between HC05 (male) cable housing metal (Portion P)
Resistance Max. 1 Ω
and PM02 (male) cable housing metal (Portion P)
If no failure is found by above checks, inverter (hybrid controller) may be
Defective inverter
5 defective.
(hybrid controller)
HB215LC-2 40-587
40 Troubleshooting
Circuit diagram related to hybrid controller sensor power supply
HB215LC-2
40 Troubleshooting
HB215LC-2
40 Troubleshooting
Failure code [GAA6KY] HYB Control. Sen. Power 2 Short Cir (HB205-GAA6KY-400-A-
Z0-A)
Action level Failure code Hybrid Controller Sensor Power 2 Short Circuit
Failure
L03 GAA6KY (Hybrid controller systems)
Detail of • Voltage of 5 V sensor power supply output 2 circuit is 6.0 V or above.
failure
• Limits the swing motor speed.
machine
information
a To measure voltage before controller stops output of power.
Hot short circuit in 2. Disconnect connectors HP04 and HP06.
2 wiring harness 3. Connect T-adapter to female side of either of disconnected connectors (e.g.
HP04).
4. Turn starting switch ON (with connectors HP04 and HP06 disconnected).
Between HP04 (female) (3) and ground Voltage 4.5 to 5.5 V
Circuit diagram related to hybrid controller sensor power supply
40-588 HB215LC-2
40 Troubleshooting
Failure code [GACLKA] Operating Lamp Open Circuit (HYB Con) (HB205-
GACLKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Hybrid Controller)
Failure
- GACLKA (Hybrid controller systems)
• Inverter (hybrid controller) determines that system operating lamp circuit is open because
Detail of voltage of output circuit remains at approximately 5 V or below for approximately 3
failure seconds after starting switch is turned to ON position, during which inverter (hybrid
controller) outputs no current to system operating lamp.
controller
• While system operating lamp lights up, battery disconnect switch must not be turned OFF.
Problem on Turning battery disconnect switch OFF may destroy data stored in inverter (hybrid
machine controller) memory.
• Although inverter (hybrid controller) is not able to light system operating lamp, no trouble
Related will result unless battery disconnect switch is turned to OFF position.
1

3. Disconnect connectors HC01 and L19, and connect T-adapters to each
defective contact of Between HC01 (female) (100) and L19 (female) (2) Max. 1 z
Defective inverter If no failure is found by above checks, inverter (hybrid controller) is defective.
3 (hybrid controller) (Since this is an internal defect, troubleshooting cannot be performed).
HB215LC-2 40-589
40 Troubleshooting
40-590 HB215LC-2
40 Troubleshooting
Failure code [GACLKB] Operating Lamp Short Circuit (HYB Con) (HB205-
GACLKB-400-A-Z0-A)
Action level Failure code Operating lamp short circuit (hybrid controller)
Failure
- GACLKB (Hybrid controller systems)
Detail of • Inverter (hybrid controller) detects short circuit because output from inverter (hybrid
failure controller) to system operating lamp does not make output voltage low.
controller
• While system operating lamp lights up, battery disconnect switch must not be turned OFF.
Problem on Turning battery disconnect switch OFF may destroy data stored in inverter (hybrid
machine controller) memory.
Related • Although inverter (hybrid controller) is not able to light system operating lamp, no trouble
information will result unless battery disconnect switch is turned to OFF position.
1
Defective inverter If cause is not found by above checks, inverter (hybrid controller) is defective.
HB215LC-2 40-591
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Troubleshooting of electrical system (E-mode) (ALL-3840-001-A-01-A)
E-1 Engine does not start (Engine does not crank) (HB205-A21-400-A-Z0-A)
Failure • Engine does not start (engine does not crank).

• Engine starting circuit has following 2 start lock mechanisms.
1. Start lock by password protection of machine monitor
2. Start lock by lock lever position
Related information • If failure symptom "Battery relay operation sound is not heard" appears when
starting switch is turned to ON position, perform troubleshooting for E-1 as well.
• If failure symptom "Machine monitor does not light up" appears while starting switch
is turned to ON position, main power supply system may be defective. Perform
troubleshooting for E-5 (lines connecting to fusible link F05 and fuse No. 17).
Loose terminal or open circuit
1 Check terminals of starting motor, alternator, battery relay, and ground
at terminal
terminals T04, T08, etc.
Between battery relay terminal R01 and
Poor contact (grounding) ground
2 between battery relay and Resis-
frame a Use machine frame as grounding point for Max. 1 z
tance
measurement.
a Loosened or rusted terminal T08
a Be ready with starting switch at OFF, then perform troubleshooting
without turning starting switch to ON position.
3 Insufficient battery capacity Battery voltage (2 batteries) Min. 24 V
Specific gravity of electrolyte
(each battery) Min. 1.26
Defects of engine controller power supply and ACC signal are
Defective engine controller
4 indicated with failure codes [DB2QKR] and [DB2RKR]. If these codes
system
appear, perform troubleshooting for causes 1 to 3 of [DB2QKR] first.
Defective fuse No. 3 in fuse If fuse is blown out, circuit may have ground fault. (See cause 22.)
5
box F01
1. Turn starting switch to ON position (to connect ACC).
6 Defective battery relay system
a If the battery relay operation sound is not heard, go to checks on
cause 19 and after.
1. Turn starting switch to OFF position, and remove fuse No. 3 in fuse
box F01.
Defective fusible link F04, 2. Turn starting switch to ON position (to connect ACC).
7 defective wiring harness Between input terminal (1A) of fuse box F01-3
Voltage 20 to 30 V
and ground
a If voltage is abnormal, go to check on cause 10.
2. Remove fuse No. 18 (30 A) in fuse box F01. (to prevent engine
Defective starting switch, lock from starting during check)
lever switch, starting motor 3. Insert T-adapter into connector E10.
8 cut-off relay R06, personal 4. Turn starting switch to START position and hold it (two persons
code relay R07, battery relay, required for this check).
or wiring harness Voltage Between E10 (1) and ground 20 to 30 V
a If voltage is abnormal, go to check on cause 13 and after.
40-592 HB215LC-2
40 Troubleshooting

If fusible link is broken, circuit may have ground fault. In this case,
perform troubleshooting for cause 6 first.
9 Defective fusible link F04 • Fuses No. 1 to 12 are connected to fusible link F04.
a Connected circuit is large in scale. Accordingly, if no failure is found
by check on cause 6, reproduce trouble and find out ground fault
position by sound and burning smell.
Open circuit in wiring harness switch to OFF position.
1 (To prevent short circuit during troubleshooting)
10 2. Disconnect fusible link F04 and fuse No. 3 of fuse box F01.
(Wire breakage or defective
contact of connector) 3. Connect T-adapter to male side of fusible link F04.
Between battery relay (R03) and F04 (male)
Resis- (1) Max. 1 z
tance
Between F04 (male) (2) and F01-1A Max. 1 z
Ground fault 1 in wiring 2. Disconnect fusible link F04, fuse No. 3 of fuse box F01, and battery
11 harness relay R03 (M terminal).
(Contact with ground circuit) 3. Connect T-adapter to male side of fusible link F04.
Between ground and battery relay R03
Min. 1 Mz
Resis- (harness side) or F04 (male) (1)
tance Between ground and F04 (male) (2) or F01-
Min. 1 Mz
1A
2. Disconnect connector H15A and connect T-adapter to male side.
3. After troubleshooting, turn starting switch to ON and START
positions to perform troubleshooting again.
Turn starting switch to
OFF position. Min. 1 Mz
Between H15A (male)
Defective starting switch (1) and (2) Turn starting switch to
12 ON position. Max. 1 z
Resis- Between H15A (male)
tance (1) and (5) Turn starting switch to
ON position. Max. 1 z
Between H15A (male)
(1) and (4) Turn starting switch to
START position. Max. 1 z

Defective lock lever switch 1. Turn starting switch to OFF position.
13 2. Disconnect connector S14 and connect T-adapter to female side.
Resis- Between S14 (female) Lock lever: FREE Min. 1 Mz
tance (1) and (3) Lock lever: LOCK Max. 1 z
HB215LC-2 40-593
40 Troubleshooting

2. Remove starting motor cut-off relay R06 and personal code relay
Defective starting motor cut-off R07.
relay R06, personal code relay Between R06 (male) (1) and (2) 200 to 600 z
14 R07
Between R06 (male) (3) and (4) Max. 1 z
(Internal open or short circuit) Resis- Between R06 (male) (3) and (5) Min. 1 Mz
tance Between R07 (male) (1) and (2) 200 to 600 z
Between R07 (male) (3) and (4) Max. 1 z
Between R07 (male) (3) and (5) Min. 1 Mz
Defective alternator Input
15 from
(Internal short circuit) Between alternator terminal IG and
Voltage alternator Max. 1 V
ground
genera-
tion
2. Turn starting switch to START position and perform
troubleshooting.
Between starting motor terminal B Power
(SB) and ground supply 20 to 30 V
Defective starting motor
16 Starting
(Internal defect) Voltage
Between starting motor terminal C input to
(SC) and ground 20 to 30 V
starting
motor
If power supply and starting input to starting motor are normal but
starting motor does not rotate, starting motor is defective.
2. Disconnect connector D01 and connect T-adapter to diode.
Defective diode D01 a Measure it with diode range of multimeter.

17 Between D01 (male) (1) (+) and (5) (-) No continuity
(Internal open or short circuit)
Between D01 (male) (2) (+) and (6) (-) No continuity
• Battery relay
Resis- Between terminal R02 and H15A (female) (2)
Max. 1 z
tance
• Battery relay
Open circuit in wiring harness 1. Turn starting switch to OFF position.
18 (Wire breakage or defective 2. Turn starting switch to ON position.
contact of connector) a Check where 24 V power is reached to, and locate open section.
Between terminals R04 and R01 20 to 30 V
Voltage
Between terminal R01 and ground Max. 1 V
40-594 HB215LC-2
40 Troubleshooting

• Alternator and starting motor
3. Insert T-adapters into connectors H15A, S14, R07, and E10.
5. Turn starting switch to START position to perform troubleshooting.
a Check where 24 V power is reached to, and locate open section.
Between H15A (4) and ground 20 to 30 V
Between S14 (1) and ground 20 to 30 V
Between S14 (3) and ground 20 to 30 V
Voltage Between R07 (4) and ground 20 to 30 V
Between E10 (1) and ground 20 to 30 V
Between alternator terminal B and ground 20 to 30 V
Between starting motor terminal B and ground 20 to 30 V
• If fuse or fusible link is blown out, replace it with new one.
2. Disconnect connectors H15A, S14, R06, R07, CM01, and E12.
3. Connect T-adapters to female sides of H15A, R06, R07, CM01, E12
and to male side of S14.
Open circuit in wiring harness 4. Remove fuse F01-3.
18 (Wire breakage or defective Between H15A (female) (4) and R06 (female)
contact of connector) (3) Max. 1 z
Between R06 (female) (5) and R07 (female)
(3) Max. 1 z
Between R07 (female) (1) and S14 (male) (1) Max. 1 z
Between R07 (female) (2) and CM01 (female)
(6) Max. 1 z
Between R07 (female) (4) and starting motor
safety relay terminal S Max. 1 z
Between starting motor safety relay terminal C
Resis-
and starting motor terminal C Max. 1 z
tance
Between starting motor B and battery relay
Max. 1 z
R03
Between E12 (female) (1) and starting motor
safety relay terminal R Max. 1 z
Between E12 (female) (1) and D01 (female)
(6) Max. 1 z
Between F01-3 and S14 (male) (1) Max. 1 z
Between S14 (male) (3) and R06 (female) (1) Max. 1 z
Between R06 (female) (2) and ground (T05) Max. 1 z
HB215LC-2 40-595
40 Troubleshooting

Defective battery relay If voltage of terminal R03 only is unusual in battery relay checks on
19 cause 18, battery relay is defective.
(Does not turn ON.)
2. Disconnect connectors H15A, S14, R06, R07, and E10.
3. Connect T-adapters to each female sides of H15A, R06 and R07,
and also to the male side of S14.
4. Remove fuse No. 3 of fuse box F01.
Between ground and H15A (female) (4) or
R06 (female) (3) Min. 1 Mz
20 Between ground and R06 (female) (5) or R07
(female) (3)
Resis- Between ground and R07 (female) (4) or E10
tance (female) (1) Min. 1 Mz
Between ground and F01-3 or S14 (male) (1) Min. 1 Mz
Between ground and S14 (male) (3) or R06

Hot short circuit in wiring 2. Insert T-adapter into connector E10.
harness
Voltage Between ground and E10 (1) or CM01 (16) Max. 1 V
40-596 HB215LC-2
40 Troubleshooting
Circuit diagram related to engine starting circuit
HB215LC-2 40-597
40 Troubleshooting
E-2 Manual preheating system does not work (HB205-FEM-400-A-Z0-A)
Failure • Manual preheating system does not work.

a This troubleshooting describes procedures to be followed when manual preheating
does not function to heat electric intake air heater mounting section.
• This machine has "Automatic preheating" and "Manual preheating" functions. When
either preheating works, preheating monitor lights up. (When only preheating
monitor does not light up, perform troubleshooting for "E-4 While preheating is
Related information working, preheating monitor does not light up").
• If failure symptom "Machine monitor displays nothing" or "Battery relay does not
make operating sound" appears when starting switch is turned to ON position, main
electric power supply system may be defective. In these cases, perform
troubleshooting for E-5 and E-1 respectively.
• Before performing troubleshooting, check that no related failure code is displayed.
(If failure codes [D110KB] is displayed, perform troubleshooting for that code first.)
Defective fuse No.17 in If fuse No. 17 in fuse box F01 is operating, the circuit probably has ground
1 fault. In this case, perform check on cause 8 first.
fuse box F01
Loose terminal or open 1. Turn starting switch to OFF position.
2
circuit at terminal Check terminals of heater relay, battery relay, electric intake air heater, etc.
2. Disconnect connector D02 and connect T-adapter to diode.
Defective diode D02
3 (Internal open or short a Measure it with diode range of multimeter.
circuit) No
Continuity continuity
Defective electric intake 1. Turn starting switch to OFF position.
4 air heater 2. Disconnect terminal E01.
(Internal open circuit) Continuity Between E01 terminal and ground Continuity
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connector H15A and connect T-adapter to male side.
Defective starting 4.Turn starting switch to OFF and HEAT positions to perform
5
switch troubleshooting.
Between H15A (male) OFF Min. 1 Mz
Resistance (1) and (3)
HEAT Max. 1 z
Open or short circuit in 2. Disconnect connectors CM01 and H15A, and connect T-adapter to female
6 wiring harness side of H15A.
Continuity Between H15A (female) (3) and ground Continuity
Open or short circuit in 2. Turn starting switch to ON position.
7 wiring harness Between input terminal on contact side of heater
Voltage 20 to 30 V
relay and ground
2. Disconnect heater relay terminal R16.
Open or short circuit in a To prevent current from flowing through heater when starting switch is
8 wiring harness turned to HEAT position
3. Turn starting switch to the HEAT position (connect R1).
Voltage Between heater relay terminal R15 and ground 20 to 30 V
40-598 HB215LC-2
40 Troubleshooting

If no failure is found by check on cause 6 and 7 and heater relay operation
9 Defective heater relay
sound is not heard, heater relay is defective.
a If no failure is found by check on cause 6 and 7, this check is not required.
2. Disconnect connectors H15A, CM01, terminal R15, E01 and starting
Ground fault in wiring motor terminal B.
harness Between heater relay terminal R15 (wiring harness
10 Min. 1 Mz
(Contact with ground side) and ground
circuit) Between input terminal on contact side of heater
Resistance relay and ground Min. 1 Mz
Between heater terminal E01 (wiring harness side)
and ground Min. 1 Mz
HB215LC-2 40-599
40 Troubleshooting
Circuit diagram related to engine preheating system
40-600 HB215LC-2
40 Troubleshooting
E-3 Automatic preheating system does not work (HB205-FE1-400-A-Z0-A)
Failure Automatic preheating system does not work.

• Automatic preheating starts when boost temperature is below -4°C.
(Monitoring code: 18500 Boost temperature)
• If automatic preheating function does not work, check whether manual preheating
Related function works first.
information • Engine controller checks primary (coil) side of preheat relay (connector R18) and
generates failure code [CA2555] or [CA2556] if it is defective.
• Engine controller generates failure code [CA153] or [CA154] if charge (boost) temperature
Defective fuse No. 6 in If fuse No. 6 in fuse box F01 is blown, circuit probably has ground fault. In this
1 case, perform check on cause 5 first.
fuse box F01
Defective preheating 2. Replace preheating relay (connector R18) with, for instance, horn relay
relay R18 (connector R08).
2
(Internal open or short 3. Turn starting switch to ON position.
circuit) If automatic preheating functions when charge (boost) temperature is -4°C
and below, original preheater relay is defective.
2. Disconnect connectors R18 and CM01, and connect T-adapter to female
side of R18.
Open circuit or ground a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z or
3 fault in wiring harness below, harness has short circuit.
a Heater relay coil resistance
Approx. 20
Resistance Between R18 (female) (5) and ground
z
Open circuit in wiring 2. Disconnect connectors R18 and CM01, and connect T-adapter to female
harness side of R18.
4 (Wire breakage or 3. Remove fuse No. 6 in fuse box F01.
defective contact of Between R18 (female) (3) and F01-6 Max. 1 z
connector) Resistance Between R18 (female) (5) and heater relay terminal
Max. 1 z
R15
If fuse is not burnt out, this check is not required.
5 2. Disconnect connectors CM01 and R18, disconnect cable from starting
(Contact with ground motor terminal B, and connect T-adapter to female side of R18.
circuit)
Resistance Between R18 (female) (3) and ground Min. 1 Mz
HB215LC-2 40-601
40 Troubleshooting
40-602 HB215LC-2
40 Troubleshooting
E-4 While preheating is working, preheating monitor does not light

up (HB205-FE2-400-A-Z0-A)
Failure While preheating is working, preheating monitor does not light up.
• This machine has "Automatic preheating" and "Manual preheating" functions. When either
Related preheating works, preheating monitor lights up.
information • Check whether manual preheating function works first.

harness 2. Disconnect connectors H15A, CM01 and R18, and connect T-adapters to
each female side.
1 (Wire breakage or Between H15A (female) (3) and CM01 (female)
defective contact of Max. 1 z
connector) Resistance (12)
Between R18 (female) (5) and CM01 (female) (12) Max. 1 z
• Reference
Defective machine 3. Disconnect heater relay terminal R16.
2
monitor
a To prevent current from flowing through heater when starting switch is
turned to HEAT position
4. Turn starting switch to HEAT position.
Resistance Between CM01 (12) and (3) 20 to 30 V
HB215LC-2 40-603
40 Troubleshooting
40-604 HB215LC-2
40 Troubleshooting
E-5 When starting switch is turned to ON position, machine monitor

displays nothing (HB205-FEG-400-A-Z0-A)
Failure When starting switch is turned to ON position, machine monitor displays nothing.
• When starting switch is turned to ON position, machine monitor displays KOMATSU
logo, screen to input password (if set), screen to check breaker mode (if set), screen
of check before starting, screen to check working mode, screen to check travel
Related information speed, and standard screen in order.
• Depending on ambient temperature and condition of battery, battery voltage may
lower suddenly and machine monitor displays nothing temporarily when engine is
started. But this phenomenon does not mean that machine monitor is defective.
Battery disconnect switch left in Turn starting switch to OFF position and check that battery disconnect
1 OFF position switch is in ON position.
a Be ready with starting switch at OFF, then perform troubleshooting
without turning starting switch to ON position.
2 Insufficient battery capacity Battery voltage (2 batteries) Min. 24 V
Specific gravity of electrolyte
(each battery) Min. 1.26
If fusible link is burnt out, circuit probably has ground fault. (See cause
3 Defective fusible link F05 9.)
4 Defective fuse F01-14 If fuse is blown, circuit may have ground fault. (See check on cause 9.)
5 Defective fuse F01-17 If fuse is blown, circuit may have ground fault. (See check on cause 9.)
Loose terminal or open circuit 1. Turn starting switch to OFF position.
6
at terminal Check terminals of battery relay, etc.
Defective wiring harness, 3. Turn battery disconnect switch to ON position, and turn starting
7 starting switch, or machine switch to ON position (connect ACC).
monitor Between CM01 (1) and (3) 20 to 30 V
2. Disconnect connector H15A and connect T-adapter to male side.
3. Turn starting switch to ON position and perform troubleshooting
Defective starting switch again.
8
(Internal open circuit) Between H15A (male) Turn starting switch to
Min. 1 Mz
Resis- (1) and (5) OFF position.
tance Between H15A (male) Turn starting switch to
(1) and (5) ON position. Max. 1 z
If no failure is found by check on cause 7, this check is not required.
2. Disconnect fusible link F05, No. 14 and 17 fuses of fuse box F01,
and connectors H15A and CM01.
3. Connect T-adapters to male side of connector F05 and female side
of H15 and CM01.
Open circuit in wiring harness Between battery (-) terminal and ground Max. 1 z
9
(Internal open circuit) Between battery (+) and F05 (male) (1) Max. 1 z
Between F05 (male) (2) and F01-16G Max. 1 z
Resis- Between F01-17 and CM01 (female) (1), (2) Max. 1 z
tance Between ground (T04) and each of CM01
(female) (3) and (4) Max. 1 z
Between F01-17 and H15A (female) (1) Max. 1 z
Between H15A (female) (5) and F01-14E Max. 1 z
HB215LC-2 40-605
40 Troubleshooting

Between F01-14 and CM01 (female) (10) Max. 1 z
40-606 HB215LC-2
40 Troubleshooting

If no failure is found by checks on causes 3 to 5 and 7, this check is
not required.
2. Disconnect fusible link F05, No. 17 and 13D terminals of fuse box
F01, and connectors H15A, CM01, and CP01.
3. Connect T-adapters to male side of connector F05 and female side
Ground fault in wiring harness of H15 and CM01.
10 Between ground and battery (+) or F05 (male)
(1)
Between ground and F05 (male) (2) or F01-
Min. 1 Mz
Resis- 16G
tance Between ground and F01-17, CM01 (female)
(1), (2), or H15A (female) (1) Min. 1 Mz
Between ground and H15A (female) (5) or
CM01 (female) (10) Min. 1 Mz
HB215LC-2 40-607
40 Troubleshooting
Circuit diagram related to machine monitor power supply
40-608 HB215LC-2
40 Troubleshooting
E-6 When starting switch is turned to ON position (before starting

engine), engine oil level monitor lights up in yellow (PC220_10-FEJ-400-A-00-A)
• When starting switch is turned to ON position (with engine stopped), engine oil level
Failure monitor lights up in yellow.
Related
information
Defective engine oil Carry out troubleshooting for failure code [B@BAZK].
level switch system
1
(Machine monitor
system)
monitor
HB215LC-2 40-609
40 Troubleshooting
E-7 When starting switch is turned to ON position (before starting

engine), radiator coolant level monitor lights up in yellow (PC220_10-FEH-400-A-00-A)
• When starting switch is turned to ON position (with engine stopped), radiator coolant level
Failure monitor lights up in yellow.
Related
information
Low radiator Coolant level may be low. Check coolant level and add coolant if necessary.
coolant level
1
(When system
works properly)
Defective radiator Carry out troubleshooting for failure code [B@BCZK].
2 sub tank coolant
level switch system
40-610 HB215LC-2
40 Troubleshooting
E-8 Engine coolant temperature monitor lights up in white while engine

is running (HB205-FES-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in white while engine is running.
• Signal voltage of coolant temperature sensor is input to engine controller and then the
Related data is transmitted to machine monitor through CAN communication system.
information • Coolant temperature can be checked with monitoring function.
(Code: 04107)
Insufficient warm-up of If monitor is lit in white, coolant temperature may be low (below approximately
machine 30°C). Warm up engine.
1
(When system works • Being lit in white: Coolant temperature is low.
properly) • Being lit in blue: Coolant temperature is proper.
If no failure is found by preceding checks, engine coolant temperature gauge
system may be defective. Perform following troubleshooting.
Defective engine
coolant temperature • E-20 Engine coolant temperature gauge display does not move from
2
gauge system minimum or maximum
• E-21 Engine coolant temperature gauge indicates incorrect temperature
(indicates neither minimum nor maximum)
HB215LC-2 40-611
40 Troubleshooting
E-9 Hydraulic oil temperature monitor lights up in white while engine is

running (HB205-FEU-400-A-Z0-A)
Failure Hydraulic oil temperature monitor lights up in white while engine is running.
• Signal of hydraulic oil temperature sensor is input to pump controller and then data is
Related transmitted to machine monitor through CAN communication system.
information • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401)
Insufficient warm-up of If monitor is lit in white, hydraulic oil temperature may be low (approximately
machine 20°C and below). Warm up engine.
1
(When system works • Be lit in white: Hydraulic oil temperature is low.
properly) • Be lit in blue: Hydraulic oil temperature is proper.
If no failure is found by preceding checks, hydraulic oil temperature gauge
Defective hydraulic oil system may be defective. Perform following troubleshooting.
2 temperature gauge
system • E-23 Hydraulic oil temperature gauge indicates incorrect temperature
40-612 HB215LC-2
40 Troubleshooting
E-10 Charge level monitor lights up in red while engine is running (PC400-FEP-
400-A-Z0-A)
Failure Charge level monitor lights up in red while engine is running

• Power generation voltage of alternator can be checked with monitoring function.
Related information (Code: 04300)
Cause Procedure, measuring location, criteria and remarks

1 Defective alternator system Perform troubleshooting for failure code [AB00KE].
HB215LC-2 40-613
40 Troubleshooting
E-11 Fuel level monitor lights up in red while engine is running (HB205-FEQ-400-A-
Z0-A)
Failure Fuel level monitor lights up in red while engine is running.

Related • Signal voltage of fuel sensor can be checked with monitoring function.
Low fuel level
1 (When system works Fuel level may be low. Check it and add fuel if necessary.
properly)
If no failure is found by preceding checks, fuel gauge system may be
Defective fuel gauge defective. Perform following troubleshooting.
2 system • E-19 Fuel gauge indicates incorrect amount (indicates neither full nor
empty)
40-614 HB215LC-2
40 Troubleshooting
E-12 Air cleaner clogging monitor lights up in yellow while engine is

running (PC400-FER-400-A-Z0-A)
Failure Air cleaner clogging monitor lights up in yellow while engine is running
• Air cleaner clogging switch signal can be checked with monitoring function.
Related information (Code 04501)
Clogging of air cleaner Air cleaner may be clogged. Check it, then clean or replace if
1
(when system works properly) necessary.
Defective air cleaner clogging
2 Perform troubleshooting for failure code [AA10NX].
switch system
HB215LC-2 40-615
40 Troubleshooting
E-13 Water separator monitor lights up in red while engine is

running (PC160-FET-400-A-Z0-A)
Failure Water separator monitor lights up in red while engine is running
Related • Condition of water detected by fuel filter sensor can be checked with monitoring function.
Increase of water level
in water separator Since water is detected in water separator, check water separator and drain
1 (when system is water in it.
normal)
Defective fuel filter
If no failure is found by above checks, fuel filter sensor system may be
2 sensor system (engine
defective. Perform troubleshooting for failure codes [CA428] and [CA429].
controller system)
monitor
40-616 HB215LC-2
40 Troubleshooting
E-14 Engine coolant temperature monitor lights up in red while engine is

running (HB205-FEV-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in red while engine is running.
• Signal voltage of coolant temperature sensor is input to engine controller, and then it is
(Code: 04107)
If monitor is lit in red, coolant temperature may be high (above approximately
Overheating of engine 102°C). Cool down coolant. (Run engine at low idle.)
coolant • Being lit in red: Coolant temperature is high (overheating).
1 • Being lit in blue: Coolant temperature is proper.
(When system works
properly) Perform troubleshooting for "S-17 Coolant temperature rises too high
(overheating)".
If no failure is found by preceding checks, engine coolant temperature gauge
Defective engine
coolant temperature • E-20 Engine coolant temperature gauge display does not move from
2
gauge system minimum or maximum
HB215LC-2 40-617
40 Troubleshooting
E-15 Hydraulic oil temperature monitor lights up in red while engine is

running (HB205-FEW-400-A-Z0-A)
Failure Hydraulic oil temperature monitor lights up in red while engine is running.
(Code: 04401)
If monitor is lit up in red, hydraulic oil temperature may be high (above
Overheating of
approximately 102°C). Cool down hydraulic oil. (Run engine at low idle or stop
hydraulic oil
1 engine.)
(When system works
• Being lit in red: Hydraulic oil temperature is high (overheating).
properly)
• Being lit in blue: Hydraulic oil temperature is proper.
If no failure is found by preceding checks, hydraulic oil temperature gauge
Defective hydraulic oil
temperature gauge • E-22 Hydraulic oil temperature gauge does not move from minimum or
2
system maximum
• E-23 Hydraulic oil temperature gauge indicates incorrect temperature
40-618 HB215LC-2
40 Troubleshooting
E-16 Hybrid temperature monitor lights up in red while engine is

running (HB205-K1S-400-A-Z0-A)
Failure Hybrid temperature monitor lights up in red while engine is running.
• Signal from hybrid temperature sensor is input to pump controller and then data is
• Hybrid temperature can be checked with monitoring function.
Related (Code: 09306 Capacitor Cell Temperature, 09402 Booster Inductor Temperature, 09403
information Booster IGBT Base Temperature, 09404 Booster IGBT JCT Temperature, 09101 Swing
Motor Coil Temperature, 09507 Swing Driver IGBT Base Temperature, 09600 Generator
Motor Temperature, 09607 Generator Driver IGBT Base Temperature #0, 09608
Generator Driver IGBT Base Temperature #1)
If monitor is lit in red, hybrid temperature may be high (above approximately
102°C). Perform cool down operation. (Run engine at low idle.)
• Being lit in red: Hybrid temperature is high (overheating).
Overheating of hybrid
• Being lit in blue: Hybrid temperature is proper.
component
1 Check the monitoring function or failure code, and perform troubleshooting.
(When system works
properly) • Y-8 Electric swing motor temperature increases abnormally
• Y-9 Motor-generator temperature increases abnormally
• Y-10 Inverter temperature increases abnormally
• Y-11 Capacitor temperature increases abnormally
If no failure is found by preceding checks, hybrid coolant temperature sensor
Defective hybrid • E-24 Hybrid temperature gauge does not move from minimum or
2 temperature system maximum
• E-25 Hybrid temperature gauge does not match hybrid temperature
monitor display
Hybrid device % Capacitor cell Booster IGBT Booster IGBT Booster inductor
temperature temperature base JCT temperature temperature
temperature
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
Motor-generator
Hybrid device Swing motor coil Motor-generator Swing inverter
% driver
temperature temperature temperature JCT temperature
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
HB215LC-2 40-619
40 Troubleshooting
Hybrid temperature gauge and temperature monitor
a If the gauge signal is not available due to an open circuit in the CAN communication line, the gauge
pointer disappears.
40-620 HB215LC-2
40 Troubleshooting
E-17 Engine oil pressure monitor lights up in red while engine is

running (HB205-FEX-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in red while engine is running.
• Signal of engine oil pressure switch is input to engine controller. If engine oil pressure
Related switch turns ON while engine is running, failure code [B@BAZG] is transmitted from
information engine controller to machine monitor through CAN communication.
Lowered engine oil
pressure Engine oil pressure may be lowered. Check it and if it is lowered, and then
1 perform troubleshooting "S-14 Engine oil pressure lowers".
(When system works
properly)
Defective engine oil If no failure is found by above check, engine oil pressure switch system may
2 pressure switch system be defective. Perform troubleshooting for failure code [CA435].
HB215LC-2 40-621
40 Troubleshooting
E-18 Fuel gauge display does not move from minimum or maximum (HB205-
FGE-400-A-Z0-A)
• While fuel is added, fuel gauge indicator does not rise from red range (E).
Failure • While fuel level is low, fuel gauge indicator does not lower from green range top (F)
Related information • Signal voltage of fuel sensor can be checked with monitoring function (Code: 04200)
Defective fuel level 1. Turn starting switch to OFF position.
1 Approx. 12
(Internal open or short Between P21 (male) (1) Fuel level: FULL
circuit) Resistance and ground z
Fuel level: EMPTY 85 to 110 z
2. Disconnect connector CM01, and connect T-adapter to female side.
2 wiring harness Approx. 12
Between CM01 (female) Fuel level: FULL
Resistance (15) and ground z
harness
3 (Wire breakage or 2. Disconnect connectors CM01 and P21 and connect T-adapters to each
connector) Resistance Between CM01 (female) (15) and P21 (female) (1) Max. 1 z
harness 2. Disconnect connectors CM01 and P21, and connect T-adapter to either
4 female side.
Between ground and CM01 (female) (15) or P21
circuit) Resistance (female) (1) Min. 1 Mz

Hot short circuit in 2. Disconnect connector P21.
wiring harness 3. Insert T-adapter into connector CM01 or connect T-adapter to female side
5 of connector P21.
(Contact with 24V
circuit)
Voltage Between ground and CM01 (15) or P21 (female) (1) Approx. 3.3
V
monitor
Circuit diagram related to fuel level sensor
40-622 HB215LC-2
40 Troubleshooting
E-19 Fuel gauge indicates incorrect amount (indicates neither full nor
empty) (HB205-FGF-400-A-Z0-A)
1) Indication of fuel gauge is different from actual fuel level.
Failure
2) Indication of fuel gauge does not accord with indication of fuel level monitor.
Related • Signal voltage of fuel sensor can be checked with monitoring function.
Defective fuel level 1. Turn starting switch to OFF position.
1 Approx. 12
(Internal open or short Between P21 (male) (1) Fuel level: FULL
circuit) Resistance and ground z
a Turn starting switch to ON position or start engine to perform
troubleshooting.
Fuel level: 304 l Fuel gauge level: 6
2
Defective machine Fuel level: 245 l Fuel gauge level: 5
monitor Color of
Fuel level: 200 l Fuel gauge level: 4 Blue
monitor
light (a) Fuel level: 100 l Fuel gauge level: 3
Fuel level: 60 l Fuel gauge level: 2
Fuel level: 41 l Fuel gauge level: 1 Red
Fuel gauge and fuel level monitor
HB215LC-2 40-623
40 Troubleshooting
E-20 Engine coolant temperature gauge display does not move from
minimum or maximum (HB205-FGG-400-A-Z0-A)
1) While coolant temperature is rising normally, it does not rise from white range (C).
Failure
2) While engine coolant temperature is stabilized normally, it rises to red range (H).
• Signal voltage of coolant temperature sensor is input to engine controller and then the
Related data is transmitted to machine monitor through CAN communication system.
(Code: 04107)
Defective engine
Engine coolant temperature sensor system may be defective. Perform
1 coolant temperature
troubleshooting for failure codes [CA144] and [CA145].
sensor system
Defective machine If no failure is found by preceding checks, machine monitor may be defective.
2
Engine coolant temperature gauge and coolant temperature monitor
40-624 HB215LC-2
40 Troubleshooting
E-21 Engine coolant temperature gauge indicates incorrect temperature

(indicates neither full nor empty) (HB205-FGH-400-A-Z0-A)
1) Coolant temperature is different from indication of engine coolant temperature gauge.
Failure 2) Indication of engine coolant temperature gauge is different from indication of coolant
temperature monitor.
• Signal voltage of coolant temperature sensor is input to engine controller, and then it is
(Code: 04107)
Defective engine
Engine coolant temperature sensor system may be defective. Perform
1 coolant temperature
troubleshooting for failure codes [CA144] and [CA145].
sensor system
troubleshooting.
Engine coolant Engine coolant
temperature 105°C temperature gauge level:
6
Red
5
Defective machine temperature gauge level:
2 Color of temperature 100°C
monitor 4
monitor
light (a) Engine coolant Engine coolant
temperature 85°C temperature gauge level: Blue
3
2
temperature 30°C temperature gauge level: White
1
Engine coolant temperature gauge and coolant temperature monitor
HB215LC-2 40-625
40 Troubleshooting
E-22 Hydraulic oil temperature gauge does not move from minimum or
maximum (HB205-FGJ-400-A-Z0-A)
• While hydraulic oil temperature is rising normally, it does not rise from white range
Failure (C).
• While hydraulic oil temperature is stabilized normally, it rises to red range (H).
• Signal from hydraulic oil temperature sensor is input to pump controller and then
Related information data is transmitted to machine monitor through CAN communication system.
• Hydr. Oil Temperature can be checked with monitoring function. (Code: 04401)
Approx. 90
10°C
kz
Defective hydraulic oil Approx. 35
temperature sensor Between P22 (male) (1) 30°C
1 kz
(Internal open or short and (2) Approx. 6.5
circuit) Resistance 80°C
kz
Approx. 3.5
100°C
kz
Between P22 (male) (2)
Whole range Min. 1 Mz
and ground
Open or short circuit in Between CP01 (female) (28) and (46)
2 wiring harness 3.5 to 90 kz
Resistance a Resistance accords with thermal characteristics
table in cause 1.
3 (Wire breakage or 2. Disconnect connectors CP01 and P22, and connect T-adapter to either
connector) Between CP01 (female) (28) and P22 (female) (2) Max. 1 z
Resistance
Between CP01 (female) (46) and P22 (female) (1) Max. 1 z
harness
4 2. Disconnect connectors CP01 and P22, and connect T-adapter to either
circuit) Between ground and CP01 (female) (28) or P22
Resistance (female) (2) Min. 1 Mz

Hot short circuit in 2. Disconnect connector P22.
wiring harness 3. Insert T-adapter into connector CP01 or connect T-adapter to female side
5 of connector P22.
(Contact with 24V
circuit) 4. Turn starting switch to ON position.
Voltage Between ground and CP01 (28) or P22 (female) (2) Approx. 5 V
Defective pump If no failure is found by preceding checks, machine monitor is defective.
controller
40-626 HB215LC-2
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
HB215LC-2 40-627
40 Troubleshooting
E-23 Hydraulic oil temperature gauge indicates incorrect temperature

(indicates neither full nor empty) (HB205-FGK-400-A-Z0-A)
1) Hydraulic oil temperature is different from indication of hydraulic oil temperature gauge.
Failure 2) Indication of hydraulic oil temperature gauge is different from indication of hydraulic oil
temperature monitor.
(Code: 04401)
Defective hydraulic oil
1 See previous page.
temperature sensor
troubleshooting.
Hydraulic oil Hydraulic oil temperature
temperature: 105°C gauge level: 6
Red
Defective machine Hydraulic oil Hydraulic oil temperature
2 Color of
monitor temperature: 100°C gauge level: 4
monitor
light (a) Hydraulic oil Hydraulic oil temperature
temperature: 85°C gauge level: 3 Blue
temperature: 20°C gauge level: 1 White
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
40-628 HB215LC-2
40 Troubleshooting
E-24 Hybrid temperature gauge does not move from minimum or

maximum (HB205-K1T-400-A-Z0-A)
1) While hybrid temperature gauge is rising normally, it does not rise from white range (C).
Failure 2) While hybrid temperature gauge is stabilized normally, temperature gauge rises to red
range (H).
• Signal from hybrid temperature sensor is input to hybrid controller and then data is
transmitted to machine monitor through communication system.
• Each hybrid temperature gauge can be checked with monitoring function.
Defective hybrid
temperature sensor Hybrid temperature sensor system may be defective. Perform troubleshooting
1
system for failure codes that start with "GA".
Defective machine If no failure is found by check on cause 1, machine monitor may be defective.
2
HB215LC-2 40-629
40 Troubleshooting
E-25 Hybrid temperature gauge indicates incorrect temperature

(indicates neither full nor empty) (HB205-K1U-400-A-Z0-A)
1) Hybrid temperature is different from indication of temperature gauge.
Failure
2) Hybrid temperature is different from indication of hybrid temperature monitor.
• Signal from hybrid temperature sensor is input to hybrid controller and then data is
• Each hybrid temperature gauge can be checked with monitoring function.
Defective hybrid Hybrid temperature sensor system may be defective. Perform
1 temperature sensor system troubleshooting for failure codes that start with "GA".
troubleshooting.
Color of
Hybrid device
% indicator Buzzer monitor light
temperature
(a)
2 Defective machine monitor A1 102 Red Q
Red
A2 100 Red
A3 95 Green
A4 50 Green
Blue
A5 20 Green
A6 0 White
a Hybrid temperature gauge indicates the thermal load of the hybrid equipments.
Hybrid device Capacitor cell Booster IGBT Booster IGBT Booster inductor
temperature % temperature base JCT temperature temperature
temperature
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
Motor-generator
Hybrid device Swing motor coil Motor-generator Swing inverter
% driver
temperature temperature temperature JCT temperature
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
40-630 HB215LC-2
40 Troubleshooting
a If the gauge signal is not available due to an open circuit in the CAN communication line, the gauge
pointer disappears.
HB215LC-2 40-631
40 Troubleshooting
E-26 Contents of display on machine monitor is different from actual

machine condition (HB205-FFB-400-A-Z1-A)
Failure • Contents of display on machine monitor is different from actual machine condition.
Related information
a Turn starting switch ON and perform troubleshooting (with
monitoring function).
Model selection 1
= OFF
Model selection 2
= ON
Defective machine model Monitoring Monitoring code HB215LC– Model selection 3
1 code signal display 02201 "Switch input 2" 2 = ON
Model selection 4
= OFF
Model selection 5
= ON
a If display on monitor is incorrect, perform troubleshooting for failure
code [DA29KQ].
If no failure is found in above checks, machine monitor is defective.
2 Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.)
40-632 HB215LC-2
40 Troubleshooting
E-27 Some areas of machine monitor screen are not displayed (HB205-FFC-400-A-
Z0-A)
Failure Some areas of machine monitor screen are not displayed.

• One of the features of liquid crystal display panels is that there may be black spots (spots
Related that do not light up) or white spots (spots that stay lit) on the screen. When there are fewer
information than 10 black or white spots, this is not a failure or a defect.
a Turn starting switch to ON position, and perform troubleshooting.
Defective machine
1 monitor If following switch operation lights up all pixel on liquid crystal panel (entire
(Liquid crystal panel) screen turns to white), liquid crystal panel is normal.
• Operation of switches: [4] and [F2] (Press simultaneously)
Defective machine
If no failure is found by check on cause 1, machine monitor may be defective.
2 monitor
(Monitor itself)
HB215LC-2 40-633
40 Troubleshooting
E-28 Function switch does not work (HB205-HBC-400-A-Z0-A)
Failure Function switch does not work.

Related • Signal of function switch can be checked with monitoring function.
Defective machine Machine monitor may be defective. (Since this is an internal defect,
monitor
40-634 HB215LC-2
40 Troubleshooting
E-29 Automatic warm-up system does not operate (in cold season) (HB205-
FEN-400-A-Z0-A)
Failure Automatic warm-up system does not operate (in cold season).
• Automatic warm-up function increases engine speed to 1,200 rpm when coolant
temperature is below 30°C.
• With starting switch at ON position or after engine is started, if fuel control dial is kept at
70% or more of full open range for 3 seconds, automatic warm-up operation is canceled.
• For the machine equipped with the air conditioner, the warm-up function of heater
Related increases the engine speed to 1,300 rpm under the following conditions; blower is ON,
information ambient temperature is 5°C and below, engine coolant temperature is below 55°C. When
the engine coolant temperature reaches 60°C, the warm-up function of heater is
canceled.
• When engine oil pressure is below 50 kPa {0.51 kg/cm2}, turbocharger protection function
works to keep engine speed 1,050 rpm and below for 20 seconds at the longest after
engine is started.
troubleshooting.
a If level indication of engine coolant temperature gauge differs from actual
coolant temperature, perform following troubleshooting.
• E-20 Engine coolant temperature gauge display does not move from
minimum or maximum
Defective engine Engine coolant
6 (a: Red)
1 coolant temperature temperature 105°C
signal system Engine coolant
5 (a: Red)
temperature 102°C
Engine coolant
Coolant Monitoring code 04107 4 (a: Blue)
temperature 100°C
temperature (Engine coolant Engine coolant
level temperature) 3 (a: Blue)
temperature 85°C
Engine coolant
2 (a: Blue)
temperature 60°C
Engine coolant
1 (a: White)
temperature 30°C
2
Engine coolant temperature gauge and engine coolant temperature monitor
HB215LC-2 40-635
40 Troubleshooting
E-30 Auto-deceleration monitor does not light up, or does not go out,
while auto-deceleration switch is operated (HB205-FFD-400-A-Z0-A)
When auto-deceleration switch is operated, auto-deceleration monitor does not light up or
Failure does not go off.
Related • Condition of signal of auto-decelerator switch can be checked with monitoring function.
monitor
40-636 HB215LC-2
40 Troubleshooting
E-31 Auto-deceleration function does not operate or is not canceled

while lever is operated (HB205-FPM-400-A-Z0-A)
Failure Auto-deceleration function does not operate or is not canceled while lever is operated.
Related • Since set engine speed for auto-deceleration is 1,150 rpm in B/L mode, auto-deceleration
information is not actuated or canceled if engine speed set with fuel control dial is below this speed.
a Start engine and perform troubleshooting (with monitoring function).
a If display of monitor is incorrect, perform troubleshooting for "E-52 to 60
Monitoring function does not display *** properly".
When lever is operated:
ON
Swing
When lever is in
NEUTRAL: OFF
ON
Travel
When lever is in
NEUTRAL: OFF
ON
Boom LOWER
Monitoring When lever is in
code NEUTRAL: OFF
01900 ON
Boom RAISE
When lever is in
NEUTRAL: OFF
ON
Arm IN
When lever is in
Defective PPC oil NEUTRAL: OFF
1 pressure signal Monitoring When lever is operated:
display ON
Arm OUT
(when When lever is in
normal) NEUTRAL: OFF
ON
Bucket CURL
When lever is in
NEUTRAL: OFF
ON
Bucket DUMP
When lever is in
NEUTRAL: OFF
Monitoring
ON
code Service
When lever is in
01901
NEUTRAL: OFF
ON
Blade RAISE
When lever is in
NEUTRAL: OFF
ON
Blade LOWER
When lever is in
NEUTRAL: OFF
Defective machine If no failure is found by preceding checks, machine monitor may be defective.
2
HB215LC-2 40-637
40 Troubleshooting

Pump controller is If no failure is found by above checks, pump controller may be defective.
3
4
40-638 HB215LC-2
40 Troubleshooting
E-32 Working mode selection screen is not displayed while working

mode selector switch is operated (HB205-FFE-400-A-Z0-A)
Failure When working mode switch is operated, working mode selection screen is not displayed.
Related • Signal of working mode switch can be checked with monitoring function.
monitor
HB215LC-2 40-639
40 Troubleshooting
E-33 Setting of engine and hydraulic pump is not changed while working
mode is changed (HB205-FP9-400-A-Z0-A)
Failure Setting of engine and hydraulic pump is not changed while working mode is changed.
Related
information
monitor
Defective pump Pump controller may be defective. (Since this is an internal defect,
controller
40-640 HB215LC-2
40 Troubleshooting
E-34 Travel speed monitor does not change when travel speed switch is
operated (HB205-FFF-400-A-Z0-A)
Failure Travel speed monitor does not change while travel speed switch is operated.
Related • Condition of signal of travel speed switch can be checked with monitoring function.
monitor
HB215LC-2 40-641
40 Troubleshooting
E-35 Travel speed does not change while travel speed selection is
changed (HB205-BQ3-400-A-Z0-A)
Failure Travel speed does not change while travel speed selection is changed.
• If cause 1 occurs, actual travel speed does not lower when travel speed selection is
Related changed to Lo.
Hot short circuit in 2. Disconnect connector V04 and connect T-adapter to female side.
2
If no failure is found by checks on Causes 1 and 2, pump controller may be
Defective pump defective.
3
controller
40-642 HB215LC-2
40 Troubleshooting
E-36 Alarm buzzer does not stop sounding (HB205-KB3-400-A-Z0-A)
Failure Alarm buzzer does not stop sounding.

• Condition of signal of alarm buzzer cancel switch can be checked with monitoring
Related function.
monitor
HB215LC-2 40-643
40 Troubleshooting
E-37 Service meter is not displayed, while starting switch is in OFF

position (HB205-FFL-400-A-Z0-A)
Failure Service meter is not displayed while starting switch is in OFF position.
• When following switches are operated while stating switch is in OFF position, service
Related meter appears at top center of screen.
information Operation of switches: [4] and [1] (press simultaneously)
When starting switch is turned to ON position, if machine monitor displays
nothing, backup power supply system may be defective. In this case, perform
Defective backup power the following troubleshooting.
1 supply system
• E-5 When starting switch is turned to ON position, machine monitor
displays nothing
2
40-644 HB215LC-2
40 Troubleshooting
E-38 Service mode cannot be selected (HB205-HB1-400-A-Z0-A)
Failure Service mode cannot be selected.

• Operate the following switch operations, then service mode is displayed.
Related Operation of switches: [4] + [1]o[2]o[3] (While pressing [4], press [1], [2] and [3] in this
information order.)
monitor
HB215LC-2 40-645
40 Troubleshooting
E-39 None of work equipment, swing or travel works (HB205-FT5-400-A-Z0-A)
Failure None of work equipment, swing or travel works

Related
information
Defective fuse No. 3 of If fuse is burnt out, circuit may have ground fault, etc. (See check on cause 7.)
1
F01
Defective PPC lock 2. Disconnect connector S14 and connect T-adapter to female side.
2 switch 3. Operate lock lever and perform troubleshooting.
(Internal open circuit) FREE Max. 1 z
Resistance Between S14 (female) (1) and (2)
Min. 1 Mz
Defective PPC lock 1. Turn starting switch to OFF position.
3
(Internal open, short Between V01 (male) (1) and (2) 20 to 60 z
circuit, or ground fault) Resistance
2. Disconnect connector D01 and connect T-adapter to male side.
Defective diode array
4 D01 a Measure it with diode range of multimeter.
(Internal ground fault) Continuity Between D01 (male) (8) (+) and (4) (-) Continuity
No
Continuity Between D01 (male) (4) (+) and (8) (-)
continuity
2. Remove fuse No. 3.
Open or short circuit in 3. Set PPC lock switch to FREE position.
5 wiring harness
Between fuse F01-3 outlet and ground
Resistance 20 to 60 z
a Resistance of PPC lock solenoid
2.Remove fuse No. 3.
Open circuit in wiring 3.Disconnect connectors S14 and V01 and connect T-adapters to each
6
harness female side.
Between V01 (female) (2) and ground Max. 1 z
Resistance Between V01 (female) (1) and S14 (male) (2) Max. 1 z
Between fuse F01-3 outlet and S14 (male) (1) Max. 1 z
Ground fault in wiring 2.Remove fuse No. 3.
harness 3.Disconnect connectors S14, D01 and V01, and then connect T-adapter to
7
(Contact with ground male side of S14 or female side of V01.
circuit) Between ground and V01 (female) (1) or S14
Min. 1 Mz
Resistance (male) (2)
Between S14 (male) (1) and ground Min. 1 Mz
40-646 HB215LC-2
40 Troubleshooting
Circuit diagram related to PPC lock solenoid
HB215LC-2 40-647
40 Troubleshooting
E-40 Any of work equipment, swing and travel cannot be locked (HB205-FT7-400-
A-Z0-A)
Failure Any of work equipment, swing, and travel cannot be locked.

Related
information
Defective lock lever 1. Turn starting switch to OFF position.

switch 2. Disconnect connector S14 and connect T-adapter to female side.
1
(Internal short circuit) Between S14 (female) Lock lever: LOCK Min. 1 Mz
Resistance (1) and (2)
Lock lever: FREE Max. 1 z
wiring harness
4. Turn lock lever to LOCK position.
Voltage Between V01 (female) (2) and (1) Max. 4.5 V
40-648 HB215LC-2
40 Troubleshooting
Circuit diagram related to PPC lock solenoid
HB215LC-2 40-649
40 Troubleshooting
E-41 Upper structure does not swing while swing parking brake cancel
switch is set to CANCEL position (HB205-FGM-400-A-Z0-A)
Upper structure does not swing while swing parking brake cancel switch is set to CANCEL
Failure position.
• Condition of swing lock switch signal and swing parking brake cancel switch signal can be
Related checked with monitoring function.
information (Hybrid controller system code: 09702 HYB Controller SW Input)
Defective fuse No. 1 in fuse If fuse is burnt out, circuit probably has ground fault. In this case,
1 perform check on cause 7 first.
box F01
Defective swing parking brake 2. Disconnect connector S25 and connect T-adapter to male side.
2 cancel switch (internal short Swing parking brake
Min. 1 Mz
circuit) Resis- Between S25 (male) cancel switch: Normal
tance (13) and (14) Swing parking brake
Max. 1 z
cancel switch: FREE
2. Remove diode array and connect T-adapter to male side.
Defective diode array D01 a Measure it with diode range of multimeter.
3
(Internal short circuit) Continuity Between D01 (male) (7) (+) and (3) (-) Continuity
No
continuity
2. Remove diode array and connect T-adapter to male side.
Defective diode array D03 a Measure it with diode range of multimeter.
4
(Internal short circuit) Continuity Between D03 (male) (5) (+) and (1) (-) Continuity
No
continuity
5 Defective wiring harness a Turn swing lock switch to OFF position
Swing parking brake
Between V03 (female) cancel switch: FREE 20 to 30 V
Voltage
(1) and (2) Swing parking brake
Max. 1 V
cancel switch: Normal
a If no failure is found by check on cause 5, this check is not
required.
Open circuit in wiring harness 2. Disconnect connectors V03 and S25 and connect T-adapters to
6 (Wire breakage or defective each male side.
contact of connector) a Turn swing lock switch to OFF position
Between V03 (female) (1) and S25 (female)
Resis- (14) Max. 1 z
tance
Between V03 (female) (2) and ground Max. 1 z
a If no failure is found by check on cause 5, this check is not
required.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
7 2. Disconnect connectors S25 and V03 and connect T-adapter to
female side of V03.
Resis- Between V03 (female) (1) and ground
Min. 1 Mz
tance
Defective swing parking brake
solenoid
40-650 HB215LC-2
40 Troubleshooting

2. Disconnect connectors V03 and connect T-adapter to female side
of V03.
(Internal open or short circuit) 20 to 60 z
HB215LC-2 40-651
40 Troubleshooting
Circuit diagram related to swing parking brake
40-652 HB215LC-2
40 Troubleshooting
E-42 Swing brake does not operate while swing parking brake cancel
switch is set to NORMAL position (HB205-FGN-400-A-Z0-A)
Swing brake does not operate while swing parking brake cancel switch is set to
Failure NORMAL position.
Condition of swing parking brake cancel switch signal can be checked with monitoring
Related information function.
(Hybrid controller system code: 09702 HYB Controller SW Input)
Defective swing parking brake 2. Disconnect connector S25 and connect T-adapter to male side.
1 cancel switch (internal short Swing parking brake
Min. 1 Mz
circuit) Resis- Between S25 (male) cancel switch: Normal
tance (13) and (14) Swing parking brake
Max. 1 z
cancel switch: FREE
Hot short circuit in wiring 3. Turn starting switch to ON position.
2 harness 4. Turn swing lock switch to ON position
a Measure voltage again with swing lock switch in OFF position.
Voltage Between V03 (female) (1) and ground Max. 1 V
HB215LC-2 40-653
40 Troubleshooting
40-654 HB215LC-2
40 Troubleshooting
E-43 One-touch power maximizing function does not operate, or

indicator is not displayed on monitor (HB205-FGL-400-A-Z0-A)
1. One-touch power maximizing function monitor is not displayed when L.H. knob switch is
Failure pressed.
2. Work equipment power is not increased when L.H. knob switch is pressed.
• One-touch power maximizing function monitor is not operated if working mode is in any of
Related breaker mode (B), lifting operation mode (L), or arm crane mode.
information • Condition of L.H.knob switch signal can be checked with monitoring function.
(Code: 02200)
If work equipment power is increased when L.H. knob switch is pressed but
Defective machine not displayed on the monitor, machine monitor may be defective. (Since this is
1
monitor an internal defect, troubleshooting cannot be performed.)
Defective fuse No. 8 in If fuse is blown out, circuit may have ground fault. (See cause 7.)
2
fuse box F01
Defective L.H.knob 2. Disconnect connector S11 and connect T-adapter to male side.
3 switch L.H.knob switch:
(Internal open circuit) Between S11 (male) (1) Min. 1 Mz
Resistance and (2) Release
L.H. knob switch: Press Max. 1 z
4
Between V02 (female) (1) and ground Min. 1 Mz
Open circuit or ground
5 fault in wiring harness a Ignore displayed failure codes.
L.H.knob switch:
Between CP01 (female) Max. 1 V
Voltage Release
(42) and ground
L.H. knob switch: Press 20 to 30 V
Open circuit in wiring 1.Turn starting switch to OFF position.
harness 2.Remove fuse No. 8 in fuse box F01.
6 (Wire breakage or 3.Disconnect connectors CP01 and S11 and connect T-adapters to each
connector) Between F01-8 and S11 (female) (1) Max. 1 z
Resistance
Between S11 (female) (2) and CP01 (female) (42) Max. 1 z
Ground fault in wiring 2. Remove fuse No. 8 in fuse box F01.
harness 3. Disconnect connectors CP01 and S11, and connect T-adapter to female
7
(Contact with ground side of S11.
circuit) Between ground and F01-8 or S11 (female) (1) Min. 1 Mz
Resistance Between ground and S11 (female) (2) or CP01
Defective pump If no failure is found by above checks, pump controller is defective. (Since this
controller
HB215LC-2 40-655
40 Troubleshooting
Circuit diagram related to one-touch power maximizing switch
40-656 HB215LC-2
40 Troubleshooting
E-44 One-touch power maximizing function cannot be canceled (HB205-FPB-400-

A-Z0-A)
Failure Work equipment power does not return to normal when L.H. knob switch is released.
Related • Condition of L.H.knob switch signal can be checked with monitoring function.
information (Code: 02200 Switch input 1)
Hot short circuit in wiring2. Disconnect connector V02 and connect T-adapter to female side.
harness
Voltage Between V02 (female) (1) and (2) Max. 4.5 V
If no failure is found by checks on cause 1, pump controller is defective.
HB215LC-2 40-657
40 Troubleshooting
E-45 Alarm does not sound during travel (HB205-KA4-400-A-Z0-A)
Failure Alarm does not sound during travel.

Related
information
Defective travel alarm 1. Turn starting switch to OFF position.
1 2. Disconnect connector M14, and connect T-adapter to male side.
(Internal defect)
Voltage Between M14 (male) (1) and (2) Continuity
harness 2. Disconnect connectors M14 and CP02, and connect T-adapters to each
defective contact of Between CP02 (female) (107) and M14 (female) (1) Max. 1 z
Resistance
connector) Between CP02 (female) (115) and M14 (female) (1) Max. 1 z
harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either
3 female side.
Between CP02 (female) (107) and ground, or M14
circuit) Resistance (female) (1) and ground Min. 1 Mz
Defective pump If no failure is found by above checks, pump controller is defective. (Since this
controller
40-658 HB215LC-2
40 Troubleshooting
E-46 Alarm does not stop sounding while machine is stopped (HB205-KB5-400-A-
Z0-A)
Failure Alarm does not stop sounding while machine is stopped.

Related information
harness 2. Disconnect connector M14 and connect T-adapter to female side.
Voltage Between M14 (female) (1) and ground Max. 4.5 V
HB215LC-2 40-659
40 Troubleshooting
E-47 Horn does not sound (HB205-KA2-400-A-Z0-A)
Failure Horn does not sound.

Related
information
Defective No. 5 fuse of If No. 5 fuse of fuse box F01 is blown out, circuit probably has ground fault. In
1 this case, perform check on cause 8 first.
fuse box F01
Defective horn relay 1.Turn starting switch to OFF position.
2 (Internal open or short 2.Replace horn relay (connector: R08) with another relay.
circuit) 3.Turn starting switch to ON position.
4.Press R.H. knob switch.
Defective horn switch 1.Turn starting switch to OFF position.
2.Disconnect connector S10 and connect T-adapter to male side.
3 (Internal open or short
circuit) Between S10 (male) (1) Switch: OFF Min. 1 Mz
Resistance and (2)
Switch: ON Max. 1 z
Defective horn (M07) 1. Turn starting switch to OFF position.
and defective bass tone 2. Disconnect connectors M07 and M08, and connect T-adapter to male
4 (M08) side.
(Internal open or short Between M07 (male) (1) and (2) Continuity
Continuity
circuit) Between M08 (male) (1) and (2) Continuity
2. Disconnect connector R08, and connect T-adapter to female side.
Defective wiring 3. Turn starting switch to ON position.
5 4. Press R.H. knob switch.
harness
Between R08 (female) (1) and (2) 20 to 30 V
Voltage
Between R08 (female) (3) and (2) 20 to 30 V
2. Disconnect connector R08, and connect T-adapter to female side.
Between R08 (female) (5) and ground Continuity
Continuity
Between R08 (female) (1) and ground Continuity
Open circuit in wiring a If no failure is found in above checks, this check is not required.
harness
6 (Wire breakage or 2.Remove No. 5 fuse of fuse box F01.
defective contact of 3.Disconnect connectors R08 and S10, and connect T-adapters to each
connector) female side.
Between F01-5 and S10 (female) (1) Max. 1 z
Between S10 (female) (2) and R08 (female) (1) Max. 1 z
Resistance
Between R08 (female) (2) and ground Max. 1 z
Between R08 (female) (3) and F01-5 Max. 1 z
a If fuse is not burnt out, this check is not required.
Ground fault in wiring 2.Remove No. 5 fuse of fuse box F01.
harness 3.Disconnect connectors R08, M07, and M08, and connect T-adapter to
7
(Contact with ground female side of R08.
circuit) Between R08 (female) (1) and ground Min. 1 Mz
Resistance Between R08 (female) (3) and ground Min. 1 Mz
Between R08 (female) (5) and ground Min. 1 Mz
Defective horn
8 If no failure is found by preceding checks, horn may be defective.
(Internal defect)
40-660 HB215LC-2
40 Troubleshooting
Circuit diagram related to horn
HB215LC-2 40-661
40 Troubleshooting
E-48 Horn does not stop sounding (HB205-KB2-400-A-Z0-A)
Failure Horn does not stop sounding.

Related
information
Defective horn switch 1. Turn starting switch to OFF position.
2. Remove horn relay (connector R08).
1 (Internal open or short
circuit)
If horn stops sounding, original horn relay is defective.
2. Disconnect connectors M07 and M08, and connect T-adapters to each
Between M07 (female) (2) and (1) Max. 1 V
Voltage
Between M08 (female) (2) and (1) Max. 1 V
Circuit diagram related to horn
40-662 HB215LC-2
40 Troubleshooting
E-49 Wiper monitor does not light up, or does not go out, while wiper
switch is operated (HB205-FG4-400-A-Z0-A)
Failure Wiper monitor does not light up or does not go out while wiper switch is operated.
• Condition of wiper switch signal can be checked with monitoring function.
Related information (Code: 04504)
monitor
HB215LC-2 40-663
40 Troubleshooting
E-50 Wiper does not operate while wiper switch is operated (HB205-FG0-400-A-Z0-A)
Failure Wiper does not operate while wiper switch is operated.

• Condition of window rear limit switch signal can be checked with monitoring function.
information • Wiper motor is troubleshooted for failure codes [DY20KA], [DY20MA], [DY2DKB], and
[DY2EKB].
Defective rear limit 2. Disconnect connector W03.
1 switch for window Front window: When
Min. 1 Mz
(internal short circuit) Between W03 (male) (1) closed
Resistance and (2) Front window: When
pulled up Max. 1 z

2 2. Disconnect connector M05 and connect T-adapter to female side.
Continuity Between M05 (female) (1) and (3) Continuity
a Wiper motor system
Open circuit in wiring See troubleshooting for [DY20KA], [DY20MA], [DY2DKB], and [DY2EKB].
harness
a Rear limit switch system
3 (Wire breakage or
defective contact of 1. Turn starting switch to OFF position.
connector) 2. Disconnect connector CP01 and connect T-adapter to female side.
3. Front window: When pulled up
Resistance Between CP01 (female) (76) and ground Max. 1 z
harness 2. Disconnect connector CP01 and connect T-adapter to female side.
4
(Contact with ground 3. Front window: When closed
circuit) Resistance Between CP01 (female) (76) and ground Min. 1 Mz
5
40-664 HB215LC-2
40 Troubleshooting
Circuit diagram related to wiper motor
HB215LC-2 40-665
40 Troubleshooting
E-51 Window washer does not operate while window washer switch is
operated (HB205-FH0-400-A-Z0-A)
Failure Window washer does not operate while window washer switch is operated.
• Condition of window washer switch signal can be checked with monitoring function.
information • Failure in window washer is expressed by failure code [DY2CKB].
monitor
Circuit diagram related to wiper motor
40-666 HB215LC-2
40 Troubleshooting
E-52 Boom LOWER is not displayed correctly with monitoring

function (HB205-FFR-400-A-Z0-A)
Failure "Boom LOWER" is not displayed correctly with monitoring function.
Related • Monitoring code:01900 Pressure Switch 1
information
Defective boom
LOWER PPC oil
1 pressure switch Perform troubleshooting for failure code [DHS9MA].
(internal open or short
circuit)
HB215LC-2 40-667
40 Troubleshooting
E-53 Arm OUT is not displayed correctly with monitoring function (HB205-FFS-
400-A-Z0-A)
Failure "Arm OUT" is not displayed correctly with monitoring function.

information
Defective Arm OUT
PPC oil pressure switch
1 Perform troubleshooting for failure code [DHSCMA].
circuit)
40-668 HB215LC-2
40 Troubleshooting
E-54 Arm IN is not displayed correctly with monitoring function (HB205-FFN-400-

A-Z0-A)
Failure "Arm IN" is not displayed correctly with monitoring function.

information
Defective arm IN PPC
oil pressure switch
1 Perform troubleshooting for failure code [DHS3MA].
circuit)
HB215LC-2 40-669
40 Troubleshooting
E-55 Boom RAISE is not displayed correctly with monitoring

function (HB205-FFM-400-A-Z0-A)
Failure "Boom RAISE" is not displayed correctly with monitoring function.
Related • Monitoring code: 01900
information
Defective boom RAISE
circuit)
40-670 HB215LC-2
40 Troubleshooting
E-56 Bucket CURL is not displayed correctly with monitoring

function (HB205-FFP-400-A-Z0-A)
Failure "Bucket CURL" is not displayed correctly with monitoring function.
information
Defective bucket CURL
circuit)
HB215LC-2 40-671
40 Troubleshooting
E-57 Bucket DUMP is not displayed correctly with monitoring

function (HB205-FFQ-400-A-Z0-A)
Failure "Bucket DUMP" is not displayed correctly with monitoring function.
information
Defective bucket DUMP
1 Perform troubleshooting for failure code [DHSDMA].
circuit)
40-672 HB215LC-2
40 Troubleshooting
E-58 Swing is not displayed correctly with monitoring function (HB205-FFT-400-A-

Z0-A)
Failure "Swing" is not displayed correctly with monitoring function.

information
Defective boom SWING
PPC oil pressure
1 Perform troubleshooting for failure codes [DHSAKZ] and [DHSBKZ].
sensor system (internal
open or short circuit)
HB215LC-2 40-673
40 Troubleshooting
E-59 Travel is not displayed correctly with monitoring function (HB205-FFU-400-A-

Z0-A)
Failure "Travel" is not displayed correctly with monitoring function.

information
Defective TRAVEL PPC
oil pressure sensor Perform troubleshooting for failure codes [DHSFMA], [DHSGMA], [DHSHMA]
1 system (internal open or and [DHSJMA].
short circuit)
40-674 HB215LC-2
40 Troubleshooting
E-60 Service is not displayed correctly with monitoring function (HB205-FFW-

400-A-Z0-A)
Failure Service is not displayed correctly with monitoring function.

• Monitoring code: 01901 Pressure Switch 2
• For safety, use "short socket adapter" 799-601-7230 for 2-pin X connector in tests
Related information for Causes 1 and 2.
k Do not check oil pressure switch connector while engine is running.
A. If monitoring function does not indicate that attachment control
pedal is operated when engine is started and attachment control pedal
is depressed at front end.
2. Disconnect connector P14 and connect "short socket adapter" to
female side.
Defective PPC oil pressure • If monitoring function indicates that "Service" is "ON", PPC oil
1 switch (P14) for front end of pressure switch (P14) for front end of attachment control pedal is
attachment control pedal defective (Note 1).
B. If monitoring function indicates that attachment control pedal is
operated when starting switch is turned to ON position.
• If monitoring function indicates that "Service" is "OFF", PPC oil
pressure switch (P14) for front end of attachment control pedal is
defective (Note 2).
A. If monitoring function does not indicate that attachment control
pedal is operated when engine is started and attachment control pedal
is depressed at rear end.
2. Disconnect connector P15 and connect "short socket adapter" to
female side.
Defective PPC oil pressure • If monitoring function indicates that "Service" is "ON", PPC oil
2 switch (P15) for rear end of pressure switch (P15) for rear end of attachment control pedal is
attachment control pedal defective (Note 1).
B. If monitoring function indicates that attachment control pedal is
operated when starting switch is turned to ON position.
2. Disconnect P15.
• If monitoring function indicates that "Service" is "OFF", PPC oil
pressure switch (P15) for rear end of attachment control pedal is
defective (Note 2).
HB215LC-2 40-675
40 Troubleshooting

2. Insert T-adapter into P13.
3. Starting engine
4. Operate attachment control pedal, and perform troubleshooting.
Defective wiring harness or
3 pump controller Between P13 (1) and Attachment control Approx. 7
(2) pedal: NEUTRAL V
Voltage Attachment control
Between P13 (1) and
(2) pedal: front end or rear Max. 1 V
end
2. Disconnect connectors CP01, P14, and P15, and connect T-
(1) Max. 1 z
contact of connector) Resis- Between CP01 (female) (35) and P15 (female) Max. 1 z
tance (1)
Between P14 (female) (2) and ground (T06) Max. 1 z
Between P15 (female) (2) and ground (T06) Max. 1 z
Ground fault in wiring harness 2. Disconnect connectors CP01, P14, and P15, and connect T-
5 adapter to any of female sides.
Resis- Between ground and CP01 (female) (35), P14
(female) (1), or P15 (female ) (1) Min. 1 Mz
tance
2. Disconnect connectors P14 and P15, and connect T-adapter to
either female side.
Between ground and P14 (female) (1) or P15 Approx. 7
Voltage
(female) (1) V
Note 1: If monitoring function indicates that "attachment control pedal" is "released" while voltage between
CP01 (35) and ground is below 1 V, pump controller is defective.
Note 2: If monitoring function indicates that "attachment control pedal" is "operated" while voltage between
CP01 (35) and ground is approximately 7 V, pump controller is defective.
40-676 HB215LC-2
40 Troubleshooting
Circuit diagram related to service oil pressure switch
HB215LC-2 40-677
40 Troubleshooting
E-61 Attachment hydraulic circuit cannot be changed (HB205-HBD-400-A-Z0-A)
• Attachment circuit cannot be changed.

Failure 1. When working mode P or E is selected, crusher circuit (2-way circuit) is not selected.
2. When working mode B is selected, breaker circuit (one-way circuit) is not selected.
Related • Failures (open circuit/short circuit) of attachment oil return selector solenoid are explained
information by failure codes [DWA2KA] and [DWA2KB].
Defective attachment oil 2. Disconnect connector V06, and connect T-adapter to male side.
1 return selector solenoid
(internal short circuit) Between V06 (male) (1) and (2) 20 to 60 z
Resistance
Hot short circuit in 2. Disconnect connector V06 and connect T-adapter to female side.
Circuit diagram related to attachment oil return selector solenoid
40-678 HB215LC-2
40 Troubleshooting
E-62 KOMTRAX system does not operate normally (HB205-F50-400-A-Z1-A)
Failure • KOMTRAX system does not operate properly.

• Perform following troubleshooting if administrator of KOMTRAX system requests to
Related check whether failure is occurring in system on machine.
information • Even when KOMTRAX system is defective, no problem appears on machine.
• Check all of results of troubleshooting on service menu display of machine monitor.
2. Display “Terminal status” screen.
1 Defective communication 1
Monitoring Check item:
To be completed
display Station set-up check
2. Display “GPS & Communication Status” screen.
N ###.##.## (Latitude)
Monitoring Check item:
2 Defective positioning by GPS E ###.##.## (Longitude)
display 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.
Monitoring Check item: Satellite in View or No Satellite in
Defective communication display Communication View
3
environment If Communication Status does never display “Satellite in View” within
15 minutes with machine stayed outdoor where opens clearly for sky,
check if connector of TC330 or antenna on top of cab are properly
connected.
4 Defective communication 2 Check item:
Monitoring
Number of message 0 to 60 (normally 0)
display
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.
HB215LC-2 40-679
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting of hydraulic and mechanical system (H-mode) (ALL-

3840-001-A-02-A)
Information described in troubleshooting table (H-mode) (ALL-5170-010-A-00-A)
(Rev. 2011/03)
Failure Failure symptom that appears on machine
Related Information on occurred failure or troubleshooting
information
1
2 Probable cause of failure <Contents of description>
(Each number is serial
3 number, not priority • Criteria to determine probable causes
4 sequence.) • Remarks for determination of probable cause
5
40-680 HB215LC-2
40 Troubleshooting
mode)
System chart of hydraulic and mechanical systems (HB205-C000-054-K-00-A)
a This system chart shows simplified overall hydraulic circuit diagram and is intended to be used as
reference material for troubleshooting of hydraulic and mechanical systems.
HB215LC-2 40-681
40 Troubleshooting
mode)
40-682 HB215LC-2
40 Troubleshooting
mode)
Failure mode and cause table (HB205-5340-40D-A-00-A)

Component causing failure
Tank Hydraulic pump
Troubleshooting code
Pump swash plate sensor
Engine system
PC-EPC valve
LS-EPC valve
Hydraulic oil
Servo piston
Piston pump
PC valve
LS valve
Strainer
Damper
Cap
Failure mode
All of work equipments and travel operations lack speed or power q q q q q q q q q q H-1
Engine speed drops significantly or engine stalls. q q q q q q q q H-2

Whole work equipment
All of work equipment and travel do not work q q q H-3

Travel
Unusual noise is heard from around hydraulic pump. q q q q H-4
Fine control performance or response is poor. q q q H-5
Boom speed or power is low. H-6
Arm speed or power is low. H-7
Bucket speed or power is low. H-8
Work equipment does not move in single operation. H-9

Work equipment
Boom H-10
Hydraulic drift of work equipment is large. Arm H-11
Bucket H-12
Time lag of work equipment is large. q H-13

When single work equipment is relieved hydraulically, other work
H-14
equipment moves.
One-touch power maximizing function does not operate. H-15
In combined operation of work equipment, equipment having heavier load
H-16
moves slower.
Machine does not travel straight. q H-17
Travel speed is slow. q H-18

Travel
Machine is not steered well or steering power is low. H-19
Travel speed does not change, or travel speed is too slow or fast. q H-20
One of tracks does not run. H-21

Upper structure does not
H-22
swing to the right or left.
Machine does not swing.
Upper structure swing only
H-23
to the right or left.
In both directions (right and
H-24
Swing acceleration or swing speed is low. left)
In only one direction H-25
Swing
Upper structure overruns excessively when it (Both right and left) H-26
stops swinging. (Either right or left) H-27
Shock is large when upper structure stops swinging. H-28
Large unusual noise is heard when upper structure stops swinging. H-29
When parking brake works. H-30

Swing drift on a slope is large. When parking brake is
H-31
OFF.
Attachment circuit cannot be changed. H-32
Attach
ment
Oil flow in attachment circuit cannot be changed. H-33
HB215LC-2 40-683
40 Troubleshooting
mode)

Control valve
Merge-divider main EPC valve
Arm lock valve (if equipped)
Pressure compensation valve
Self-pressure reducing valve
Merge-divider LS-EPC valve
Service valve (safety valve)

Merge-divider main valve
Boom regeneration valve
Arm regeneration valve

Merge-divider LS valve
Arm quick return valve
Travel junction valve

Back pressure valve
Main relief valve
LS shuttle valve
Boom lock valve
LS line orifice
Suction valve
Unload valve
Safety valve
Spool
Failure mode
All of work equipments and travel operations lack speed or power q q q H-1
Engine speed drops significantly or engine stalls. H-2

All of work equipment and travel do not work q H-3

Travel
Unusual noise is heard from around hydraulic pump. H-4
Fine control performance or response is poor. q H-5
Boom speed or power is low. q q q q q q q q q q q H-6
Arm speed or power is low. q q q q q q q q q q q q H-7
Bucket speed or power is low. q q q q q H-8
Work equipment does not move in single operation. q q H-9

Work equipment
Boom q q q q H-10
Hydraulic drift of work equipment is large. Arm q q q H-11
Bucket q q q q H-12
Time lag of work equipment is large. q q H-13

q H-14
equipment moves.
One-touch power maximizing function does not operate. q H-15
In combined operation of work equipment, equipment having heavier
q H-16
load moves slower.
Machine does not travel straight. q q q q q H-17
Travel speed is slow. q q q q q H-18

Travel
Machine is not steered well or steering power is low. q q q q q q q q q H-19
Travel speed does not change, or travel speed is too slow or fast. H-20
One of tracks does not run. q H-21

Upper structure does
not swing to the right or q H-22
Machine does not swing. left.
Upper structure swing
q H-23
only to the right or left.
In both directions (right
q q H-24
Swing acceleration or swing speed is low. and left)
In only one direction q q H-25
Swing
stops swinging. (Either right or left) q H-27
Large unusual noise is heard when upper structure stops swinging. q H-29
When parking brake
H-30
Swing drift on a slope is large. works.
When parking brake is
q q H-31
OFF.
40-684 HB215LC-2
Attach
ment
Failure mode
HB215LC-2
Attachment circuit cannot be changed.
Oil flow in attachment circuit cannot be changed.

Spool
Unload valve
Main relief valve
Pressure compensation valve
Self-pressure reducing valve
LS line orifice
Merge-divider main EPC valve
Merge-divider LS-EPC valve
Merge-divider main valve
Merge-divider LS valve
Boom regeneration valve
Boom lock valve

Control valve
Safety valve
Suction valve
LS shuttle valve
Arm regeneration valve
Arm quick return valve
Arm lock valve (if equipped)
Travel junction valve
Back pressure valve
q
Service valve (safety valve)
H-33
H-32
40 Troubleshooting
mode)
40-685
40 Troubleshooting
mode)
Component causing failure Swing

Solenoid valve
motor
ATT oil flow adjustment EPC valve
Travel speed selector solenoid
Work equipment lock Solenoid
Swing parking brake solenoid
ATT return selector solenoid

PPC valve (Travel lever)

PPC valve (Right lever)
PPC valve (Left lever)

PPC valve (Service)
Parking brake
Failure mode
All of work equipments and travel operations lack speed or power H-1
Engine speed drops significantly or engine stalls. q H-2

All of work equipment and travel do not work H-3

Travel
Fine control performance or response is poor. H-5
Boom speed or power is low. q H-6
Arm speed or power is low. q H-7
Bucket speed or power is low. q H-8
Work equipment does not move in single operation. q q H-9

Work equipment
Boom H-10
Hydraulic drift of work equipment is large. Arm H-11
Bucket H-12
Time lag of work equipment is large. H-13

H-14
equipment moves.
One-touch power maximizing function does not operate. q H-15
H-16
moves slower.
Machine does not travel straight. q q H-17
Travel speed is slow. q H-18

Travel
Machine is not steered well or steering power is low. q q H-19
One of tracks does not run. H-21

q q H-22
q H-23
q H-24
In only one direction q H-25
Swing
stops swinging. (Either right or left) q H-27
Shock is large when upper structure stops swinging. q H-28
Large unusual noise is heard when upper structure stops swinging. H-29
When parking brake works. q q H-30

H-31
OFF.
40-686 HB215LC-2
Attach
ment
Failure mode
HB215LC-2
Attachment circuit cannot be changed.
Oil flow in attachment circuit cannot be changed.

PPC valve (Right lever)
PPC valve (Left lever)
PPC valve (Travel lever)

q
PPC valve (Service)

q
ATT oil flow adjustment EPC valve
Work equipment lock Solenoid
Travel speed selector solenoid

Solenoid valve

q
ATT return selector solenoid
Parking brake
motor
Swing
H-33
H-32
40 Troubleshooting
mode)
40-687
40 Troubleshooting
mode)

Travel motor
Counterbalance valve
Center swivel joint
Hydraulic cylinders
Swing machinery
Parking brake
Piston motor
Safety valve
Check valve
Final drive
Failure mode
All of work equipments and travel operations lack speed or power H-1
Engine speed drops significantly or engine stalls. H-2

All of work equipment and travel do not work H-3

Travel
Fine control performance or response is poor. H-5
Boom speed or power is low. q H-6
Arm speed or power is low. q H-7
Bucket speed or power is low. q H-8
Work equipment does not move in single operation. H-9

Work equipment
Boom q H-10
Hydraulic drift of work equipment is large. Arm q H-11
Bucket q H-12
Time lag of work equipment is large. H-13

H-14
equipment moves.
One-touch power maximizing function does not operate. H-15
H-16
moves slower.
Machine does not travel straight. q q q q q H-17
Travel speed is slow. q q H-18

Travel
Machine is not steered well or steering power is low. q q q q H-19
One of tracks does not run. q q q q q H-21

q H-22
H-23
q H-24
In only one direction H-25
Swing
stops swinging. (Either right or left) H-27
Large unusual noise is heard when upper structure stops swinging. q H-29
When parking brake works. H-30

H-31
OFF.
Attachment circuit cannot be changed. H-32
Attach
ment
Oil flow in attachment circuit cannot be changed. H-33
40-688 HB215LC-2
40 Troubleshooting
mode)
H-1 All of work equipments and travel operations lack speed or

power (HB205-A8A-400-A-Z0-A)
Failure • All of work equipments and travel operations lack speed or power
• Perform all troubleshooting with working mode set in power (P) mode.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DKR0MA, DKR1MA, DXA8KA, DXA8KB, DXA9KA, DXA9KB, DXE0KA, DXE0KB)
• Check if speed of functions other than swing becomes normal when swing lock switch is
Related ON.
information If speeds become normal, perform check in cause (1) (2) of malfunctioning pump swash
plate sensor.
If speeds does not become normal, perform checks in causes (3) and after.
• F pump and R pump pressures can be checked with monitoring function. (Monitoring code:
F pump pressure 01100, R pump pressure 01101)
a Be ready with engine stopped, then perform troubleshooting with engine
at high idle.
Malfunction of pump swash All control levers in NEUTRAL 1.35 ± 0.63 V
1 plate sensor (front)
Sensor output Either track running idle off ground
voltage during L.H Travel 3.35 ± 0.63 V
Swing lock switch: ON
at high idle.
Malfunction of pump swash All control levers in NEUTRAL 1.35 ± 0.63 V
2 plate sensor (rear)
Sensor output Either track running idle off ground
voltage during R.H Travel 3.35 ± 0.63 V
Malfunction of unload valve at high idle.
3 (front)
3.5 ± 1.0 MPa
Unload pressure All control levers in NEUTRAL
{36 ± 10 kg/cm2}
Malfunction of unload valve at high idle.
4 (rear)
3.5 ± 1.0 MPa
Unload pressure All control levers in NEUTRAL
{36 ± 10 kg/cm2}
at high idle.
Malfunction of main relief
5 valve (front) 33.1 to 37.2 MPa
Main relief
Boom RAISE hydraulic relief {338 to 380 kg/
pressure
cm2}
at high idle.
6 valve (rear) 33.1 to 37.2 MPa
Main relief
pressure Arm IN relief {338 to 380 kg/
cm2}
Malfunction of main relief When pressure cannot be adjusted to normal level, check main relief valve
7 valve (front) for malfunction (fatigue of spring) and internal defect (defective valve seat).
Malfunction of main relief When pressure cannot be adjusted to normal level, check main relief valve
8 valve (rear) for malfunction (fatigue of spring) and internal defect (defective valve seat).
HB215LC-2 40-689
40 Troubleshooting
mode)

at high idle.
Control circuit 2.84 to 3.43 MPa
Malfunction of self- All control levers in NEUTRAL
9 pressure reducing valve source pressure {29 to 35 kg/cm2}
a Since relief valve of self-pressure reducing valve is not adjustable,
replace self-pressure reducing valve assembly if normal pressure is not
obtained.
running at low idle and at high idle.
Engine at low idle and all levers in 2.9 MPa
Malfunction of PC-EPC NEUTRAL {30 kg/cm2}
10 valve (front) PC-EPC valve
output pressure Engine at high idle and all levers in 0.70 to 1.09 MPa
NEUTRAL {7.1 to 11.1kg/
cm2}
Replace PC-EPC valve if any failure is found.
running at low idle and at high idle.
Engine at low idle and all levers in 2.9 MPa
Malfunction of PC-EPC NEUTRAL {30 kg/cm2}
11 valve (rear) PC-EPC valve
output pressure Engine at high idle and all levers in 0.70 to 1.09 MPa
NEUTRAL {7.1 to 11.1kg/
cm2}
Replace PC-EPC valve if any failure is found.
at high idle.
Oil pressure to be Oil pressure ratio
Measurement condition
measured
Defective adjustment of PC Pump discharge Swing lock switch: ON
12 valve (front) pressure 1
Boom RAISE hydraulic relief
PC valve output Swing lock switch: ON Approx. 0.6
pressure Boom RAISE hydraulic relief (approx. 3/5)
When pressure cannot be adjusted to normal level, check PC valve for
malfunction (fatigue of spring) or internal defect (stuck or seized PC spool).
at high idle.
measured
Defective adjustment of PC Pump discharge Swing lock switch: ON
13 valve (rear) pressure 1
Arm IN relief
pressure Arm IN relief (approx. 3/5)
When pressure cannot be adjusted to normal level, check PC valve for
malfunction (fatigue of spring) or internal defect (stuck or seized PC spool).
40-690 HB215LC-2
40 Troubleshooting
mode)

Malfunction of PC valve When pressure cannot be adjusted to normal level, check PC valve for
14 (front) malfunction (fatigue of spring) or internal defect (stuck or seized PC spool).
Malfunction of PC valve When pressure cannot be adjusted to normal level, check PC valve for
15 (rear) malfunction (fatigue of spring) or internal defect (stuck or seized PC spool).
at high idle.
Malfunction of LS-EPC Travel lever: 2.9 MPa
16 Travel speed: Lo
valve LS-EPC valve NEUTRAL {30 kg/cm2}
output pressure Travel lever: Fine
Travel speed: Hi 0 MPa {0 kg/cm2}
operation
at high idle.
Lever position and oil pressure ratio
L.H. track:
Running idle off
Oil pressure to be ground in Hi
Defective adjustment of LS measured All control levers in NEUTRAL
17 valve (front) speed setting
Lever moved
halfway
Pump discharge Almost same as LS valve output
pressure pressure 1
LS valve output Almost same as pump discharge Approx. 0.6
pressure pressure (approx. 3/5)
at high idle.
R.H. track:
Running idle off
18 valve (rear) speed setting
Lever moved
halfway
pressure pressure 1
If normal oil pressure is not obtained after adjustment, check LS valve for
Malfunction of LS valve
19 malfunction (fatigue of spring) and internal failure (stuck or seized LS
(front)
spool).
20 malfunction (fatigue of spring) and internal failure (stuck or seized LS
(rear)
spool).
If sensor output voltage is normal in check for cause (1), (2) servo piston is
Malfunction of servo piston judged normal.
21 or PC valve (*)
Check orifices and filters in pump servo devices for clogging.
If no failure is found by above checks, piston pump may have degraded
22 Malfunction of piston pump performance, malfunction, or have internal failure.
Check hydraulic tank strainer and return filter element for metal particles.
(*) Since PC valve is built in servo piston, replace servo piston assembly if PC valve is defective.
HB215LC-2 40-691
40 Troubleshooting
mode)
H-2 Engine speed drops significantly or engine stalls (PC200LC_10-FPN-400-A-Z0-A)
Failure • Engine speed drops significantly or engine stalls.

• Perform all troubleshooting with working mode set in P mode.
• If failure codes are displayed, perform troubleshooting for them first. (DKR0MA,
DKR1MA, DXA8KA, DXA8KB, DXA9KA, DXA9KB, DXE0KA, DXE0KB)
• As for speed other than swing speed, check whether normal speed is obtained with swing
Related lock switch turned ON.
information If normal speed is obtained, perform troubleshooting on causes (1) and (2) to check pump
swash plate sensor for malfunction.
If normal speed is not obtained, perform troubleshooting on cause (3) and after.
• F pump pressure and R pump can be checked with monitoring function. (Code: F pump
pressure 01100, R pump pressure 01101)
a Be ready with engine stopped, then perform troubleshooting with
Malfunction of pump swash All levers in NEUTRAL 1.35 ± 0.63 V
1 plate sensor (front) Sensor output L.H. track only: Running idle
voltage off ground 3.35 ± 0.63 V
2 plate sensor (rear) Sensor output R.H. track only: Running idle
voltage off ground 3.35 ± 0.63 V
Malfunction of main relief engine running at high idle.
3 valve (front) 33.1 to 37.2 MPa
Main relief pressure Boom RAISE hydraulic relief
{338 to 380 kg/cm2}
Malfunction of main relief engine running at high idle.
4 valve (rear) 33.1 to 37.2 MPa
Main relief pressure Arm IN hydraulic relief
{338 to 380 kg/cm2}
If normal oil pressure is not obtained after adjustment, check main relief
5 valve for malfunction (setting of spring) and internal failure (defective
valve (front)
valve seat).
If normal oil pressure is not obtained after adjustment, check main relief
6 valve for malfunction (setting of spring) and internal failure (defective
valve (rear)
valve seat).
engine running at low idle and at high idle.
Malfunction of PC-EPC valve Engine at low idle and all 2.9 MPa
7 (front) PC-EPC valve levers in NEUTRAL {30 kg/cm2}
output pressure Engine at high idle and all 0.70 to 1.09 MPa
levers in NEUTRAL {7.1 to 11.1 kg/cm2}
engine running at low idle and at high idle.
Malfunction of PC-EPC valve Engine at low idle and all 2.9 MPa {30 kg/
8 (rear) levers in NEUTRAL cm2}
PC-EPC valve
output pressure 0.70 to 1.09 MPa
Engine at high idle and all
levers in NEUTRAL {7.1 to 11.1 kg/cm2}
40-692 HB215LC-2
40 Troubleshooting
mode)

Defective adjustment of PC measured
9 valve (front) Swing lock switch: ON
Pump delivery
pressure 1
pressure Boom RAISE hydraulic relief (Approx. 3/5)

Defective adjustment of PC measured
10 valve (rear) Swing lock switch: ON
Pump delivery
pressure 1
Arm IN hydraulic relief
pressure Arm IN hydraulic relief (Approx. 3/5)
If normal oil pressure is not obtained after adjustment, check PC valve
11 Malfunction of PC valve (front) for malfunction (setting of spring) and internal failure (locked or trapped
PC spool).
If normal oil pressure is not obtained after adjustment, check PC valve
12 Malfunction of PC valve (rear) for malfunction (setting of spring) and internal failure (locked or trapped
PC spool).
Travel Approx. 2.9 MPa
Travel control lever: {Approx. 30 kg/
13 Malfunction of LS-EPC valve speed:
LS-EPC valve NEUTRAL cm2}
Lo
output pressure
Travel control lever: Travel
speed: 0 MPa {0 kg/cm2}
Finely moved
Hi
Track running idle
Oil pressure to be off ground
Defective adjustment of LS measured All levers in NEUTRAL
14 valve (front) (Lever moved
halfway)
Pump delivery Almost same as LS valve
pressure pressure 1
Pump delivery pressure is
LS valve output Approx. 0.6
almost same as LS valve
pressure (Approx. 3/5)
pressure.
Track running idle
Oil pressure to be off ground
measured All levers in NEUTRAL
Defective adjustment of LS (Lever moved
15 valve (rear) halfway)
Pump delivery
almost same as LS valve 1
pressure
pressure.
LS valve output Approx. 0.6
almost same as LS valve
pressure (Approx. 3/5)
pressure.
HB215LC-2 40-693
40 Troubleshooting
mode)

If normal oil pressure is not obtained after adjustment, check LS valve
16 Malfunction of LS valve (front) for malfunction (setting of spring) and internal failure (locked or trapped
LS spool).
If normal oil pressure is not obtained after adjustment, check LS valve
17 Malfunction of LS valve (rear) for malfunction (setting of spring) and internal failure (locked or trapped
LS spool).
If sensor output voltage is normal in checks on causes (1) and (2),
Malfunction of servo piston or determine that servo piston is normal.
18 PC valve (*)
If no failure is found by above checks, piston pump may malfunction, or
have internal failure.
19 Malfunction of piston pump
Check hydraulic tank strainer and return filter element for metal
particles.
(*) Since PC valve is built in servo piston, servo piston assembly must be replaced if PC valve is defective.
40-694 HB215LC-2
40 Troubleshooting
mode)
H-3 None of work equipment or travel works (HB205-FT5-400-A-Z1-A)
Failure • None of work equipment, or travel works.

Related • Perform all troubleshooting with working mode set in power (P) mode.
information
Cause
o.
Malfunction of work equipment 0 MPa
1 When locked
lock solenoid valve Solenoid output {0 kg/cm2}
pressure 2.9 MPa
When disengaged
{30 kg/cm2}
Control circuit source All control levers in 2.84 to 3.43 MPa
Malfunction of self-pressure
2 reducing valve pressure NEUTRAL {29 to 35 kg/cm2}
replace self-pressure reducing valve assembly if normal pressure is
not obtained.
Piston pump may malfunction or has internal defect. Check it by
following method.
3 Defective piston pump
• Crank the engine with main oil pressure pickup port plug removed.
o If any oil flows out, piston pump is normal.
HB215LC-2 40-695
40 Troubleshooting
mode)
H-4 Unusual sound is heard from around hydraulic pump (PC400-BAA-400-A-Z0-A)
Failure • Unusual sound is heard from around hydraulic pump

Related information —
Check hydraulic oil level directly.
1 Lowering of hydraulic oil level (Reference) If the hydraulic oil level is low while no hydraulic oil leaks to
the outside, it is assumed that hydraulic oil may flow in the flywheel
chamber due to a pump shaft seal damage.
2 Defective hydraulic oil Air may mix in hydraulic oil. Check it for bubbles or milky state.
Cap of the hydraulic tank cap may be clogged, causing negative
3 Clogging of hydraulic tank cap
pressure inside the tank. Check the cap.
Clogging of hydraulic tank Strainer in the hydraulic tank may be clogged, causing negative
4 pressure in the suction circuit. Check the strainer.
strainer
Clogging of hydraulic tank Check the return filter in the hydraulic tank may be clogged, especially
5 by metallic materials. Check the return filter.
return filter
If any metallic materials are detected in Cause 4 and 5 above, piston
6 Defective piston pump
pump may have internal defect.
40-696 HB215LC-2
40 Troubleshooting
mode)
H-5 Fine control performance or response is poor (PC200LC_10-FTB-400-A-Z0-A)
Failure • Fine control performance or response is poor.

• If failure codes are displayed, perform troubleshooting for them first. (DKR0MA, DKR1MA,
Related DXE0KA, DAXE0KB)
information • Signal voltage from swash plate sensor can be checked with monitoring function. (Code: F
pump side 01138, R pump side 01140)
running at high idle.
1 plate sensor (front)
Sensor output L.H. track only: Running idle off
voltage ground 3.35 ± 0.63 V
2 plate sensor (rear)
Sensor output R.H. track only: Running idle off
voltage ground 3.35 ± 0.63 V
Malfunction of LS-EPC Travel control 2.9 MPa
3 Travel speed: Lo
valve LS-EPC valve lever: NEUTRAL {30 kg/cm2}
output pressure Travel control
lever: Finely Travel speed: Hi 0 MPa {0 kg/cm2}
moved
4 Clogged orifice in LS circuit Orifice may be clogged. Check it.
L.H. track:
Running idle off
Lever moved
halfway
Pump delivery Almost same as LS valve output
pressure pressure 1
LS valve output Almost same as pump delivery Approx. 0.6
pressure pressure (Approx. 3/5)
R.H. track:
Running idle off
Lever moved
halfway
Pump delivery Almost same as LS valve output
pressure pressure 1
LS valve output Almost same as pump delivery Approx. 0.6
pressure pressure (Approx. 3/5)
HB215LC-2 40-697
40 Troubleshooting
mode)

7 (front) malfunction (setting of spring) and internal failure (locked or trapped LS
spool).
8 (rear) malfunction (setting of spring) and internal failure (locked or trapped LS
spool).
If sensor output voltage is normal in checks on causes (1) and (2) is
9 Malfunction of servo piston normal, determine that servo piston is normal.
40-698 HB215LC-2
40 Troubleshooting
mode)
H-6 Boom speed or power is low (PC200LC_10-A8B-400-A-Z0-A)
Failure Speed or power of boom is low.

• If failure codes are displayed, perform troubleshooting for them first. (DXE5KB, DXE6KA,
DXE6KB)
• Boom RAISE PPC pressure can be checked with monitoring function. (Code: 07400)
Related • Current to merge-divider (main) solenoid can be checked with monitoring function. (Code:
information 08000)
• Current to merge-divider (LS) solenoid can be checked with monitoring function. (Code:
08001)
• F pump pressure and R pump pressure can be checked with monitoring function. (Code: F
pump pressure 01100, R pump pressure 01101)
running at full speed.
R.H. work
Malfunction of right PPC equipment control NEUTRAL 0 MPa {0 kg/cm2}
1 valve (boom circuit)
PPC valve output lever
pressure R.H. work
Boom RAISE or 2.84 to 3.43 MPa
equipment control
LOWER {29 to 35 kg/cm2}
lever
a If boom lacks speed, check all work equipment speeds. If any failure is
found, perform troubleshooting on causes (3) to (5) related to merge-
divider valve failure.
a Perform troubleshooting with engine running at full speed.
Malfunction of merge-
2 divider valve assembly Max. 4.8/3.7
Boom RAISE/LOWER
seconds
Time required for
Max. 4.5/3.5
work equipment Arm IN/OUT
seconds
to move
Max. 3.3/2.7
Bucket CURL/DUMP
seconds
All work equipment control levers in 0 to 0.49 MPa
Main EPC output NEUTRAL {0 to 5 kg/cm2}
Malfunction of merge- pressure
3
divider main EPC valve Bucket CURL and Arm IN hydraulic 2.84 to 3.43 MPa
relief {29 to 35 kg/cm2}
All work equipment control levers in
0 mA
NEUTRAL
EPC current
Bucket CURL and Arm IN hydraulic
800 to 1000 mA
relief
LS-EPC output NEUTRAL {0 to 5 kg/cm2}
4
divider LS-EPC valve Bucket CURL and Arm IN hydraulic 2.84 to 3.43 MPa
0 mA
NEUTRAL
EPC current
Bucket CURL and Arm IN hydraulic 800 to 1000 mA
relief
HB215LC-2 40-699
40 Troubleshooting
mode)

a Release remaining pressure from hydraulic tank and piping and then
perform troubleshooting with engine stopped.
Malfunction of merge- • Check for stuck or seized main spool in merge-divider valve body.
5 divider main spool
(Spool must move smoothly.)
• Remove main spool from valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing spool.
Malfunction of merge- • Check for stuck or seized LS spool in merge-divider valve body.
6 divider LS spool
• Remove LS spool from valve body and check it for defects and dirt.
Malfunction of boom • Check for stuck or seized boom spool in control valve body.
7 control valve (spool)
• Remove boom spool from valve body and check it for defects and dirt.
Boom relief 33.1 to 37.2
pressure {338 to 380g/cm2}
a Check hydraulic drift of boom cylinder with engine stopped.
Hydraulic oil temperature within If visible hydraulic
operating range, bucket wit rated drift is observed,
Malfunction of boom Hydraulic drift
load, boom horizontal, arm cylinder control valve is
control valve (pressure fully retracted defective.
8 compensation valve)
(boom RAISE side) a Check whether boom cylinder moves slowly when performing hydraulic
relief of other work equipment. (If boom cylinder moves, control valve is
defective.)
a If any failure is found in either of above check items, interchange
pressure compensation valves on RAISE and LOWER sides, and
check whether failure symptom changes.
(Pressure compensation valves have different area ratio, so return them
to their original positions after test.)
40-700 HB215LC-2
40 Troubleshooting
mode)

33.1 to 37.2 MPa
Boom relief Boom LOWER At low-pressure
pressure hydraulic relief setting {338 to 380 kg/
cm2}
a Check hydraulic drift of boom cylinder with engine stopped.
Malfunction of boom
control valve (pressure Hydraulic drift operating range, arm cylinder fully drift is observed,
9 compensation valve) extended, machine raised off ground control valve is
defective.
(boom LOWER side)
a Check whether boom cylinder moves slowly when performing hydraulic
relief of other work equipment. (If boom cylinder moves, control valve is
defective.)
pressure compensation valves on RAISE and LOWER sides, and
(Pressure compensation valves have different area ratio, so return them
to their original positions after test.)
• Check for locked or trapped boom regeneration valve in control valve
body.
Malfunction of boom
(Valve must move smoothly.)
10 control valve (regeneration • Check that regeneration valve (check valve ) is seated on control valve
valve)
in position (it is not stopped halfway), and then remove it from control
valve body and check it for dents and dirt.
• Check spring of check valve for setting and deformation.
• Take care not to let foreign matter enter control valve when re-installing
check valve.
Boom relief Boom RAISE hydraulic relief, arm IN 33.1 to 37.2 MPa
pressure and arm hydraulic relief, and arm OUT {338 to 380 kg/
Malfunction of boom relief pressure hydraulic relief cm2}
11 control valve (safety valve
for lock valve) a Among above relief pressures, if arm IN lief pressure and boom RAISE
relief pressure is below standard relief pressure, safety valve may be
defective. Check safety valve for damaged sealing material.
a Since relief pressure cannot be adjusted with safety valve installed on
machine, replace safety valve assembly if safety valve is found to be
defective.
• Check that pilot piston and poppet are seated on lock valve body in
position (they are not trapped halfway).
• Check for locked or trapped pilot piston and poppet in lock valve body
(pilot piston and poppet must move smoothly).
Malfunction of boom • Remove pilot piston and poppet from valve body and check them for
12 control valve (lock valve)
defects and dirt.
• Check poppet spring for setting and deformation.
• Take care not to let foreign matter enter lock valve when re-installing
pilot piston and poppet.
HB215LC-2 40-701
40 Troubleshooting
mode)

33.1 to 37.2 MPa
Boom relief
Boom RAISE hydraulic relief {338 to 380 kg/
pressure
cm2}
Malfunction of boom
13 control valve (suction a If boom RAISE relief pressure is below standard value, suction valve
valve) (boom RAISE side) may be defective. Check it.
• Check that check valve is seated on valve body in position (it is not
trapped halfway).
• Remove check valve from valve body and check it for defects and dirt.
• Check spring for setting and deformation.
check valve.
33.1 to 37.2 MPa
Boom relief Boom LOWER At low-pressure
pressure hydraulic relief setting {338 to 380 kg/
Malfunction of boom cm2}
control valve (suction-
14 safety valve) (boom a If boom LOWER relief pressure is below standard value, suction-safety
valve may be defective. Check it.
LOWER side)
trapped halfway).
defective.
All work equipment control lever in 3.5± 1.0 MPa
NEUTRAL {36 10 kg/cm2}
Malfunction of boom LS differential 1.8(+0.05/-0.1)
15 control valve (LS shuttle pressure MPa
valve) Fine control of boom RAISE
{18(+0.5/-1.0) kg/
cm2}
If LS differential pressure is above standard value, LS shuttle valve may be
defective. Clean check valve seat on shuttle valve block of boom control
valve.Also check for defects on check valve.
Malfunction of LS shuttle
16 valve (L.H. travel control Clean check valve seat on shuttle valve block of L.H. travel control valve.
valve)
17 valve (bucket control valve) Clean check valve seat on shuttle valve block of bucket control valve.
18 valve (service valve) Clean check valve seat on shuttle valve block of service valve.

19 Defective boom cylinder running at full speed.
Leakage from
Boom RAISE hydraulic relief Max. 20 cc/min
boom cylinder
40-702 HB215LC-2
40 Troubleshooting
mode)
H-7 Arm speed or power is low (PC200LC_10-A8C-400-A-Z0-A)
Failure • Speed or power of arm is low.

• If failure codes are displayed, perform troubleshooting for them first. (DHS3MA, DXE5KA,
DXE5KB, DXE6KA, DXE6KB)
• Arm IN PPC pressure can be checked with monitoring function. (Code: 07200)
information 08000)
08001)
L.H. work
Malfunction of left PPC 0 MPa {0 kg/cm2}
1 valve (arm circuit) equipment control NEUTRAL
pressure L.H. work 2.84 to 3.43 MPa
equipment control Arm IN or OUT {29 to 35 kg/cm2}
lever
a If arm lacks speed, check all work equipment speeds. If any failure is
Boom RAISE/LOWER
seconds
Time required for
Max. 4.5/3.5
seconds
to move
Max. 3.3/2.7
Bucket CURL/DUMP
seconds
3
divider main EPC valve Bucket CURL and Arm IN hydraulic 2.84 to 3.43 MPa
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
4
divider LS-EPC valve Bucket CURL and Arm IN hydraulic 2.84 to 3.43 MPa
0 mA
NEUTRAL
EPC current
relief
HB215LC-2 40-703
40 Troubleshooting
mode)

Malfunction of merge- • Check for locked or trapped main spool in merge-divider valve body.
5 divider main spool (Spool must move smoothly.)
• Take care not to let foreign matter enter valve when re-installing main
spool.
Malfunction of merge- • Check for locked or trapped LS spool in merge-divider valve body.
6 divider LS spool (Spool must move smoothly.)
• Take care not to let foreign matter enter valve when re-installing LS
spool.
Malfunction of arm control • Check for locked or trapped arm spool in control valve body.
7 valve (spool) (Spool must move smoothly.)
• Remove arm spool from valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing arm
spool.
33.1 to 37.2 MPa
Arm relief
Arm IN hydraulic relief {338 to 380 kg/
pressure
cm2}
a Check hydraulic drift of arm cylinder with engine stopped.
Malfunction of arm control Hydraulic drift operating range, bucket with rated drift is observed,
valve (pressure load, arm cylinder fully extended control valve is
8 compensation valve) (arm defective.
IN side) a Check whether arm cylinder moves slowly when performing hydraulic
relief of other work equipment. (If arm cylinder moves, control valve is
defective.)
pressure compensation valves on arm IN and OUT sides, and check
whether failure symptom changes.
(Pressure compensation valves have different area ratio, so be sure to
return them to their original positions after test.)
40-704 HB215LC-2
40 Troubleshooting
mode)

33.1 to 37.2 MPa
Arm relief
Arm OUT hydraulic relief {338 to 380 kg/
pressure
cm2}
Malfunction of arm control
valve (pressure Hydraulic drift operating range, bucket with rated drift is observed,
9 compensation valve) (arm load, arm cylinder fully retracted: control valve is
defective.
OUT side)
a Check whether arm cylinder moves slowly when performing hydraulic
defective.)
pressure compensation valves on arm IN and OUT sides, and check
• Check for locked or trapped arm regeneration valve in control valve
body.
Malfunction of arm control (Regeneration valve must move smoothly.)
10 valve (regeneration valve) • Check that regeneration valve (check valve ) is seated on control valve
in position (it is not trapped halfway), and then remove it from control
valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing check
valve.
Measurement condition Hydraulic drift
If visible hydraulic
• Hydraulic oil temperature within operating range,
drift is observed,
bucket with rated load, arm cylinder fully extended
control valve is
•
defective.
11 valve (quick return valve) • Check that pilot spool and check valve are seated on valve body in
• Check for locked or trapped pilot spool and check valve in quick return
valve body.
(Pilot spool and check valve must move smoothly.)
• Remove pilot spool and check valve from valve body and check them
for defects and dirt.
pilot spool and check valve.
HB215LC-2 40-705
40 Troubleshooting
mode)

relief pressure hydraulic relief cm2}
a Among above relief pressures, if arm OUT relief pressure and boom
12 valve (safety valve for lock RAISE relief pressure is below standard value, safety valve may be
valve)
machine, replace safety valve if safety valve is found to be defective.
(Reference) Safety valve circuit connects to both boom RAISE and arm
OUT circuits via check valve. Determine that boom lock valve is defective if
arm IN or OUT relief pressure is normal.
Malfunction of arm control (pilot piston and poppet should move smoothly).
13 valve (lock valve)(if • Remove pilot piston and poppet from valve body and check them for
equipped) defects and dirt.
• Take care not to let foreign matter enter valve when re-installing piston
and poppet.
33.1 to 37.2 MPa
Arm relief
Arm OUT hydraulic relief {338 to 380 kg/
pressure
cm2}
14 valve (suction valve) (arm a If arm OUT relief pressure is below standard value, suction valve (check
OUT side) valve) may be defective. Check it.
trapped halfway).
• Remove check valve from valve body and check it for defects and dirt.
• Check spring for setting and deformation.
• Take care not to let foreign matter enter valve when re-installing check
valve.
33.1 to 37.2 MPa
Arm relief
pressure
cm2}
a If arm IN relief pressure is below standard value, suction-safety valve
15 valve (suction-safety valve)
(arm IN side) may be defective. Check it.
• Check that check valve of suction-safety valve is seated on valve body
in position (it is not trapped halfway).
defective.
40-706 HB215LC-2
40 Troubleshooting
mode)

All work equipment control lever in 3.5 ± 1.0 MPa
NEUTRAL {36 ± 10 kg/cm2}
Malfunction of arm control LS differential 1.8(+0.05/-0.1)
16 valve (LS shuttle valve) pressure MPa
Finely moved to arm IN and OUT
{18(+0.5/-1.0) kg/
cm2}
a If LS differential pressure is above standard value, LS shuttle valve may
be defective. Clean check valve seat on shuttle valve block of arm
control valve.Also check for defects on check valve.
Clean check valve seat on shuttle valve block of R.H. travel control valve,
17 valve (R.H. travel control
valve) and then check it.

18 Defective arm cylinder running at full speed.
Leakage from
Arm IN hydraulic relief Max. 20 cc/min
arm cylinder
HB215LC-2 40-707
40 Troubleshooting
mode)
H-8 Bucket speed or power is low (PC200LC_10-A8D-400-A-Z0-A)
Failure • Speed or power of bucket is low.

• If failure codes are displayed, perform troubleshooting for them first. (DHS4MA, DXE5KA,
DXE5KB, DXE6KA, DXE6KB)
• Bucket CURL PPC pressure can be checked with monitoring function. (Code: 07300)
information 08000)
08001)
R.H. work
Malfunction of right PPC equipment control NEUTRAL 0 MPa {0 kg/cm2}
1 valve (bucket circuit)
pressure R.H. work 2.84 to 3.43 MPa
equipment control Arm IN or OUT {29 to 35 kg/cm2}
lever
a If bucket lacks speed, check all work equipment speeds. If any failure is
Boom RAISE/LOWER
seconds
Time required for
Max. 4.5/3.5
seconds
to move
Max. 3.3/2.7
Bucket CURL/DUMP
seconds
All work equipment control levers in 0 to 0.49 MPa {0
Main EPC output NEUTRAL to 5 kg/cm2}
3 Bucket CURL and Arm IN hydraulic 2.84 to 3.43 MPa
divider main EPC valve {29 to 35 kg/cm2}
relief
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
All work equipment control levers in 0 to 0.49 MPa {0
LS-EPC output NEUTRAL to 5 kg/cm2}
Malfunction of merge- pressure 2.84 to 3.43 MPa
4 Bucket CURL and Arm IN hydraulic
divider LS-EPC valve {29 to 35 kg/cm2}
relief
0 mA
NEUTRAL
EPC current
relief
40-708 HB215LC-2
40 Troubleshooting
mode)

Malfunction of merge- • Check for locked or trapped main spool in merge-divider valve body.
5 divider main spool (Spool must move smoothly.)
main spool.
Malfunction of merge- • Check for locked or trapped LS spool in merge-divider valve body.
6 divider LS spool (Spool must move smoothly.)
LS spool.
Malfunction of bucket • Check for locked or trapped bucket spool in control valve body.
7 control valve (spool) (Spool must move smoothly.)
• Remove bucket spool from valve body and check it for defects and dirt.
bucket spool.
33.1 to 37.2 MPa
Bucket relief
Bucket CURL hydraulic relief {338 to 380 kg/
pressure
cm2}
a Check hydraulic drift of bucket cylinder with engine stopped.
Hydraulic oil temperature within
operating range, bucket with rated If visible hydraulic
Malfunction of bucket load, arm cylinder fully retracted, drift is observed,
Hydraulic drift
control valve (pressure bucket cylinder fully extended, boom control valve is
top face horizontal defective.
(bucket CURL side)
a Check whether bucket cylinder moves slowly when performing
hydraulic relief of other work equipment. (If bucket cylinder moves,
control valve is defective.)
pressure compensation valves on bucket CURL and DUMP sides, and
33.1 to 37.2 MPa
Bucket relief
Bucket DUMP hydraulic relief {338 to 380 kg/
pressure
Malfunction of bucket cm2}
control valve (pressure
9 compensation valve) a Check hydraulic drift of bucket cylinder with engine stopped.
(bucket DUMP side) Hydraulic oil temperature within
operating range, bucket with no load, If visible hydraulic
Hydraulic drift arm cylinder fully retracted, bucket drift is observed,
cylinder fully retracted, boom top control valve is
face horizontal defective.
HB215LC-2 40-709
40 Troubleshooting
mode)

hydraulic relief of other work equipment. (If bucket cylinder moves,
control valve is defective.)
pressure compensation valves on bucket CURL and DUMP sides, and
33.1 to 37.2 MPa
Bucket relief
Bucket CURL hydraulic relief {338 to 380 kg/
Malfunction of bucket pressure
cm2}
control valve (suction-
10 safety valve) (bucket CURL • If bucket CURL relief pressure is below standard value, suction valve
may be defective. Check it.
side) • Check that check valve of suction-safety valve is seated on valve body
defective.
33.1 to 37.2 MPa
Bucket relief
Bucket DUMP hydraulic relief {338 to 380 kg/
Malfunction of bucket pressure
cm2}
control valve (suction- • If bucket DUMP relief pressure is below standard value, suction valve
11 safety valve) (bucket
may be defective. Check it.
DUMP side) • Check that check valve of suction-safety valve is seated on valve body
defective.
All work equipment control lever in 3.5 ± 1.0 MPa
NEUTRAL {36 ± 10 kg/cm2}
Malfunction of bucket LS differential 1.8(+0.05/-0.1)
12 control valve (LS shuttle pressure Finely moved to bucket CURL or MPa
valve) DUMP {18(+0.5/-1.0) kg/
cm2}
a If LS differential pressure is above standard value, LS shuttle valve may
be defective. Clean check valve seat on shuttle valve block of bucket
control valve.Also check for defects on check valve.
Clean check valve seat on shuttle valve block of L.H. travel control valve,
13 valve (L.H. travel control
valve) and then check it.

14 Defective bucket cylinder running at full speed.
Leakage from
Bucket CURL hydraulic relief Max. 20 cc/min
bucket cylinder
40-710 HB215LC-2
40 Troubleshooting
mode)
H-9 Work equipment does not move in single operation (HB205-FTC-400-A-Z0-A)
(1) Boom does not move in single operation.

Failure (2) Arm does not move in single operation.
(3) Bucket does not move in single operation.
(DHS3MA, DHS4MA, DHS8MA, DHS9MA, DHSCMA, DHSDMA)
• PPC pressure of each work equipment can be checked with monitoring function.
Monitoring codes for them are shown below.
Related Boom RAISE PPC pressure: 07400
information Boom LOWER PPC pressure: 07500
Arm IN PPC pressure: 07200
Arm Dump PPC Pressure: 07600
Bucket CURL PPC pressure: 07300
Bucket DUMP PPC pressure: 07301
at high idle.
1 Malfunction of PPC valve Work equipment 0 MPa {0 kg/cm2}
NEUTRAL
PPC valve output control lever
pressure Work equipment 2.84 to 3.43 MPa
Operation
control lever {29 to 35 kg/cm2}
a Release remaining pressure from hydraulic tank and piping, and then
Malfunction of boom • Check for stuck or seized boom spool in the control valve body.
2 control valve (spool) (It must be moved smoothly and must not be caught.)
• Remove boom spool from valve body and check for defects and dirt.
• Be careful to prevent foreign matter from entering into it when restoring
it.
Malfunction of arm control • Check for stuck or seized arm spool in control valve body.
3 valve (spool) (It must be moved smoothly and must not be caught.)
• Remove arm spool from valve body and check for defects and dirt.
it.
Malfunction of bucket • Check for stuck or seized bucket spool in control valve body.
it.
(Reference) While work equipment is moved in single operation, if pump pressure remains at approximately 4
MPa {approximately 40 kg/cm2}, control valve spool probably stays at NEUTRAL position. (All the oil from the
pump is drained to the tank through unload valve.)
HB215LC-2 40-711
40 Troubleshooting
mode)
H-10 Hydraulic drift of boom is large (PC200LC_10-MS3-400-A-Z0-A)
Failure • Hydraulic drift of boom is large.

Related • Perform all troubleshooting with working mode set in P mode.
information
1 Defective boom cylinder running at high idle.
Leak from boom
Boom RAISE hydraulic relief Max. 20 cc/min
cylinder
Malfunction of boom relief pressure hydraulic relief cm2}
2 control valve (safety valve
for lock valve) a Among above relief pressures, if arm OUT relief pressure and boom
RAISE relief pressure is below standard value, safety valve may be
defective.
Malfunction of boom
3 control valve (lock valve) (pilot piston and poppet must move smoothly).
• Remove pilot piston and poppet from valve body and check them for
defects and dirt.
40-712 HB215LC-2
40 Troubleshooting
mode)
H-11 Hydraulic drift of arm is large (PC200LC_10-MS4-400-A-Z0-A)
Failure • Hydraulic drift of arm is large.

information
1 Defective arm cylinder running at high idle.
Leak from arm
Arm IN hydraulic relief Max. 20 cc/min
cylinder
Malfunction of arm control relief pressure hydraulic relief cm2}
2 valve (safety valve for lock
valve) a Among above relief pressures, if arm OUT relief pressure and boom
RAISE relief pressure is below standard value, safety valve may be
defective.
Malfunction of arm control • Check for locked or trapped pilot piston and poppet in lock valve body
3 valve (lock valve)(if (pilot piston and poppet must move smoothly).
equipped) • Remove pilot piston and poppet from valve body and check them for
defects and dirt.
33.1 to 37.2 MPa
Arm relief
pressure
cm2}
4 valve (suction-safety valve) a If arm IN relief pressure is below standard value, suction-safety valve
(arm IN side) may be defective. Check it.
• Check that check valve of suction-safety valve is seated on valve body
defective.
Malfunction of arm control perform troubleshooting with engine stopped.
5 valve (spool) • Check for locked or trapped arm spool in control valve body.
• Remove arm spool from valve body and check it for defects and dirt.
a Check whether arm cylinder moves slowly when performing hydraulic
defective.)
6 valve (pressure a If any failure is found in either of above check items, interchange
compensation valve) pressure compensation valves on arm IN and OUT sides, and check
HB215LC-2 40-713
40 Troubleshooting
mode)
H-12 Hydraulic drift of bucket is large (PC200LC_10-MS2-400-A-Z0-A)
Failure • Hydraulic drift of bucket is large.

information
1 Defective bucket cylinder running at high idle.
Leak from bucket
Bucket CURL hydraulic relief Max. 20 cc/min
cylinder
33.1 to 37.2 MPa
Bucket relief Bucket CURL or DUMP hydraulic
Malfunction of bucket {338 to 380 kg/
pressure relief
2 control valve (suction- cm2}
safety valve)
a If relief pressure is below standard value, suction-safety valve may be
defective..
a You can replace suction-safety valve with other one and check whether
failure symptom changes for judgment.
Malfunction of bucket • Check for locked or trapped bucket spool in control valve body.
3 control valve (spool) (Spool must move smoothly.)
bucket spool.
hydraulic relief of other work equipment.
(If bucket cylinder moves, control valve is defective.)
Malfunction of bucket
4 control valve (pressure a If any failure is found in above check item, interchange pressure
compensation valve) compensation valves on bucket CURL and DUMP sides, and check
40-714 HB215LC-2
40 Troubleshooting
mode)
H-13 Time lag of work equipment is large (PC200LC_10-FTD-400-A-Z0-A)
Failure • Time lag of work equipment is large.

Related • If failure codes are displayed, perform troubleshooting for them first. (DXE0KA, DXE0KB)
information • F pump pressure and R pump pressure can be checked with monitoring function. (Code: F
Approx. 2.9 MPa
Malfunction of LS-EPC Travel control Travel speed: Lo {Approx. 30 kg/
1 lever: NEUTRAL
valve LS-EPC valve cm2}
output pressure Travel control
lever: Finely Travel speed: Hi 0 MPa {0 kg/cm2}
moved
• Check for locked or trapped boom regeneration valve in control valve
Malfunction of boom body.
2 control valve (regeneration (Regeneration valve must move smoothly.)
valve) • Check that regeneration valve (check valve ) is seated on control valve
• Check for locked or trapped arm regeneration valve in control valve
Malfunction of arm control body.
3 valve (regeneration valve) (Regeneration valve must move smoothly.)
• Check that regeneration valve (check valve ) is seated on control valve
a Check relief pressure of each work equipment. If relief pressure only of
Malfunction of boom boom cylinder head end is unusual, suction-safety valve of boom
4 control valve (suction- control valve may malfunction.
safety valve)
arm cylinder bottom end is unusual, suction-safety valve of arm control
5 valve (suction-safety valve) valve may malfunction.
Malfunction of bucket bucket cylinder head end is unusual, suction-safety valve of bucket
control valve may malfunction.
6 control valve (suction-
safety valve) a You can replace suction-safety valve with other one and check whether
HB215LC-2 40-715
40 Troubleshooting
mode)

a Check whether boom cylinder moves slowly to RAISE side when
performing hydraulic relief of other work equipment. (If boom cylinder
Malfunction of boom moves, control valve is defective.)
control valve (pressure a If any failure is found in above check item, interchange pressure
compensation valves between both ports, and check whether failure
(boom RAISE side) symptom changes.
Malfunction of boom
control valve (pressure a Check whether boom cylinder moves slowly to LOWER side when
8 compensation valve) performing hydraulic relief of other work equipment. (If boom cylinder
(boom LOWER side) moves, control valve is defective.)
valve (pressure a Check whether arm cylinder moves slowly to arm IN side when
9 compensation valve) (arm performing hydraulic relief of other work equipment. (If arm cylinder
IN side) moves, control valve is defective.)
valve (pressure a Check whether arm cylinder moves slowly to arm OUT side when
10 compensation valve) (arm performing hydraulic relief of other work equipment. (If arm cylinder
OUT side) moves, control valve is defective.)
control valve (pressure a Check whether bucket cylinder moves slowly to bucket CURL side
11 compensation valve) when performing hydraulic relief of other work equipment. (If bucket
(bucket CURL side) cylinder moves, control valve is defective.)
control valve (pressure a Check whether bucket cylinder moves slowly to bucket DUMP side
12 compensation valve) when performing hydraulic relief of other work equipment. (If bucket
(bucket DUMP side) cylinder moves, control valve is defective.)
40-716 HB215LC-2
40 Troubleshooting
mode)
H-14 When part of work equipment is relieved singly, other parts of work
equipment move (PC300-FT4-400-A-Z0-A)
Failure • Other wok equipment moves when one of work equipment is relieved.
information
When work equipment other than boom is hydraulically relieved singly, if
boom moves to RAISE side arbitrarily, pressure compensation valve on
Malfunction of boom boom RAISE side may malfunction.
1 compensation valve) a Pressure compensation valve is equipped with outer seal, inner seal,
(boom RAISE side) and LS check valve (ball).
Since slipper seal is installed to inner seal, damage on O-ring inside
inner seal cannot be checked visually.
When work equipment other than arm is hydraulically relieved singly, if arm
valve (pressure
2 compensation valve) (arm moves to IN side arbitrarily, pressure compensation valve on arm IN side
may malfunction.
IN side)
When work equipment other than bucket is hydraulically relieved singly, if
3 compensation valve) bucket moves to CURL side arbitrarily, pressure compensation valve on
bucket CURL side may malfunction.
(bucket CURL side)
When work equipment other than bucket is hydraulically relieved singly, if
4 compensation valve) bucket moves to DUMP side arbitrarily, pressure compensation valve on
bucket DUMP side may malfunction.
(bucket DUMP side)
HB215LC-2 40-717
40 Troubleshooting
mode)
H-15 One-touch power maximizing function does not operate (PC200LC_10-FGL-

400-A-Z0-A)
Failure • One-touch power maximizing function does not work..

information • If failure codes are displayed, perform troubleshooting for them first. (DWK0KA, DWK0KB)
Malfunction of 2-stage
1 2-stage relief Swing lock switch OFF 0 MPa {0 kg/cm2}
relief solenoid valve
solenoid output 2.9 MPa
pressure Swing lock switch ON
{30 kg/cm2}
33.1 to 37.2 MPa
Normal hydraulic Hydraulic relief of
relief bucket only {338 to 380 kg/
Defective adjustment or cm2}
Front pump main
2 malfunction of main relief relief pressure Hydraulic relief
36.1 to 39.7 MPa
valve (front) during one-touch Hydraulic relief of
{368 to 405 kg/
power bucket only
cm2}
maximizing
If normal relief pressure is not obtained after adjustment, check main relief
valve for malfunction (setting of spring) and internal failure (defective valve
seat).
33.1 to 37.2 MPa
Normal hydraulic Hydraulic relief of
relief arm only {338 to 380 kg/
Defective adjustment or cm2}
Rear pump main
3 malfunction of main relief relief pressure Hydraulic relief
36.1 to 39.7 MPa
valve (rear) during one-touch Hydraulic relief of
{368 to 405 kg/
power arm only
cm2}
maximizing
If normal relief pressure is not obtained after adjustment, check main relief
valve for malfunction (setting of spring) and internal failure (defective valve
seat).
40-718 HB215LC-2
40 Troubleshooting
mode)
H-16 In combined operation of work equipment, equipment having

heavier load moves slower (PC200LC_10-D34-400-A-Z0-A)
Failure • In combined operation of work equipment, equipment having heavier load moves slower.
Related
information
Operations
Malfunction of control valve Heavier load side Smaller load side
combined
on smaller load side Boom RAISE and
1 (pressure compensation Boom RAISE Arm IN
arm IN
valve) (arm IN) Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
combined
on smaller load side Boom RAISE and
2 (pressure compensation Arm OUT Boom RAISE
arm OUT
valve) (boom RAISE) Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
Heavier load side Smaller load side
combined
Boom RAISE and
Boom RAISE Bucket CURL
bucket CURL
Malfunction of control valve Pressure compensation valve of control valve on smaller load side may
on smaller load side malfunction.
3 (pressure compensation
Operations
valve) (bucket CURL) Heavier load side Smaller load side
combined
Arm OUT and
Arm OUT Bucket CURL
bucket CURL
Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
combined
on smaller load side Boom LOWER
4 (pressure compensation Arm OUT Boom LOWER
and arm OUT
valve) (boom LOWER) Pressure compensation valve of control valve on smaller load side may
malfunction.
a Pressure compensation valve is equipped with outer seal, inner seal, and LS check valve (ball).
Since slipper seal is installed to inner seal, damage on O-ring inside inner seal cannot be checked visually.
HB215LC-2 40-719
40 Troubleshooting
mode)
H-17 Machine does not travel straight (HB205-FTF-400-A-Z0-A)
Failure • Machine does not travel straight.

• If failure codes are displayed, perform troubleshooting for them first. (DW91KA, DW91KB,
Related DHSFMA, DHSGMA, DHSHMA, DHSJMA, DXE5KA, DXE5KB, DXE6KA, DXE6KB)
information • Travel PPC Pressure can be checked in the monitor (monitoring code: Travel Fwd LH PPC
Pressure 07102, Travel Fwd RH PPC Pressure 07103, Travel Rev LH PPC Pressure
07104, Travel Rev RH PPC Pressure 07105)
at high idle.
Malfunction of R.H. travel
1 R.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
PPC valve
valve output R.H. travel lever FORWARD and 2.84 to 3.43 MPa
pressure REVERSE {29 to 35 kg/cm2}
at high idle.
NEUTRAL 0 MPa {0 kg/cm2}
Malfunction of L.H. travel
2 L.H. travel PPC L.H. travel lever FORWARD and 2.84 to 3.43 MPa
PPC valve
valve output REVERSE {29 to 35 kg/cm2}
pressure Difference in output pressures Max. 0.4 MPa
between L.H. and R.H. PPC valves {Max. 4 kg/cm2}
at high idle.
Malfunction of self- Control circuit 2.84 to 3.43 MPa
3 pressure reducing valve source pressure All control levers in NEUTRAL {29 to 35 kg/cm2}
replace self-pressure reducing valve assembly if normal pressure is not
obtained.
at high idle.
L.H. track:
Running idle off
Lever moved
halfway
pressure pressure 1
at high idle.
R.H. track:
Running idle off
Lever moved
halfway
pressure pressure 1
40-720 HB215LC-2
40 Troubleshooting
mode)

6 (front) malfunction (fatigue of spring) and internal failure (stuck or seized LS
spool).
7 (rear) malfunction (fatigue of spring) and internal failure (stuck or seized LS
spool).
at high idle.
Malfunction of travel Both levers in
8 junction solenoid valve 0 MPa {0 kg/cm2}
Output pressure NEUTRAL
Travel levers When either lever 2.9 MPa
of solenoid valve
is operated {30 kg/cm2}
• Check for stuck or seized travel junction valve spool in merge-divider
valve body.
Malfunction of travel
9 junction valve (spool) (It must be moved smoothly and must not be caught.)
• Remove travel junction valve spool from valve body and check it for
defects and dirt.
it.
HB215LC-2 40-721
40 Troubleshooting
mode)

Malfunction of R.H.travel • Check for stuck or seized travel spool in control valve body.
• Remove travel spool from valve body and check it for defects and dirt.
it.
Malfunction of L.H.travel perform troubleshooting with engine stopped.
11 control valve (spool) • Check for stuck or seized travel spool in control valve body.
(It must be moved smoothly and must not be caught.)
at high idle.
36.8 to 40.2 MPa
Malfunction of travel control Travel relief R.H. travel hydraulic relief
pressure {375 to 410 kg/
valve (pressure FORWARD
12 compensation valve) (R.H. cm2}
travel FORWARD side) a If relief pressure is abnormal, pressure compensation valve may
malfunction.
Interchange pressure compensation valves on FORWARD and
REVERSE sides, and check whether failure symptom changes.
Malfunction of travel control
at high idle.
valve (pressure
13 compensation valve) (R.H. 36.8 to 40.2 MPa
Travel relief R.H. travel hydraulic relief
travel REVERSE side) pressure {375 to 410 kg/
REVERSE
cm2}
at high idle.
valve (pressure
14 compensation valve) (L.H. 36.8 to 40.2 MPa
Travel relief L.H. travel FORWARD hydraulic
travel FORWARD side) pressure {375 to 410 kg/
relief
cm2}
at high idle.
valve (pressure
Travel relief
travel REVERSE side) L.H. travel REVESE hydraulic relief {375 to 410 kg/
pressure
cm2}
Connect hoses from L.H. and R.H. travel motors to swivel joint changing
Defective center swivel
16 joint connecting ports with each other, and check whether direction in which
machine deviates changes.
17 Defective travel motor at high idle.
Leakage from Travel hydraulic relief Max. 27.2 l/min
travel motor
18 Defective final drive a Check for unusual noise, unusual heat, and metallic powders in drained
oil to make judgment.
40-722 HB215LC-2
40 Troubleshooting
mode)
H-18 Travel speed is slow (HB205-D20-400-A-Z0-A)
Failure • Travel speed is slow.

(DXE0KA, DXE0KB)
• Pump pressures can be checked with monitoring function. (Monitoring code: F pump
Related pressure 01100, R pump pressure 01101)
information • Travel PPC Pressure can be checked in the monitor (monitoring code: Travel Fwd LH PPC
Pressure 07102, Travel Fwd RH PPC Pressure 07103, Travel Rev LH PPC Pressure
07104, Travel Rev RH PPC Pressure 07105)
• LS-EPC solenoid current can also be checked on the monitor (Monitoring code: 01500).
at high idle.
PPC valve
at high idle.
2 L.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
PPC valve
valve output L.H. travel lever FORWARD and 2.84 to 3.43 MPa
Malfunction of self- at high idle.
3 pressure reducing valve
Control circuit 2.84 to 3.43 MPa
source pressure All control levers in NEUTRAL {29 to 35 kg/cm2}
at high idle.
Approximately
Malfunction of LS-EPC Travel lever: 2.9 MPa
4 Travel speed: Lo
valve LS-EPC valve NEUTRAL {Approximately
output pressure 30 kg/cm2}
Travel lever: Fine
operation
it.
at high idle.
valve (pressure
FORWARD
cm2}
HB215LC-2 40-723
40 Troubleshooting
mode)

a If only 1 place of right, left, forward, and reverse is abnormal, pressure
compensation valve may malfunction.
Interchange pressure compensation valves on FORWARD and
at high idle.
valve (pressure
travel REVERSE side) pressure {375 to 410 kg/
REVERSE
cm2}
at high idle.
valve (pressure
Travel relief L.H. travel FORWARD hydraulic
relief
cm2}
Malfunction of travel control at high idle.
valve (pressure 36.8 to 40.2 MPa
10 compensation valve) (L.H.
Travel relief {375 to 410 kg/
travel REVERSE side) L.H. travel REVESE hydraulic relief
pressure cm2}
40-724 HB215LC-2
40 Troubleshooting
mode)

If relief pressure of only 1 port is low after adjusting relief valve, suction
Malfunction of travel control valve may malfunction.
11 valve (suction valve)
Check suction valve (check valve) for defects and fatigue of spring.
12 Defective travel motor at high idle.
Leakage from Travel hydraulic relief Max. 27.2 l/min
travel motor
HB215LC-2 40-725
40 Troubleshooting
mode)
H-19 Machine is hard to steer or travel power is low (HB205-L18-400-A-Z0-A)
Failure • Machine is hard to steer or travel power is low.

• If failure codes are displayed, perform troubleshooting for them first. (DW91KA, DW91KB,
DHSFMA, DHSGMA, DHSHMA, DHSJMA, DXE5KA, DXE5KB, DXE6KA, DXE6KB)
• Travel PPC Pressure can be checked in the monitor (monitoring code: Travel Fwd LH PPC
Related Pressure 07102, Travel Fwd RH PPC Pressure 07103, Travel Rev LH PPC Pressure
information 07104, Travel Rev RH PPC Pressure 07105)
• Merge-divider (main) solenoid current can also be checked on the monitor (Monitoring
code: 08000).
• Merge-divider (LS) solenoid current can also be checked on the monitor (Monitoring code:
08001).
at high idle.
PPC valve
at high idle.
2 L.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
PPC valve
valve output L.H. travel lever FORWARD and 2.84 to 3.43 MPa
at high idle.
Malfunction of travel Both levers in
3 junction solenoid valve Travel junction 0 MPa {0 kg/cm2}
NEUTRAL
solenoid valve Travel levers 2.9 MPa
When either lever
output pressure
is operated {30 kg/cm2}
• Check for stuck or seized travel junction valve spool in merge-divider
Malfunction of travel valve body.
4 junction valve (spool) (It must be moved smoothly and must not be caught.)
• Remove travel junction valve spool from valve body and check it for
defects and dirt.
it.
at high idle.
Work equipment control lever in 0 to 0.49 MPa
5 Bucket CURL and arm IN hydraulic 2.84 to 3.43 MPa
divider main EPC valve
Work equipment control lever in
0 mA
NEUTRAL
EPC Current
Bucket CURL and arm IN hydraulic 800 to 1000 mA
relief
40-726 HB215LC-2
40 Troubleshooting
mode)

at high idle.
Work equipment control lever in 0 to 0.49 MPa
6 Bucket CURL and arm IN hydraulic 2.84 to 3.43 MPa
divider LS-EPC valve
Work equipment control lever in
0 mA
NEUTRAL
EPC Current
Bucket CURL and arm IN hydraulic
800 to 1000 mA
relief
Malfunction of merge- • Check for stuck or seized main spool in merge-divider valve body.
7 divider main spool (It must be moved smoothly and must not be caught.)
it.
Malfunction of merge- • Check for stuck or seized LS spool in merge-divider valve body.
8 divider LS spool (It must be moved smoothly and must not be caught.)
it.
it.
at high idle.
36.8 to 40.2 MPa
pressure FORWARD {375 to 410 kg/
cm2}
valve (pressure a If only 1 place of right, left, forward, and reverse is abnormal, pressure
11 compensation valve) (R.H.
compensation valve may malfunction.
travel FORWARD side) Interchange pressure compensation valves on FORWARD and
a If relief pressures of R.H. travel FORWARD and L.H. travel REVERSE
are the same and low, main relief valve of rear pump may malfunction.
Check arm relief pressure additionally.
HB215LC-2 40-727
40 Troubleshooting
mode)

at high idle.
Malfunction of travel control 36.8 to 40.2 MPa
valve (pressure Travel relief R.H. travel hydraulic relief
12 compensation valve) (R.H. pressure REVERSE {375 to 410 kg/
cm2}
travel REVERSE side)
If measured values in checks on causes (11) and (12) are the same and
low, main relief valve of rear pump may malfunction. Check arm relief
pressure additionally.
at high idle.
valve (pressure Travel relief L.H. travel FORWARD hydraulic
13 compensation valve) (L.H. pressure {375 to 410 kg/
relief
cm2}
travel FORWARD side)
If relief pressures of L.H. travel FORWARD and L.H. travel REVERSE are
same and low, main relief valve of front pump may malfunction. Check
bucket relief pressure additionally.
at high idle.
valve (pressure Travel relief
14 compensation valve) (L.H. L.H. travel REVESE hydraulic relief {375 to 410 kg/
pressure
cm2}
travel REVERSE side)
If measured values in checks on causes (13) and (14) are same and low,
main relief valve of front pump may malfunction. Check bucket relief
pressure additionally.
If relief pressure of only 1 port is low after adjusting relief valve, suction
Malfunction of travel control valve may malfunction.
15 valve (suction valve)
Check suction valve (check valve) for defects and fatigue of spring.
Connect hoses from L.H. and R.H. travel motors to swivel joint changing
Defective center swivel
16 joint connecting ports with each other, and check whether direction in which
machine deviates changes.
If relief pressures of both R.H. travel FORWARD and REVERSE or those
of R.H. travel FORWARD and REVERSE are unusual in checks on causes
Defective R.H. travel motor (11) and (12) respectively, respective safety valves are probably defective.
17 (safety valve)
Interchange safety valves of L.H. and R.H. travel motors, and check
40-728 HB215LC-2
40 Troubleshooting
mode)

If relief pressures of both L.H. travel FORWARD and REVERSE are
unusual in checks on causes (13) and (14) respectively, respective safety
Defective L.H. travel motor valves may be defective.
18 (safety valve)
If pressure compensation valves are found to be normal in checks on
Defective R.H. travel motor causes (11) and (12), check valves may malfunction.
19 (check valve)
Interchange check valves on FORWARD and REVERSE sides of same
travel motor, and check whether failure symptom changes.
If pressure compensation valves are found to be normal in checks on
Defective L.H. travel motor causes (13) and (14), check valves may malfunction.
20 (check valve)
21 Defective R.H. travel motor at high idle.
Leakage from R.H. travel hydraulic relief Max. 27.2 l/min
travel motor
22 Defective L.H. travel motor at high idle.
Leakage from L.H. travel hydraulic relief Max. 27.2 l/min
travel motor
HB215LC-2 40-729
40 Troubleshooting
mode)
H-20 Travel speed does not change, or travel speed is too slow or
fast (HB205-BQ4-400-A-Z1-A)
Failure • Travel speed does not change, or travel speed is too slow or fast.
• If failure codes are displayed, perform troubleshooting for them first.(DW43KA, DW43KB)
Related • LS-EPC solenoid current can also be checked on the monitor (Monitoring code: 01500).
information • Travel speed selector solenoid (ON/OFF) can be checked with monitoring function.
(monitoring code: 02300)
a Be ready with engine stopped. Then run engine at high idle for
troubleshooting.
a Perform troubleshooting by fine control of travel lever.
Travel speed: Lo 600 mA (refer *)
LS-EPC current Travel lever: Fine Travel speed: Mi
operation 644 mA
value
Travel speed: Hi 0 mA
Malfunction of LS-EPC
1 a Be ready with engine stopped. Then run engine at high idle for
valve
troubleshooting.
Approximately
Travel lever: 2.9 MPa
Travel speed: Lo
LS-EPC output NEUTRAL {Approximately
pressure 30 kg/cm2}
Travel lever: Fine
operation
troubleshooting.
Travel lever: Travel speed: Lo 0 MPa {0 kg/cm2}
Malfunction of travel speed NEUTRAL
2
solenoid valve Output pressure Approximately
of solenoid valve Travel lever: Fine 2.9 MPa
Travel speed: Hi
operation {Approximately
30 kg/cm2}
Malfunction of travel motor If no failure is found by checks on causes (1) and (2), speed switching part
3 (speed switching section) of travel motor may malfunction.
*: Travel speed of Lo setting can be adjusted by using adjustment function of machine monitor. If it is changed
from default value, the value changes slightly.
40-730 HB215LC-2
40 Troubleshooting
mode)
H-21 One of tracks does not run (HB205-BG1-400-A-Z0-A)
Failure • One of tracks does not run.

• Travel PPC Pressure can be checked in the monitor (monitoring code: Travel Fwd LH PPC
Related Pressure 07102, Travel Fwd RH PPC Pressure 07103, Travel Rev LH PPC Pressure
information 07104, Travel Rev RH PPC Pressure 07105)
• Pump pressures can be checked with monitoring function. (Monitoring code: F pump
pressure 01100, R pump pressure 01101)
at high idle.
1 R.H. travel lever NEUTRAL 0 MPa {0 kg/cm2}
PPC valve PPC valve output
pressure FORWARD and 2.84 to 3.43 MPa
R.H. travel lever {29 to 35 kg/cm2}
REVERSE
at high idle.
2 L.H. travel lever NEUTRAL 0 MPa {0 kg/cm2}
PPC valve PPC valve output
pressure FORWARD and 2.84 to 3.43 MPa
L.H. travel lever {29 to 35 kg/cm2}
REVERSE
If no failure is found by check on cause (1) and one track does not run
Malfunction of R.H.travel
3 control valve (spool) when travel control lever is operated with pump pressure at approximately
4 MPa, check whether spool is stuck near NEUTRAL position.
If no failure is found by check on cause (2) and one track does not run
Malfunction of L.H.travel
4 control valve (spool) when travel control lever is operated with pump pressure at approximately
4 MPa, check whether spool is stuck near NEUTRAL position.
When R.H. travel lever is operated, if R.H. track does not run because of
5 control valve (suction low pump pressure, check suction valve.
valve)
When L.H. travel lever is operated, if L.H. track does not run because of
6 control valve (suction low pump pressure, check suction valve.
valve)
at high idle.
36.8 to 40.2 MPa
Travel relief R.H. travel FORWARD and
Defective R.H. travel motor pressure hydraulic relief {375 to 410 kg/
7 (safety valve) REVERSE
cm2}
If relief pressures of travel FORWARD and REVERSE are unusual to the
same degree, sealing of safety valve may be defective.
at high idle.
36.8 to 40.2 MPa
Travel relief L.H. travel FORWARD and
Defective L.H. travel motor pressure hydraulic relief {375 to 410 kg/
8 (safety valve) REVERSE
cm2}
If relief pressures of travel FORWARD and REVERSE are unusual to the
same degree, sealing of safety valve may be defective.
If safety valve is found to be normal in checks on cause (7), sealing of
Defective R.H. travel motor check valve may be defective.
9 (check valve)
Defective L.H. travel motor If safety valve is found to be normal in checks on cause (8), sealing of
10 (check valve) check valve may be defective.
HB215LC-2 40-731
40 Troubleshooting
mode)

Defective R.H. travel motor When running R.H. track idle off ground, if R.H. track does not run with R.
11 (parking brake) H. travel circuit pressure reaching relief pressure, travel parking brake may
malfunction.
Defective L.H. travel motor When running L.H. track idle off ground, if L.H. track does not run with L.H.
12 (parking brake) travel circuit pressure reaching relief pressure, travel parking brake may
malfunction.
13 Defective R.H. travel motor at high idle.
R.H. travel motor R.H. travel
leakage R.H. travel lever hydraulic relief Max. 27.2 l/min

14 Defective L.H. travel motor at high idle.
Leakage from L. L.H. travel
L.H. travel lever hydraulic relief Max. 27.2 l/min
H. travel motor
40-732 HB215LC-2
40 Troubleshooting
mode)
H-22 Upper structure does not swing to the right or left (HB205-L41-400-A-Z1-A)
Failure • Upper structure does not swing to the right or left.

information
Perform troubleshooting. For the failure code details, see "Troubleshooting for hybrid systems (Y mode)"
since this failure relates to hybrid systems.
HB215LC-2 40-733
40 Troubleshooting
mode)
H-23 Upper structure swings only to the right or left (HB205-L42-400-A-Z1-A)
Failure • Upper structure swing only to the right or left.

information
40-734 HB215LC-2
40 Troubleshooting
mode)
H-24 Swing acceleration or swing speed is low in both directions (right

and left) (HB205-L44-400-A-Z1-A)
Failure • Swing acceleration or swing speed is low in both directions (right and left).
information
HB215LC-2 40-735
40 Troubleshooting
mode)
H-25 Swing acceleration performance is poor or swing speed is slow in

only one direction (HB205-L45-400-A-Z1-A)
Failure • Swing acceleration performance is poor or swing speed is slow in only one direction.
information
40-736 HB215LC-2
40 Troubleshooting
mode)
H-26 Upper structure overruns excessively when it stops swinging (both

right and left) (HB205-L47-400-A-Z1-A)
Failure • Upper structure overruns excessively when it stops swinging (both right and left).
information
HB215LC-2 40-737
40 Troubleshooting
mode)
H-27 Upper structure overruns excessively when it stops swinging

(either right or left) (HB205-L48-400-A-Z1-A)
Failure • Upper structure overruns excessively when it stops swinging (either right or left).
information
40-738 HB215LC-2
40 Troubleshooting
mode)
H-28 Shock is large when upper structure stops swinging (HB205-L49-400-A-Z1-A)
Failure • Shock is large when upper structure stops swinging.

information
HB215LC-2 40-739
40 Troubleshooting
mode)
H-29 Large unusual noise is heard when upper structure stops

swinging (HB205-BAB-400-A-Z1-A)
Failure • Large unusual noise is heard when upper structure stops swinging.
information
40-740 HB215LC-2
40 Troubleshooting
mode)
H-30 Swing drift on a slope is large while swing parking brake is

applied (HB205-MS6-400-A-Z1-A)
Failure • Swing drift on a slope is large while swing holding brake is applied.
• When swing lock switch is set to ON position or swing parking brake cancel switch is set to
Related NORMAL position, swing parking brake is applied and swing system is locked by disc
information brake.
HB215LC-2 40-741
40 Troubleshooting
mode)
H-31 Swing drift on a slope is large while swing parking brake is

released (HB205-MS7-400-A-Z1-A)
Failure • Swing drift on a slope is large while swing holding brake is released.
information
40-742 HB215LC-2
40 Troubleshooting
mode)
H-32 Attachment hydraulic circuit cannot be changed while attachment

is installed (HB205-HBD-400-A-Z2-A)
Failure • Attachment hydraulic circuit cannot be changed while attachment is installed.
• For machines with provision for attachment, attachment circuit switches as follows
depending on selected working mode.
1. In ATT mode: The double acting circuit is selected and the safety valve is set to the low
pressure.
2. In B mode: The single acting circuit is selected and the safety valve is set to the high
Related pressure.
information
a Note that set pressure of safety valve switches only on port B side, and that on port A
side remains at low-pressure setting without switching.
• If failure codes are displayed, perform troubleshooting for them first. (DWA2KA, DWA2KB)
• F pump and R pump pressures can be checked with monitoring function. (Monitoring code:
F pump pressure 01100, R pump pressure 01101)
at high idle.
Malfunction of ATT return ATT return Working mode ATT mode 0 MPa {0 kg/cm2}
1
selector solenoid valve selector solenoid
2.9 MPa
valve output Working mode B mode
pressure {30 kg/cm2}
If no failure is found by check on cause (1), ATT return selector valve may
Malfunction of ATT return malfunction.
2
selector valve
Check for stuck valve spool, defects of valve, and fatigue of spring.
Defective adjustment or Safety valve of service valve may malfunction.
3 malfunction of service If normal pressure is not obtained after adjustment, safety valve may have
valve (safety valve) internal failure.
HB215LC-2 40-743
40 Troubleshooting
mode)
H-33 Oil flow in attachment circuit cannot be controlled (HB205-HBE-400-A-Z1-A)
Failure • Oil flow in attachment circuit cannot be controlled.

• For machines with provision for attachment, oil flow rate of attachment circuit varies
depending on selected working mode.
Related • Procedure for oil flow rate adjustment differs between working modes, ATT mode and B
information mode. For details, see Operation and Maintenance Manual.
• If failure codes are displayed, perform troubleshooting for them first. (DXE4KA, DXE4KB)
at high idle.
Attachment When valve is in 0 MPa {0 kg/cm2}
ATT oil flow control pedal neutral
adjustment EPC Pressure
valve output Attachment corresponding to
Malfunction of ATT oil flow pressure Depressed
1 adjustment EPC valve control pedal selected oil flow
setting
a If output pressure of EPC valve is 0 MPa, check "Service solenoid
current" with monitoring function. (monitoring code: 01700)
If current value is 0.3 to 0.91 A, EPC valve may be defective.
Check that output pressure changes according to selected oil flow
setting.
at high idle.
Attachment When valve is in 0 MPa {0 kg/cm2}
Malfunction of service PPC control pedal neutral
2 Service PPC
valve valve output Pressure
pressure Attachment corresponding to
Depressed
control pedal selected oil flow
setting
• Check that output pressure changes according to pedal stroke.
40-744 HB215LC-2
40 Troubleshooting
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode) (ALL-3840-001-A-03-A)
Information mentioned in troubleshooting table (S mode) (ALL-5170-010-A-01-A)
(Rev. 2011/01)
a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on engine
Related Information related to the detected failure or troubleshooting
information
Probable cause Contents of check and remarks Remedy
1 <Contents of description>
2 Probable causes for
trouble (Each number is • Contents of check to judge • Actions to eliminate probable
3 serial number, not priority probable causes causes of trouble
4 sequence.) • Remarks required for
5 judgment
HB215LC-2 40-745
40 Troubleshooting
S-1 Engine does not crank when starting switch is turned to START
position (D65-A26-400-A-Z0-A)
Failure Engine does not crank when starting switch is turned to START position.
Related • See E mode (E-1) for troubleshooting of electrical system.
information • If any failure code is displayed, perform troubleshooting for that code first.
No. Cause Point to check, remarks Remedy
Defective wiring harness in • When starting switch is turned to START Perform
1 starting circuit position, starting motor pinion is not pushed troubleshooting for E-1
out and take remedies.
• Grating noise is heard from starting motor
pinion.
(When starting switch is turned to START
position, starting motor pinion is pushed
out.)
• Starting motor pinion disengages during
operation.
position, starting motor pinion is pushed Perform
2 Defective starting motor troubleshooting for E-1
out.)
• Rattling noise is heard and starting motor and take remedies.
does not rotate.
position, starting motor pinion is pushed
out.)
(Reference: Rattling noise is caused when
starting motor pinion is repeatedly pushed
out and pulled in.)
• If grating noise is heard from starting motor
3 Broken flywheel ring gear pinion and starting motor does not rotate, Replace if damaged
visually check flywheel ring gear.
• Remove EGR cooler outlet gas piping and
check whether coolant containing
Cracked EGR cooler COOLANT flows out. Replace EGR cooler
4 (Reference: coolant in and drain water from
exhaust gas) a Water in exhaust gas can be normally engine cylinders
condensed, so check that condensate is
coolant or not.
40-746 HB215LC-2
40 Troubleshooting
S-2 Engine cranks but no exhaust smoke comes out (WA380_7-A27-400-A-Z0-A)
Failure Engine cranks but no exhaust smoke comes out.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
1 Insufficient fuel in tank • Fuel tank is empty. Add fuel.
Flush air breather hole
Clogged air breather hole in
2 • Air breather hole in fuel tank cap is clogged. in fuel tank cap and
fuel tank cap clean surrounding
area.
• Check used hours of fuel filter. If used
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
3
may be clogged. element.
Foreign material in fuel • Rust and water are found in fuel drained Replace fuel.
4
from fuel tank.
• Air is bled during air bleeding of fuel system. Perform air bleeding.
5 Air in fuel piping system (Reference: See Testing and adjusting, Repair or replace fuel
"Bleeding air from fuel system".) piping.
• Fuel leaks from fuel piping.
Leakage from fuel piping Repair or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts.
"Checking fuel circuit for leakage".)
• Injector return rate is excessive.
Fuel leakage from injector (Reference: See Testing and adjusting, Tighten or replace inlet
7 "Measuring fuel delivery, return and
and inlet connector connector.
leakage".)
• See Testing and adjusting, "Measuring fuel Replace supply pump
8 Defective supply pump
delivery, return and leakage". or pressure limiter.
• No resistance is felt or large effort is
9 Defective priming pump Replace priming pump.
required when operating priming pump.
• Monitored common rail pressure does not Loosen injection piping
Improper air bleeding of lower even after engine is stopped. (Code: and high-pressure pipe
10 common rail or injection 36400 Common rail pressure) mounting nuts on
piping (Pressure may not decrease if air still common rail and bleed
remains.) air.
HB215LC-2 40-747
40 Troubleshooting
S-3 Fuel is being injected but engine does not start (misfiring: engine
cranks but does not start) (WA380_7-A28-400-A-Z0-A)
Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
Failure does not start).
information
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge battery.
area.
4
5
from fuel tank.
• Injector return rate is excessive.
Fuel leakage from injector (Reference: See Testing and adjusting, Tighten or replace inlet
8 "Measuring fuel delivery, return and connector.
and inlet connector
leakage".)
• No resistance is felt or large effort is
required when operating priming pump.
10 Clogged air cleaner element • Air cleaner dust indicator indicates that dust Check and clean air
is at caution level. cleaner element.
• When preheating works, intake air heater
mounting area does not become hot.
• When preheating works or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor does heater.
not indicate properly.
• Check valve clearance.
(Reference: See Testing and adjusting,
Worn valve or rocker arm, "Testing and adjusting valve clearance".) Replace valve or
12
etc. • When engine is cranked, unusual noise is rocker arm.
heard from around cylinder head.
• Measuring compression pressure
Replace piston ring or
13 Defective piston ring (Reference: See Testing and adjusting,
piston.
"Testing compression pressure".)
• When engine is run in cylinder cutout mode
Defective injector with some cylinder cut out, engine speed
14 (clogged injector or defective does not change. Replace injector.
fuel spray) (Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
Since this is an internal defect, troubleshooting Replace engine
cannot be performed. controller.
40-748 HB215LC-2
40 Troubleshooting
S-4 Engine startability is poor (PC160-A10-400-A-Z0-A)
Failure Engine startability is poor.

• If any failure code is displayed, perform troubleshooting for that code first.
• Common rail fuel injection system (CRI) controls fuel injection timing electrically.
Related
Therefore, in some cases, engine does not start before crankshaft makes two turns
information
maximum even if starting operation is performed. This does not indicate any abnormality,
however.
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge battery.
• Fuel other than specified one is used.
• Fuel used does not accord with ambient
temperature. Use proper fuel
(Reference: If engine can start in warm specified in Operation
3 Improper fuel used
weather but does not easily start in cold and Maintenance
weather) Manual.
• Deposited wax (milky) is found in clear bowl
of fuel pre-filter.
area.
5
6
from fuel tank.
• See Testing and adjusting, "Measuring fuel Replace supply pump
delivery, return and leakage". or pressure limiter.
• Air cleaner dust indicator indicates that dust Check and clean air
10 Clogged air cleaner element
is at caution level. cleaner element.
• When preheating works, intake air heater
mounting area does not become hot.
• When preheating works or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor does heater.
not indicate properly.
• Remove exhaust gas piping from EGR
cooler outlet and inlet, and check whether
Cracked EGR cooler Replace EGR cooler
coolant containing COOLANT flows out.
12 (Reference: Coolant enters and drain water from
exhaust gas piping.) a Water in exhaust gas can be normally engine cylinders
condensed, so check that condensate is
coolant or not.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
13 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
Since this is an internal defect, troubleshooting Replace engine
14 Defective engine controller cannot be performed. controller.
HB215LC-2 40-749
40 Troubleshooting

• Measure compression pressure (see
Standard value table).
(Reference: See Testing and adjusting, Correct contact
Defective contact between "Testing compression pressure".) between valve and
15
valve and valve seat • Check valve clearance. valve seat or replace
(Reference: See Testing and adjusting, them.
"Testing and adjusting valve clearance".)
• Check exhaust gas color at KDOC muffler
outlet.
"Testing exhaust color".)
16 Defective piston ring • Measure compression pressure (see
piston.
• Check piston ring and piston ring groove.
40-750 HB215LC-2
40 Troubleshooting
S-5 Engine does not pick up smoothly (PC160-A30-400-A-Z0-A)
Failure Engine does not pick-up smoothly

information
Flush air breather hole in
Clogged air breather
2 • Air breather hole in fuel tank cap is clogged. fuel tank cap and clean
hole in fuel tank cap
surrounding area.
• Check used hours of fuel filter. If used beyond
Clogged fuel filter specified hours, fuel filter element may be Replace fuel filter
3
element clogged. element.
• Rust and water are found in fuel drained from
4 Foreign material in fuel Replace fuel.
fuel tank.
Leakage from fuel Repair or replace fuel
6 piping system (Reference: See Testing and adjusting, "Testing
piping related parts.
fuel circuit for leakage".)
• See Testing and adjusting, "Testing fuel Replace supply pump or
7 Defective supply pump discharge, return and leakage". pressure limiter.
• When crankcase pressure high error (failure
code: CA555) is still displayed even after KCCV
Abnormally high filter is replaced, blowby pressure is probably Perform following checks
8 crankcase pressure high (see Testing and adjusting, "Testing blowby on causes 10 and after.
pressure"). In this case, VFT may be seized or
damaged.
• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately
after engine is started.
• When engine runs in cylinder cutout mode with
some cylinder cut out, engine speed does not
change.
• Unusual noise is heard from VFT.
• Check whether VFT shaft rotates.
10 Seized or broken VFT Replace VFT.
(Move VFT vanes with hand in axial and radial
directions to make judgment.)
• When engine is cranked, unusual noise is heard
from around cylinder head.
Incorrect valve • Check valve clearance. Adjustment of valve
11
clearance (Reference: See Testing and adjusting, "Testing clearance
and adjusting valve clearance".)
Defective engine • Since this is an internal defect, troubleshooting Replace engine
12 cannot be performed.
controller controller.
HB215LC-2 40-751
40 Troubleshooting

• Measure compression pressure (see Standard
value table).
Defective contact (Reference: See Testing and adjusting, "Testing Correct contact between
13 between valve and compression pressure".) valve and valve seat or
valve seat • Check valve clearance. replace them.
(Reference: See Testing and adjusting, "Testing
• Open exhaust color inspection hole that is just
upstream of the KDOC muffler, and check
exhaust gas.
exhaust gas color".) Replace piston ring or
14 Defective piston ring • Measure compression pressure (see Standard piston.
value table).
compression pressure".)
40-752 HB215LC-2
40 Troubleshooting
S-6 Engine stops during operation (PC160-AF0-400-A-00-A)
Failure Engine stops during operation

information
surrounding area.
3
Foreign material in fuel • Rust and water are found in fuel drained from Replace fuel.
4
fuel tank.
6 (Reference: See Testing and adjusting, "Testing
piping system piping related parts.
• No resistance is felt or large effort is required
when operating priming pump.
discharge, return and leakage". pressure limiter.
Defective air intake
hose
9 • Visually check air intake hose for breakage. Replace air intake hose.
(between air cleaner
and VFT inlet)
Defective air intake • Check air intake manifold for internal breakage. Replace air intake
10
manifold manifold.
Defective boost piping
and connections Correct or replace boost
11 • Air leaks from boost piping.
(between VFT outlet piping.
and air intake manifold)
Defective exhaust gas • Check exhaust gas piping for damage and
piping exhaust gas leakage. Replace exhaust gas
12 (Check soot on heat insulation cover and heat piping.
(from exhaust manifold
to KDOC muffler inlet) insulation plate.)
• Check valve and rocker arm.
Damaged valve or (Unusual noise is heard and engine stops Replace valve or rocker
13
rocker arm suddenly.) arm.
• Metal particles are found in oil drained from oil
pan.
Broken or seized piston • Remove oil pan and check piston and Replace piston and
14 connecting rod connecting rod. connecting rod.
(Reference: Unusual noise is heard and engine
stops suddenly, or stops due to overheat.)
• Metal particles are found in oil drained from oil
Broken or seized pan. Replace crankshaft main
15 crankshaft bearing • Remove oil pan and check crankshaft main bearing.
bearing
• Check wiring harness of engine controller power
Defective wiring Repair wiring harness of
supply.
16 harness of engine engine controller power
(Reference: See Troubleshooting, "Failure code
controller power supply supply.
[CA343]".)
HB215LC-2 40-753
40 Troubleshooting

Defective starting Perform troubleshooting
17 switch wiring • Check starting switch wiring harness. for E-1 and take
remedies.
Perform troubleshooting
Defective hydraulic • See H-mode, "H-2 Engine speed lowers for failure symptom H-2
18 system significantly or engine stalls". and take appropriate
measures.
40-754 HB215LC-2
40 Troubleshooting
S-7 Engine runs rough or is unstable (PC160-A40-400-A-00-A)
Failure Engine runs rough or is unstable

information
surrounding area.
3
4
fuel tank.
• Check boost system (between VFT outlet and
Fuel leakage from boost Repair or replace boost
7 aftercooler, aftercooler and air intake manifold)
for fuel leakage.
• Replace sensor and check whether symptom
Defective mass air flow disappears. Replace mass air flow
8 and temperature sensor (Failure code may not be generated if sensor is and temperature sensor.
covered with dust.)
HB215LC-2 40-755
40 Troubleshooting
S-8 Engine lacks power (PC160-A60-400-A-Z0-A)
Failure Engine lacks power

information
surrounding area.
3
4
fuel tank.
discharge, return and leakage". pressure limiter.
Clogged air cleaner • Air cleaner dust indicator indicates that dust is Check and clean air
8
element at caution level. cleaner element.
• Check air cleaner and rectifying wire net for Correct or replace air
9 Defective air cleaner
deformation. cleaner.
Defective air intake
hose
10 • Visually check air intake hose for breakage. Replace air intake hose.
(between air cleaner
and VFT inlet)
Defective air intake • Check air intake manifold for internal breakage. Replace air intake
11
manifold manifold.
Defective boost piping
and connections Correct or replace boost
(between VFT outlet piping.
and air intake manifold)
Defective installation of • Air leaks from mounting part of charge pressure Correct installation of
13 charge pressure sensor charge pressure sensor.
sensor.
Defective exhaust gas • Check exhaust gas piping for damage and
piping exhaust gas leakage. Replace exhaust gas
14 (Check soot on heat insulation cover and heat piping.
(from exhaust manifold
to KDOC muffler inlet) insulation plate.)
Gas leakage from EGR
15 • Gas leaks from EGR piping. Replace EGR piping.
piping
Check intake and
exhaust system
(between VFT outlet • Measure boost pressure.
Repair or replace
16 and air intake manifold, (Reference: See Testing and adjusting, "Testing
defective part.
between exhaust boost pressure".)
manifold and KDOC
muffler)
• Check whether shaft rotates.
(Move vanes with hand in axial and radial
Excessive soot load in • Check exhaust gas color at KDOC muffler outlet Clean or replace KDOC
18 (see standard value table).
KDOC muffler muffler.
40-756 HB215LC-2
40 Troubleshooting

exhaust gas color".)
• When engine is cranked, unusual noise is heard
from around cylinder head.
Incorrect valve • Check valve clearance. Adjustment of valve
19
clearance (Reference: See Testing and adjusting, "Testing clearance
change.
Defective engine • Since this is an internal defect, troubleshooting Replace engine
21 cannot be performed.
controller controller.
• Measure compression pressure (see Standard
value table).
Defective contact (Reference: See Testing and adjusting, "Testing Correct contact between
22 between valve and compression pressure".) valve and valve seat or
valve seat • Check valve clearance. replace them.
• Check exhaust gas at KDOC muffler outlet.
exhaust gas color".)
• Measure compression pressure (see Standard Replace piston ring or
23 Defective piston ring value table). piston.
HB215LC-2 40-757
40 Troubleshooting
S-9 Exhaust smoke is black (D37-AH5-400-A-Z0-A)
Failure Exhaust smoke is black.

information
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
1
and Maintenance
Manual.
2
from fuel tank.
• Check air cleaner and rectifying wire net for Correct or replace air
3 Defective air cleaner
Defective exhaust gas piping • Check exhaust gas piping for damage and
exhaust gas leakage. Replace exhaust gas
4 (from exhaust manifold to (Check soot on heat insulation cover and piping.
KDOC muffler inlet) heat insulation plate.)
Defective installation of Correct installation of
• Air leakage from installed position of charge
5 charge (boost) pressure charge (boost)
(boost) pressure sensor
sensor pressure sensor.
Defective boost piping and
connections Correct or replace
(between VFT outlet and air boost piping.
intake manifold)
• KDOC muffler is clogged. Check exhaust
Replace KDOC
7 Defective KDOC muffler pressure pressure at location just upstream
muffler.
of KDOC muffler.
8 Gas leakage from EGR piping • Gas leaks from EGR piping. Replace EGR piping.
(Move VFT vanes with hand in axial and
radial directions to make judgment.)
does not change.
• Measured fuel return rate is excessive.
Correct or replace fuel
11 Defective fuel return piping "Testing fuel discharge, return and
return piping.
leakage".)
• Check fuel return piping for clogging.
• Replace sensor and check whether
Defective mass air flow and symptom disappears. Replace mass air flow
12 temperature sensor (Failure code may not be generated if and temperature
sensor is covered with dust.) sensor.
• When engine is cranked, unusual noise is
heard from around cylinder head.
• Check valve clearance. Adjusting valve
13 Incorrect valve clearance
(Reference: See Testing and adjusting, clearance
40-758 HB215LC-2
40 Troubleshooting

• Measure compression pressure (see
(Reference: See Testing and adjusting, Correct contact
Defective contact between "Testing compression pressure".) between valve and
14
valve and valve seat • Check valve clearance. valve seat or replace
(Reference: See Testing and adjusting, them.
• Check exhaust gas at KDOC muffler outlet.
"Testing exhaust gas color".)
• Measure compression pressure (see Replace piston ring or
15 Defective piston ring Standard value table). piston.
HB215LC-2 40-759
40 Troubleshooting
S-10 Engine oil consumption is excessive (PC160-B10-400-A-Z0-A)
Failure Engine oil consumption is excessive.

information
Dust sucked from air • When intake piping between air cleaner and Clean or replace intake
1 intake system engine is removed, dust is found inside. piping.
• Measured blowby pressure exceeds standard
value.
• Blowby pressure is still high after KCCV filter
Broken or worn piston element is replaced. Replace piston ring or
2 ring • Measure compression pressure (see Standard correct its installation.
value table).
Oil leakage from KCCV Correct installation of oil
3 • Check oil leakage from KCCV oil return piping.
oil return piping piping or replace it.
Oil leakage outside
4 • Check for oil leakage. Repair oil leaks.
engine
Oil leakage from oil filter • Check oil filter for oil leakage. Reinstall or replace oil
5
filter.
Oil leakage from oil Correct installation of oil
6 • Check oil piping for oil leakage.
piping piping or replace it.
Oil leakage from oil
7 • Check oil drain plug for oil leakage. Retighten oil drain plug.
drain plug
Correct installation of oil
8 Oil leakage from oil pan • Check oil pan for oil leakage.
pan or replace it.
Oil leakage from Correct installation of
9 • Check cylinder head for oil leakage. cylinder head or replace
cylinder head
it.
Worn or damaged rear • Oil in clutch chamber or damper chamber on Correct installation of
10 rear oil seal or replace it.
oil seal machine increases.
• VFT blower inlet and outlet, and turbine outlet
are dirty with oil.
11 Oil leakage from VFT • Check whether VFT shaft rotates. Replace VFT.
(Move VFT vanes with hand in axial and radial
• Oil is in coolant.
• Remove oil cooler and check for oil leakage
Oil leakage from oil outside oil cooler. Replace oil cooler.
12
cooler • Check oil cooler for oil leakage by applying air
pressure.
Oil leakage from EGR • When EGR valve is removed, outlet port is
13 Replace EGR valve.
valve stem found to be dirty with oil.
• Check valve guide and stem seal.
Worn or damaged valve • Remove cylinder head, and check inside Replace valve guide and
14 guide or stem seal diameter of guide and stem seal for damage. stem seal.
(Reference: See "Maintenance standards".)
40-760 HB215LC-2
40 Troubleshooting
S-11 Oil becomes contaminated quickly (PC160-B20-400-A-Z0-A)
Failure Oil becomes contaminated early

information
Use proper fuel specified
1 Improper fuel used • Fuel other than specified one is used. in Operation and
Maintenance Manual.
Use proper oil specified
2 Improper oil used • Oil other than specified one is used. in Operation and
Maintenance Manual.
• Check exhaust gas color at before KDOC
muffler (see standard value table). Perform troubleshooting
Black exhaust gas at (Reference: See Testing and adjusting, "Testing
3 for "S-9 Exhaust smoke
before KDOC muffler. exhaust gas color".) is black".
(Black exhaust gas at before KDOC muffler)
value. Perform following
4 Excessive blowby gas • Blowby pressure is still high after KCCV filter
checks.
element is replaced.
• Rotate VFT shaft and check for play.
Defective seal on VFT (Move VFT vanes with hand in axial and radial Replace VFT.
5
turbine side directions to make judgment.)
• Remove EGR valve and check stem seal,
guide, and stem.
6 Worn EGR valve guide • When EGR valve is removed, outlet port is Replace EGR valve.
found to be dirty with oil.
• Check oil level for excessive refilling.
Refill with oil to correct oil
7 Excessive refilling of oil (If oil level is excessive, oil will reach high
temperatures and early deteriorates.) level.
• Visually check oil cooler element for
contamination. Clean or replace oil
8 Dirty oil cooler element (Contaminated oil cooler element can increased cooler element.
oil temperature.)
value.
• Blowby pressure is still high after KCCV filter
Broken or worn piston element is replaced. Replace piston ring or
9 ring • Measure compression pressure (see Standard correct its installation.
value table).
• Check valve guide and stem seal.
Worn or damaged valve • Remove cylinder head, and check inside Replace valve guide and
10 guide or stem seal diameter of guide and stem seal for damage. stem seal.
(Reference: See "Maintenance standards".)
HB215LC-2 40-761
40 Troubleshooting
S-12 Fuel consumption is excessive (D65-B70-400-A-Z0-A)
Failure Fuel consumption is excessive.

information
Replace injector.
• Measure spill rate from injector.
Excessive spill of fuel from (Reference: See Testing and adjusting, Lots of dusts are is
1 injector "Measuring fuel delivery, return and probably in fuel. Check
leakage".) storage management
of fuel.
• Check fuel return piping for clogging.
Clean or replace fuel
2 Clogged fuel return piping (Injection rate may be increased due to
return piping.
clogged fuel return piping.)
does not change.
Fuel leakage from cylinder • Check for increased oil level. Repair defective parts.
4
head • Check for smell of diesel fuel.
• Check for increased engine oil level and
Fuel leakage from feed pump smell of diesel fuel. Replace feed pump oil
5
oil seal • Check feed pump oil seal. seal.
6 Fuel leakage outside engine • Check for fuel leakage outside engine. Repair defective parts.
40-762 HB215LC-2
40 Troubleshooting
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) (PC400-
B40-400-A-Z0-A)
Failure Oil is in coolant (or coolant spurts or coolant level goes down)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Perform
troubleshooting for "S-
1 Milky engine oil • Engine oil level rises and oil is milky
16 Water mixes into
engine oil (milky)".
Damaged oil cooler element Replace oil cooler
2 • Check oil cooler element
element
• Coolant in radiator has excessive air
bubbles and blows back.
3 Damaged cylinder head • Overhaul engine and perform a pressure Replace cylinder head
tightness test on cylinder head to check for
abnormalities
• Coolant in radiator has excessive air
Damaged cylinder head bubbles and blows back. Replace cylinder head
4 gasket • Overhaul engine and check cylinder head gasket
gasket for abnormalities
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
5
block or pitting in cylinder block
HB215LC-2 40-763
40 Troubleshooting
S-14 Oil pressure drops (PC400-10D-400-A-Z0-A)
Failure Oil pressure drops

• If any failure code is displayed, carry out troubleshooting for it first.
Related information • Confirm if machine has been operated on a slope steeper than specified in the
Operation and Maintenance Manual.
• Oil level in oil pan is low
1 Lack of oil in oil pan • Oil pressure monitor indicates low oil Add oil
pressure when operating on slopes
Defective oil pressure sensor, Replace oil pressure
• Check oil pressure sensor, wiring harness,
2 wiring harness sensor, wiring harness,
and connector
or connector
If oil is contaminated
with fuel, carry out
• Perform oil analysis and check for fuel in oil
3 Fuel in oil troubleshooting for "S-
• Engine oil smells of diesel fuel
15 Fuel mixes into
engine oil"
If oil is contaminated
• Perform oil analysis and check for water in with water, carry out
4 Water in oil oil troubleshooting for "S-
• Oil is milky 16 Water mixes into
engine oil (milky)"
• Check oil filter
(Reference: Oil filter has been used beyond
5 Clogged oil filter the specified period, oil heavily Replace oil filter
deteriorated, etc.)
• Water in oil can cause oil filter blockage
6 Clogged oil strainer • Check oil strainer Clean oil strainer
Crushed or clogged hydraulic Replace hydraulic
7 • Hydraulic piping is crushed or clogged
piping piping
• Check oil pump
8 Defective oil pump (worn or damaged gear) Replace oil pump
• Oil pump rotation is heavy or it has play
Defective regulator valve • Check valve spring for fatigue or damage Replace regulator
9
valve
• Valve and spring of oil pump relief valve is Replace oil pump relief
10 Defective oil pump relief valve fatigued, damaged. valve
Cracks in oil pump suction • Check around oil pump suction piping Replace oil pump
11 piping (cracked piping) suction piping
Defective seal between oil
12 pump and oil pump suction • Check seal Replace seal
piping
Replace boost oil
13 Defective boost oil pump • Check boost oil pump
pump
Defective boost oil pump relief • Check boost oil pump relief valve for fatigue Replace boost oil
14 or damage on valve and spring pump relief valve
valve
Oil leakage from EGR Replace EGR
15 hydraulic piping • Check EGR hydraulic piping
hydraulic piping
• Check main journal bearing
Replace main journal
16 Worn main journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
• Check pin journal bearing
Replace pin journal
17 Worn pin journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
Worn idler bushing, damaged Replace idler bushing
18 idler gear • Check idler bushing and idler gear
or idler gear
Breakage or falling off of Replace piston cooling
19 piston cooling nozzle • Check piston cooling nozzle
nozzle
40-764 HB215LC-2
40 Troubleshooting
S-15 Fuel mixes into engine oil (PC400-B31-400-A-Z0-A)
Failure Fuel mixes into engine oil (smells of diluted diesel fuel)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
1 Defective injector • When a certain cylinder is cut out, engine Replace Injector
speed does not change
"Handling of cylinder cut-out operation".)
Fuel leakage from injector or
2 • Check injector or O-ring Replace injector O-ring
O-ring (spill circuit)
Defective seal between
• Check seal between injector and injection
3 injector and injection piping, Repair or replace
piping, and check injection piping for cracks
cracks in injection piping
• Confirm that fuel no longer mixes into oil
4 Defects in supply pump Replace supply pump
after supply pump is replaced
HB215LC-2 40-765
40 Troubleshooting
S-16 Water mixes into engine oil (milky) (D65-B32-400-A-Z0-A)
Failure Water mixes into engine oil (milky).

• If oil mixes into coolant, perform troubleshooting for "S-13 Oil mixes into coolant".
When engine starting and stopping is frequently repeated in low ambient temperatures,
Related since KCCV is installed, condensed water vapor in blowby gas may mix into oil leading to
information milky oil or emulsified oil inside engine, but this is normal. This is not problem if coolant is
not leaking.
If coolant leakage is suspected from rapid drop of coolant level, perform following
troubleshooting procedures.
• Coolant containing COOLANT flows out
when gas piping are removed from EGR
cooler outlet.
(Check whether water contains COOLANT
or not. It can be condensed water.)
1 Cracks in EGR cooler (Reference: Note that cracks in EGR cooler Replace EGR cooler.
are caused by and preceded by drop of
coolant level of cooling system in some
cases. When replacing EGR cooler, check
cooling system piping and radiator for water
leakage.)
Damaged oil cooler element • Check oil cooler element and gasket Replace oil cooler
2 or gasket • Pressure test on oil cooler shows that water element or gasket.
leaks.
Replace cylinder head
Damaged cylinder head or • Disassemble engine to check cylinder head
3 or cylinder head
cylinder head gasket and cylinder head gasket.
gasket.
• Engine oil level increases and oil is milky.
Cracks or pitting in cylinder • Disassemble engine and check inside of Replace cylinder block.
4
block cylinder block for cracks or pitting.
40-766 HB215LC-2
40 Troubleshooting
S-17 Coolant temperature rises too high (overheating) (PC160-AL0-400-A-Z0-A)
Failure Coolant temperature rises too high (overheating).

information
Clogged radiator core • Check radiator core for clogging, and check
1 Clean radiator core.
fin for crush.
• Thermostat does not open at cracking
temperature.
2 Malfunction of thermostat a Thermostat cracking temperature: 79.4 to Replace thermostat.
83.3 °C
(Full open temperature: 95 °C)
• Error related to coolant temperature is Replace coolant
Defective coolant temperature temperature sensor,
3 displayed, but measured value of radiator
gauge monitor or wiring
coolant temperature is normal.
harness.
Perform
Increased fuel injection rate • Fuel injection rate is high. troubleshooting for "S-
4
12 Fuel consumption is
excessive".
5 Low coolant level • Check coolant level. for lowering. Refill with coolant.
Replace coolant
6 Leakage of coolant • Check water leakage from coolant piping.
piping.
• Visually check water pump.
(Check shaft seal for water leakage,
7 Breakage of water pump Replace water pump.
impeller for damage, and shaft for
breakage.)
Overheating due to increased
EGR ratio (EGR amount Replace mass air flow
against fresh air amount) • Check mass air flow and temperature
8 and temperature
caused by defective mass air sensor.
sensor.
flow and temperature sensor
Overheating due to increased
EGR ratio (EGR amount
• Check air cleaner and rectifying wire net for Repair or replace air
9 against fresh air amount)
caused by air cleaner
deformation
Defective cylinder head or • Check radiator coolant for excessive Perform
10 cylinder head gasket bubbles and spurt back. troubleshooting for "S-
13 Oil is in coolant".
• Check exhaust gas color at KDOC muffler
outlet.
"Testing exhaust color".)
11 Defective piston ring • Measure compression pressure (see
piston.
HB215LC-2 40-767
40 Troubleshooting
S-18 Unusual noise is heard (PC160-BA1-400-A-Z0-A)
Failure Unusual noise is heard

• Check whether noise source is in or outside engine before starting troubleshooting.
• Engine runs in low-temperature mode while it is not warmed up sufficiently. Accordingly,
engine sound becomes slightly larger. This does not indicate abnormality, however.
Related • When engine accelerates, it switches into acceleration mode and its sound becomes
information slightly large further for up to approximately 3 to 5 seconds. This does not indicate
abnormality, however.
• Exhaust gas leaks from piping between cylinder
head and exhaust manifold, between exhaust
Gas leakage from Repair or replace
1 manifold and VFT, or between VFT outlet and
piping defective parts.
KDOC muffler.
• Gas leaks from EGR piping or air intake piping.
Vibration of exhaust Check and retighten
2 piping or exhaust • Visually check for vibration.
piping brackets.
bellows
3 Seized or broken VFT (Move VFT vanes with hand in axial and radial Replace VFT.
Damage inside KDOC Clean or replace KDOC
4 • Check inside KDOC muffler.
muffler muffler.
change.
• Check valve clearance.
Incorrect valve (Reference: See Testing and adjusting, "Testing Adjustment of valve
6
clearance and adjusting valve clearance".) clearance
Seized pin bushing,
Repair or replace
7 front bearing or main • Check for metal particles in oil pan.
damaged parts.
bearing
• If metal particles is found in oil pan or oil filter,
overhaul engine and check piston ring and
cylinder liner.
Worn piston ring or Replace piston ring or
8 • Measure compression pressure (see Standard
cylinder liner cylinder liner.
value table).
Damaged valve or • Overhaul engine and check valves and rocker Replace valve or rocker
9 arm parts.
rocker arm arm.
10 Damaged idler gear • Overhaul engine and check idler gear parts. Replace idler gear.
40-768 HB215LC-2
40 Troubleshooting
S-19 Vibration is excessive (HB205-BC0-400-A-Z0-A)
Failure Vibration is excessive

• If unusual noise is heard and vibration is excessive, perform troubleshooting for "S-18
Related Unusual noise is heard" as well.
information • If any failure code is displayed, perform troubleshooting for that code first.
• Visually check engine mounting bolts for
Loose engine mounting bolts Retighten bolts or
1 looseness and cushions for cracks and
or defective cushions replace cushions.
hardening.
• Check output shaft and coupling for Replace defective
2 Abnormality in output shaft
damage. parts.
Misalignment and facial
runout at connection of • Measure misalignment and facial runout at
Replace defective
3 engine, motor-generator, and connection of engine, motor-generator, and
parts.
hydraulic pump are out of hydraulic pump.
standard range.
• When engine runs in cylinder cutout mode
does not change.
Worn main bearing or • If metal particles are found in oil pan or oil Repair or replace
5 connecting rod bearing filter, overhaul engine. damaged parts.
• If metal particles are found in oil pan or oil Repair or replace
6 Stuck valve or rocker arm filter, open cylinder head cover and check damaged parts.
valves and rocker arms.
• If metal particles are found in oil pan or oil
Replace camshaft
7 Worn camshaft bushing filter, overhaul engine and check camshaft
bushings.
bushings.
HB215LC-2 40-769
40 Troubleshooting
S-20 Air cannot be bled from fuel circuit (WA380_7-A29-400-A-Z0-A)
Failure Air cannot be bled from fuel circuit.

information
• Check drain valve of fuel pre-filter for
Loosened drain valve of fuel looseness.
2 pre-filter (Air enters fuel circuit from loosened drain Close drain valve.
valve.)
3
• Air is bled during air bleeding of fuel system.
Repair or replace fuel
4 Air in fuel piping system (Reference: See Testing and adjusting,
piping.
"Bleeding air from fuel system".)
40-770 HB215LC-2
40 Troubleshooting
Troubleshooting for hybrid systems (Y mode)
Troubleshooting for hybrid systems (Y mode) (HB380-5170-010-A-00-A)
k Before performing testing and adjusting related to hybrid equipment, understand the following
items fully.
1. Only personnel who completed the special training for low-voltage electric work can perform removal of
hybrid equipment (motor-generator, capacitor, inverter, electric swing motor) and high-voltage wires.
2. Even qualified personnel can never disassemble the equipment listed above for quality assurance
reasons.
4. Before removing hybrid equipment, make sure to discharge the capacitors first.
(For details, see Testing and Adjusting, "Discharge of capacitor electric charge" in "Special functions of
machine monitor".)
a However, capacitors can be discharged by using the machine monitor only when the hybrid system is
operating normally.
a If any of failure code GA**** explained in the next page is displayed indicating the hybrid system is
abnormal, capacitors cannot be discharged by using the machine monitor even if the monitor instructs to
perform the discharge operation. (Conditions to consume the electric charge of the capacitors are not
met.) Therefore, use the special capacitor discharging generator 796-426-1800.
a Capacitor voltage may not be completely 0 V when its charge is 0 %. Voltage tends to be restored after
discharge due to the characteristics of the capacitor. Take extreme care when removing power cable
connectors.
a Avoid key switch operations as described below after discharging the capacitors, since this will cause the
capacitors to be recharged.
• After turning the key switch to the OFF position, the switch should not be turned to the ON position
before the engine stops completely.
• After turning the key switch to the OFF position and the engine stops completely, the engine should not
be started by turning the key switch to the ON position.
k The items with the mark relate to handling of hybrid equipment. Before performing work,
understand 00-200 Foreword, Safety, Basic information, "Handling Hybrid Equipment and High-
Voltage Wires".
a For monitoring items applicable to troubleshooting of hybrid equipment, refer to list in Failure code
[GA——] (Separate sheet 1).
a For the check sheet to record results of diagnostic checks on abnormal hybrid equipment, refer to Failure
code [GA——] (Separate sheet 2). (This check sheet is used when making inquiries to the factory.)
complete. Do not work with bare hands. Always wear insulating gloves.
a When a connector is removed at the capacitor side, cover the connector halves (harness and capacitor
sides) with plastic bags, etc. to prevent entry of foreign material.
a Perform troubleshooting with the engine stopped.
a Do not connect the tester directly to the connector at the capacitor (female) side.
HB215LC-2 40-771
40 Troubleshooting
Y-1 Hybrid monitor does not go out (HB205-K11-400-A-Z0-A)
Failure Hybrid monitor stays lit and does not go out.

• Hybrid controller SW input can be checked with monitoring function.
Related (Code: 09702 Hybrid controller SW input)
Low voltage in capacitor If capacitor voltage is less than150 V, run the engine at low idle for
1
more than 5 minutes.
If the error of action level L02 to L04 is displayed, perform
2 Defective hybrid system
If no failure is found by checks on causes 1 and 2, hybrid controller
3 may be defective. (Since this is an internal defect, troubleshooting
controller)
cannot be performed.)
40-772 HB215LC-2
40 Troubleshooting
Y-2 Machine does not swing (HB205-K12-400-A-Z0-A)
Failure (1) Upper structure does not swing to the right or left
• Perform all troubleshooting with swing lock switch and HYB system stop switch in OFF
(NORMAL).
Related (DHVAL8, DHVAMA, DHVBL8, DHVBMA, or failure code that begins with "GA")
information • Swing PPC pressure can be checked even with monitoring function (Monitoring code:
09001 Swing LH PPC pressure, 09009 Swing LH PPC pressure #2, 09002 Swing RH
PPC pressure, 09008 Swing RH PPC Pressure #2).
• Swing parking brake solenoid (ON, OFF) can be checked even with monitoring function
(Monitoring code: 02300 Solenoid 1, 09700 HYB Con Solenoid)
Malfunction of swing parking Swing parking brake solenoid
1 L.H. work equipment control lever
brake solenoid valve output pressure
Left swing / Right swing 2.9 MPa {30 kg/cm2}
Malfunction of swing parking Since swing parking brake may malfunction, check it.
2
brake
a If hybrid system stop monitor is not displayed on the machine
monitor, checking is not necessary.
3
harness 2. Disconnect connector CH02 and insert T-adapter into it.
Voltage Between HC02 (3) and ground Max. 1 V
Since swing machinery may have internal failure, check it
4 Defective swing machinery Check for unusual noise, unusual heat, and metallic powders in
drained oil to make judgment.
Defective swing RIGHT PPC When failure code [DHVAL8] is displayed, perform troubleshooting
5 pressure sensor since one of these values may not be correct.
Defective swing LEFT PPC When failure code [DHVAL8] is displayed, perform troubleshooting
If no failure is found by checks on causes 1 to 6, inverter (hybrid
7 Defective inverter controller) may be defective. (Since this is an internal defect,
HB215LC-2 40-773
40 Troubleshooting
Failure (2) Upper structure swing only to the right or left

• Perform all troubleshooting with swing lock switch and HYB system stop switch in OFF
(NORMAL).
Related (DHVAL8, DHVAMA, DHVBL8, DHVBMA, or failure code that begins with "GA")
information • Swing PPC pressure can be checked even with monitoring function (Monitoring code:
• Swing parking brake solenoid (ON, OFF) can be checked with monitoring function
(Monitoring code: 02300 Solenoid 1, 09700 HYB Con Solenoid)
Malfunction of swing PPC L.H. work equipment control lever PPC valve output pressure
1
valve NEUTRAL 0 MPa {0 kg/cm2}
2.84 to 3.43 MPa
Left swing / Right swing
{29 to 35 kg/cm2}
Defective swing RIGHT PPC When failure code [DHVAL8] is displayed, perform troubleshooting
Defective swing LEFT PPC When failure code [DHVAL8] is displayed, perform troubleshooting
40-774 HB215LC-2
40 Troubleshooting
Circuit diagram related to swing
HB215LC-2 40-775
40 Troubleshooting
Y-3 Swing acceleration or swing speed is low (HB205-K13-400-A-Z0-A)
Failure (1) Swing acceleration or swing speed is low in both directions (right and left).
• Set working mode to power (P) mode, and perform all troubleshooting with power mode
(P).
(DHSAKZ, DHSBKZ, DHVAKZ, DHVAL8, DHVBKZ, DHVBL8, DW45KY, or failure code
that begins with "GA")
Related • Swing PPC pressure can be checked even with monitoring function (Monitoring code:
information 09001 Swing LH PPC pressure, 09009 Swing LH PPC pressure #2, 09002 Swing RH
• Capacitor voltage can be checked with monitoring function. (Monitoring code: 09300
Capacitor Voltage)
• If hybrid temperature monitor lights up in red, perform troubleshooting for "E-16 Hybrid
temperature monitor lights up in red while engine is running" first.
Malfunction of swing parking Since swing parking brake may malfunction, check it.
1
brake
Since swing machinery may have internal failure, check it
2 Defective swing machinery Check for unusual noise, unusual heat, and metallic powders in
If voltage in capacitor always becomes 200 V and below when swinging
3 Malfunction of capacitor at normal swing (approximately 90 deg.), capacitor may be defective.
If no failure is found by checks on causes 1 and 3, engine controller
4 Defective inverter may be defective. (Since this is an internal defect, troubleshooting
Failure (2) Swing acceleration performance is poor or swing speed is slow in only one direction.
• Set working mode to power (P) mode, and perform all troubleshooting with power mode
(P).
Related (DHSAKZ, DHSBKZ, DHVAKZ, DHVAL8, DHVBKZ, DHVBL8, DW45KY, or failure code
information that begins with "GA")
• Swing PPC pressure can be checked even with monitoring function (Monitoring code:
Malfunction of swing PPC L.H. work equipment control lever PPC valve output pressure
1
valve NEUTRAL 0 MPa {0 kg/cm2}
2.84 to 3.43 MPa
Left swing/Right swing
{29 to 35 kg/cm2}
If no failure is found by checks on causes 1, hybrid controller may be
2 Defective inverter defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
40-776 HB215LC-2
40 Troubleshooting
Y-4 Upper structure overruns excessively when it stops swinging (HB380-K14-

400-A-Z0-A)
Failure (1) Upper structure overruns excessively when it stops swinging (both right and left)
information
1 Wrong software Confirm software version.
Failure (2) Upper structure overruns excessively when it stops swinging (either right or left)
information
Malfunction of swing PPC L.H. work equipment control lever
1 output pressure
valve
2.84 to 3.43 MPa
Left swing and right swing
{29 to 35 kg/cm2}
2 Wrong software Confirm software version.
HB215LC-2 40-777
40 Troubleshooting
Y-5 Shock is large when upper structure stops swinging (HB380-K15-400-A-Z0-A)
Failure • Shock is large when upper structure stops swinging

information
Malfunction of swing PPC L.H. work equipment control lever
1 output pressure
valve
2.84 to 3.43 MPa
Left swing and right swing
{29 to 35 kg/cm2}
40-778 HB215LC-2
40 Troubleshooting
Y-6 Large unusual noise is heard when upper structure stops

swinging (HB380-K16-400-A-Z0-A)
Failure • Large unusual noise is heard when upper structure stops swinging (both right and left)
information
Swing machinery may have internal defect. Check it.
1 Defective swing machinery *Check for unusual noise, unusual heat, and metallic powders in
HB215LC-2 40-779
40 Troubleshooting
Y-7 Swing drift on a slope is large (HB205-K17-400-A-Z0-A)
Failure (1) Swing drift on a slope is large (while parking brake is applied).
• When swing lock switch is set to ON position or swing parking brake cancel switch is set
Related to NORMAL position, swing parking brake is applied and swing system is locked by disc
information brake.
Malfunction of swing parking Swing parking brake solenoid
1 L.H. work equipment control lever
brake solenoid valve output pressure
Left swing/Right swing 2.9 MPa {30 kg/cm2}
Malfunction of swing parking Since parking brake of swing motor may malfunction. Check it.
2
brake
Failure (2) Swing drift on a slope is large (while swing parking brake is released).
• When swing lock switch is set to ON position or swing parking brake cancel switch is set
Related to NORMAL position, swing parking brake is applied and swing system is locked by disc
information brake.
1 Defective swing motor Since swing motor may be defective, check it.
Hybrid controller may be defective.
2 Defective inverter
40-780 HB215LC-2
40 Troubleshooting
Y-8 Electric swing motor temperature increases abnormally (HB380-K18-400-A-Z0-A)
Failure • Electric swing motor overheats and failure code [GA70NS] is displayed.
Check if operator has repeatedly performed swing and swing stopping
1 discharge of capacitors (when
only.
system is normal)
Ground fault in electric swing
motor coil temperature sensor
2 harness See failure codes [GA70NS] and [GA71KZ].
Insufficient cooling
3 Check oil level with dipstick, and add oil if it is low.
(lubricating) oil
Defective cooling (lubricating) Check cooling (lubricating) oil for metallic powder and other
4
oil contaminants.
a Be ready with engine stopped, then troubleshoot with engine at high
Defective lubricating oil idle.
5 passages in electric swing Place all control levers in NEUTRAL position Max. 0.3
motor Pressure and take measurements at pressure pickup MPa {3.1
plugs. kg/cm2}
Clogging of cooling
6 Check it and clean if any dirt is seen.
(lubricating) oil filter
Lubrication pump may malfunction or has internal defect. Check it by
following method.
7 Defective lubrication pump 1. Disconnect hose from electric swing motor cooling (lubricating) oil
inlet.
2. Turn engine by manually cranking at flywheel.
3. It is normal if oil flows from disconnected hose.
If coolant level cannot be seen in sight glass on hybrid radiator, add
8 Low coolant level coolant through filler port until coolant level appears in sight glass.
Defective wiring or open circuit
9 See failure code [GA1TNS].
in water pump
10 Defective water pump impeller Unusual noise or vibration is generated from water pump.
Since air may be trapped at the water pump suction side, check it by
following method.
Air trapped at water pump 1. Open radiator cap on the hybrid radiator.
11
suction side 2. Turn starting switch to ON position to run the water pump.
3. If unusual noise or vibration is not generated from water pump and
coolant level is seen in sight gauge, the system is normal.
Clogged or crushed hybrid Check hybrid radiator fins.
12
radiator fins
13 Clogged hybrid radiator core Check hybrid radiator core.
Defective hybrid radiator cap If coolant flows out from hybrid radiator overflow hose, check hybrid
14 (pressure valve) radiator cap.
Insufficient water pressure of
15 hybrid coolant Perform Testing and adjusting, "Check hybrid coolant pressure".
Slipping fan belt, worn fan If dust or dirt is not clogged inside radiator shrouds or undercovers,
16 pulley check fan belt and fan pulley.
17 Defective electric swing motor
18 controller)
HB215LC-2 40-781
40 Troubleshooting
Y-9 Motor-generator temperature increases abnormally (HB205-K19-400-A-Z0-A)
Failure • Motor-generator temperature increases, and failure code [GA61NS] is displayed.

• Motor-generator temperature can be checked with monitoring function.
Related (Code: 09600 Generator Motor Temperature)
1 discharge of the capacitor Check if it has only swung or stopped swinging repeatedly.
(when system is normal)
Motor-generator temperature
sensor wiring harness short
2 circuiting See failure code [GA61KZ] and [GA61NS]
Low oil level of cooling
3 Check the oil level with dipstick, and refill it if the level is low.
(lubricating) oil
Defective cooling (lubricating) Check if water or metallic powder is mixed in cooling (lubricating) oil.
4
oil
Defective lubricating oil route troubleshooting.
5 in motor-generator 0.6 MPa
Set all control lever to NEUTRAL position, and
Pressure {6.1 kg/
measure it with pressure pickup plug.
cm2}
Clogging of cooling
6 Check it, and clean it if it is contaminated.
(lubricating) oil filter
lubrication pump may malfunction or has internal defect. Check it by
following method.
7 Defective lubrication pump 1. Disconnect inlet hose of cooling (lubricating) oil of motor-generator.
2. Perform cranking (manual rotation) at flywheel part.
3. If oil flows from disconnected hose, it is normal.
Radiator coolant temperature may be overheating. Perform
Radiator coolant temperature troubleshooting for S-mode, "S-17 Coolant temperature rises too high
8
overheat (overheating)",
10 controller)
40-782 HB215LC-2
40 Troubleshooting
Y-10 Inverter temperature increases abnormally (HB380-K1A-400-A-Z0-A)
• Inverter overheats, and either failure code [GA1ZNS] or [GA1YNS] is displayed, or both
Failure codes are displayed.
• Inverter booster IGBT temperature and booster inductor temperature can be checked
Related with monitoring function.
information (Code: 09402, 09403)
only.
system is normal)
in water pump
4 Defective water pump impeller Unusual noise or vibration is not generated from water pump.
following method.
5
suction side 2. Turn the starting switch to ON position to run the water pump.
6
radiator fins
9 Perform Testing and adjusting, "Check hybrid coolant pressure".
hybrid coolant
Slipping fan belts, worn fan If dust or dirt is not clogged inside radiator shrouds or undercovers,
10 pulley check fan belts and fan pulley.
Defective engine and fuel If engine speed lowers significantly due to defective engine, fuel
11 system system and pump, or hydraulic system, the frequency of assistance
increases, possibly reporting this error. Check engine speed by
referring to item "Engine speed when 2 pumps relieved" of standard
Defective pump and hydraulic value table in Chapter 20. If the engine speed is out of the standard
12 system value range, perform troubleshooting by referring to the following.
• "S-7 Engine runs rough or is unstable" (S mode)
• "H-2 Engine speed drops significantly or engine stalls" (H mode)
Defective inverter (hybrid Since this is a high voltage part, inspection or troubleshooting cannot
13 controller) be performed.
HB215LC-2 40-783
40 Troubleshooting
Y-11 Capacitor temperature increases abnormally (HB380-K1B-400-A-Z0-A)
Failure • Capacitor overheats and failure code [GA1TNS] is displayed.

• Capacitor cell center temperature and capacitor base temperature can be checked with
Related (Code: 09306, 09304)
information • Capacitor cell center temperature is a calculated value derived from capacitor base
temperature.
only.
system is normal)
Ground fault in capacitor base
2 temperature sensor harness See failure code [GA1TNS].
in water pump
5 Defective water pump impeller Unusual noise or vibration is generated from water pump.
following method.
6
suction side 2. Turn the starting switch to ON position to run the water pump.
7
radiator fins
10 Perform Testing and adjusting, "Check hybrid coolant pressure".
hybrid coolant
Slipping fan belts, worn fan If dust or dirt is not clogged inside radiator shrouds or undercovers,
11 pulley check fan belts and fan pulley.
Defective engine and fuel If engine speed lowers significantly due to defective engine, fuel
12 system system and pump, or hydraulic system, the frequency of assistance
increases, possibly reporting this error. Check engine speed by
referring to item "Engine speed when 2 pumps relieved" of standard
Defective pump and hydraulic value table in Chapter 20. If the engine speed is out of the standard
13 system value range, perform troubleshooting by referring to the following.
• "S-7 Engine runs rough or is unstable" (S mode)
• "H-2 Engine speed drops significantly or engine stalls" (H mode)
14 Defective capacitor Perform check 1. in common troubleshooting of high-voltage parts.
40-784 HB215LC-2
SHOP MANUAL HB205-2,HB215-2
SJA01980-01
?????????
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
50 Disassembly and assembly

7 50 Disassembly and assembly
HB215LC-2 50-1
Table of contents
Table of contents
50 Disassembly and assembly ........................................................................................................... 50-1
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Precautions related to hybrid equipment ................................................................................ 50-6
Coating materials list ............................................................................................................ 50-7
Special tools list ................................................................................................................. 50-11
Sketches of special tools .................................................................................................... 50-16
Engine and cooling system ........................................................................................................ 50-23
Removal and installation of supply pump assembly............................................................... 50-23
Removal and installation of injector assembly....................................................................... 50-27
Removal and installation of cylinder head assembly.............................................................. 50-33
Removal and installation of radiator assembly ...................................................................... 50-51
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-54
Removal and installation of aftercooler assembly .................................................................. 50-57
Removal and installation of engine, motor-generator, and main pump assembly ...................... 50-59
Removal and installation of fan belt...................................................................................... 50-71
Removal and installation of starting motor ............................................................................ 50-74
Removal and installation of engine front oil seal .................................................................... 50-76
Removal and installation of engine rear oil seal..................................................................... 50-79
Removal and installation of fuel cooler assembly .................................................................. 50-82
Removal and installation of fuel tank assembly ..................................................................... 50-84
Removal and installation of engine hood assembly ............................................................... 50-86
Removal and installation of KDOC assembly ........................................................................ 50-89
Removal and installation of KCCV assembly ........................................................................ 50-90
Removal and installation of air cleaner assembly .................................................................. 50-96
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly........................ 50-97
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly....................... 50-99
Hybrid system ........................................................................................................................ 50-102
Draining coolant, refilling with coolant, and bleeding air for hybrid system ............................. 50-102
Removal and installation of hybrid radiator assembly .......................................................... 50-106
Removal and installation of hybrid water pump assembly .................................................... 50-109
Removal and installation of inverter assembly .....................................................................50-111
Removal and installation of inverter and capacitor assembly ................................................ 50-114
Procedure for draining and refilling generator lubricating oil ................................................. 50-119
Removal and installation of tandem pump assembly ........................................................... 50-121
Removal and installation of motor-generator and housing assembly ..................................... 50-124
Removal and installation of electric swing motor assembly .................................................. 50-131
Power train system ................................................................................................................. 50-136
Removal and installation of travel motor and final drive assembly ......................................... 50-136
Disassembly and assembly of final drive ............................................................................ 50-137
Removal and installation of swing motor and swing machinery assembly .............................. 50-146
Disassembly and assembly of swing machinery assembly................................................... 50-150
Removal and installation of swing circle assembly .............................................................. 50-164
Undercarriage and frame......................................................................................................... 50-165
Separation and connection of track shoe assembly ............................................................. 50-165
Removal and installation of sprocket.................................................................................. 50-168
Removal and installation of idler and idler cushion assembly ............................................... 50-169
Disassembly and assembly of idler assembly ..................................................................... 50-170
Disassembly and assembly of idler cushion assembly......................................................... 50-172
Disassembly and assembly of track roller assembly ............................................................ 50-174
Disassembly and assembly of carrier roller assembly .......................................................... 50-176
Removal and installation of revolving frame assembly ......................................................... 50-179
Removal and installation of counterweight assembly ........................................................... 50-181
Hydraulic system .................................................................................................................... 50-184
Removal and installation of center swivel joint assembly ..................................................... 50-184
Disassembly and assembly of center swivel joint assembly ................................................. 50-187
Table of contents
50-2 HB215LC-2
Table of contents
Removal and installation of hydraulic tank assembly ........................................................... 50-189

Removal and installation of main pump assembly ............................................................... 50-192
Removal and installation of control valve assembly ............................................................. 50-196
Disassembly and assembly of control valve assembly......................................................... 50-200
Disassembly and assembly of work equipment PPC valve................................................... 50-206
Disassembly and assembly of travel PPC valve assembly ................................................... 50-208
Work equipment ..................................................................................................................... 50-210
Removal and installation of work equipment assembly ........................................................ 50-210
Disassembly and assembly of work equipment cylinder assembly........................................ 50-213
Removal and installation of operator's cab assembly........................................................... 50-220
Removal and installation of operator cab glass (adhered glass) ........................................... 50-225
Removal and installation of front window assembly ............................................................. 50-235
Removal and installation of floor frame assembly................................................................ 50-241
Removal and installation of air conditioner unit assembly..................................................... 50-247
Removal and installation of operator's seat......................................................................... 50-251
Removal and installation of seat belt .................................................................................. 50-253
Removal and installation of work equipment control lever assembly ...................................... 50-254-1
Removal and installation of front wiper assembly ................................................................ 50-255
Removal and installation of air conditioner compressor assembly......................................... 50-262
Removal and installation of air conditioner condenser assembly .......................................... 50-264
Removal and installation of engine controller assembly ....................................................... 50-266
Removal and installation of pump controller assembly......................................................... 50-268
Removal and installation of machine monitor assembly ....................................................... 50-271
Removal and installation of pump swash plate sensor ......................................................... 50-273
Removal and installation of mass air flow and temperature sensor ....................................... 50-274
Removal and installation of KOMTRAX terminal assembly .................................................. 50-275
HB215LC-2 50-3
Related information on disassembly and assembly
Related information on disassembly and assembly (ALL-3851-001-A-00-A)
How to read this manual (ALL-0320-011-A-00-A)

(Rev.2013.05)
Removal and installation of 6666 assembly • The general tools required for "Installation" are
Special tools listed as [1], [2], ..., without description of part
• The special tools required for removal and number, part name, and quantity.
installation work are described in the list as • Marks used in "Installation" section are
symbols such as A1, ..., X1. Part number, part explained below.
name, necessity, and quantity are described. k: This mark shows safety-related precautions
• Mark used in the column of necessity are which must be followed when performing the
explained below. work.
V: Tools are not substituted, must always be
equipped (used). C : This mark gives knowledge or precautions
S: Tools extremely useful if available or tools when performing the work.
that can be substituted with commercially
available tools. 4 : This mark shows the weight of the part
• For details and the sketches of the special tools, or equipment.
see "Special tool list" and "Sketches of special
tools." 2 : This mark shows a specific coating
agent to be used.
Removal
• In "Removal" section, the work procedures, 3 : This mark shows the specified
precautions and know-how to do the work, and tightening torque.
the amount of oil and coolant to be drained are
described. 5 : This mark shows the amount of oil or
• The general tools required for "Removal" are coolant to be added.
listed as [1], [2], ..., without description of part • For details of oil or coolant to be
number, part name, and quantity. added after installation, see
• Marks used in "Removal" section are explained Specification "Table of fuel, coolant
below. and lubricants".
k: This mark shows safety-related precautions Disassembly and assembly of 6666 assembly
which must be followed when performing the Special tools
work. • The special tools required for disassembly and
assembly work are described in the list as
C : This mark gives knowledge or precautions
symbols such as A1, ..., X1. Part number, part
when performing the work.
name, necessity, and quantity are described.
[*1]: This mark indicates that knowledge or • Mark used in the column of necessity are
precautions for the assembly installation work are explained below.
given in the "Installation" section. V: Tools are not substituted, must always be
equipped (used).
6 : This mark shows the amount of oil or S: Tools extremely useful if available or tools
coolant to be drained. that can be substituted with commercially
available tools.
4 : This mark shows the weight of the part • For details and the sketches of the special tools,
or equipment. see "Special tool list" and "Sketches of special
Installation tools."
• The work procedure of "Installation" is in the Disassembly
reversed order to removal unless otherwise • "Disassembly" describes the work procedure as
specified. well as the precautions, knowledge, and drain
• For knowledge and precautions required for amounts of oil and coolant required for the work.
"Installation", a [*1] mark is assigned to the • The general tools required for "Disassembly" are
"Removal" work procedure to indicate the work listed as [1], [2], ..., without description of part
item of the installation knowledge or precaution. number, part name, and quantity.
Related information on disassembly

50-4 and assembly
HB215LC-2
• Marks used in the section of "Disassembly" are

explained below.
k: This mark shows safety-related precautions
which must be followed when performing the
work.

6 : This mark shows the amount of oil or

coolant to be drained.
4 : This mark shows the weight of the part

or equipment.
Assembly
• "Assembly" describes the work procedure as
well as the precautions, knowledge, and drain
amounts of oil and water required for the work.
• The general tools required for "Assembly" are
listed as [1], [2], ..., without description of part
number, part name, and quantity.
• Marks used in the section of "Assembly" are
explained below.
k: This mark shows safety-related precautions
which must be followed when performing the
work.

4 : This mark shows the weight of the part

or equipment.
2 : This mark shows a specific coating
agent to be used.
3 : This mark shows the specified
tightening torque.
5 : This mark shows the amount of oil or

coolant to be added.
• For details of oil or coolant to be
added after installation, see
Specification "Table of fuel, coolant
and lubricants".
HB215LC-2 50-5
k Before performing testing and adjusting related to hybrid equipment, understand the following
items fully.
1. Only personnel who completed the special training for low-voltage electric work can perform removal of
hybrid equipment (motor-generator, capacitor, inverter, electric swing motor) and high-voltage wires.
2. Even qualified personnel can never disassemble the equipment listed above for quality assurance
reasons.
4. Before removing hybrid equipment, make sure to discharge the capacitors first.
(For details, see Testing and Adjusting, "Discharge of capacitor electric charge" in "Special functions of
machine monitor".)
C However, capacitors can be discharged by using the machine monitor only when the hybrid system is
operating normally.
C If any of failure code GA**** explained in the next page is displayed indicating the hybrid system is
abnormal, capacitors cannot be discharged by using the machine monitor even if the monitor instructs to
perform the discharge operation. (Conditions to consume the electric charge of the capacitors are not
met.) Therefore, use the special capacitor discharging generator 796-426-1800.
C Capacitor voltage may not be completely 0 V when its charge is 0 %. Voltage tends to be restored after
discharge due to the characteristics of the capacitor. Take extreme care when removing power cable
connectors.
C Avoid key switch operations as described below after discharging the capacitors, since this will cause the
capacitors to be recharged.
• After turning the key switch to the OFF position, the switch should not be turned to the ON position
before the engine stops completely.
• After turning the key switch to the OFF position and the engine stops completely, the engine should not
be started by turning the key switch to the ON position.
k The items with the mark relate to handling of hybrid equipment. Before performing work,
understand 00-200 Foreword, Safety, Basic information, "Handling Hybrid Equipment and High-
Voltage Wires".
C For monitoring items applicable to troubleshooting of hybrid equipment, refer to list in Failure code
[GA——] (Separate sheet 1).
C For the check sheet to record results of diagnostic checks on abnormal hybrid equipment, refer to Failure
code [GA——] (Separate sheet 2). (This check sheet is used when making inquiries to the factory.)
complete. Do not work with bare hands. Always wear insulating gloves.
C When a connector is removed at the capacitor side, cover the connector halves (harness and capacitor
sides) with plastic bags, etc. to prevent entry of foreign material.
C Perform troubleshooting with the engine stopped.
C Do not connect the tester directly to the connector at the capacitor (female) side.
50-6 HB215LC-2
Coating materials list (ALL-3540-071-A-00-A)
(Rev.2012.11)
C The coating materials such as adhesives, liquid gasket, and grease used for disassembly and assembly
are listed below.
C For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming
out.
• Use for plastic (except polyethylene,
20 g Polyethy- polypropylene, tetrafluoroethylene and
LT-1B 790-129-9050 (contained 2 lene vinyl chloride), rubber, metal, and non-
pieces) container metal parts which require immediate
and strong adhesion.
• Features: Resistance to heat and
Polyethy- chemicals
LT-2 790-129–9180 50 g lene • Use to prevent bolts and plugs from
container coming loose and as sealant.
Adhesive:
790-129-9060 1 kg • Use to bond and seal metal, glass and
LT-3 Set of adhesive Can plastics.
Hardener:
and hardener 500 g
Polyethy-
LT-4 790-129-9040 250 g lene • Use to seal plugs for blank holes.
container
• Heat-resistant seal used to repair
Holts MH705 790-129-9120 75 g Tube engines
• Instantaneous adhesive
Polyethy- • Curing time: From 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 50 g lene • Use mainly to bond metals, rubbers,
container plastics, and woods.
• Instantaneous adhesive
2g Polyethy- • Quick-curing type (max. strength is
Aron Alpha 201 790-129-9130 (contained 5 lene obtained after 30 minutes)
pieces) container • Use mainly to bond rubbers, plastics,
and metals.
• General-purpose instantaneous
adhesive with excellent resistance to
Loctite 499 428-99-80070 20 cc Tube heat and impact
• Use on the bushing mounting faces of
axle supports.
Polyethy- • Features: Resistance to heat and
Loctite 648-50 79A-129-9110 50 cc lene chemicals
container • Use to bond high-temperature fit parts.
HB215LC-2 50-7
Liquid gasket
• Use to seal various threaded parts,
LG-5 Polyethy- pipe joints, and flanges.
790-129-9080 1 kg lene
ThreeBond 1110F • Use to seal taper plugs, elbows, and
container nipples for hydraulic piping.
• Features: Silicon-based heat and cold-
LG-6 resistant sealant.
790-129-9160 250 g Tube • Use to seal flange surface and
ThreeBond 1215 threaded parts.
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
LG-7 sealant
790-129-9170 150 g Tube • Use to seal flywheel housing, intake
ThreeBond 1207C manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based heat, vibration,
419-15-18131 100 g Tube and shock-resistant sealant.
ThreeBond 1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the
LG-9 circle gear top seal which is not
790-129-9310 200 g Tube clamped by bolts, gaps in the weld
ThreeBond 1206D which must be caulked, etc.
• Can be coated with paint.
• Use as lubricant or sealant when the
LG-10
790-129-9320 200 g Tube radiator hoses are put on.
ThreeBond 1206E • Can be coated with paint.
• Feature: Can be used together with
LG-11 solid gaskets.
790-129-9330 200 g Tube
ThreeBond 1121 • Use for covers of the transmission case
and steering case etc.
ThreeBond 1211 790-129-9090 100 g Tube • Liquid gasket used to repair engine
Molybdenum disulfide lubricant

• Use to prevent galling and seizure of
press-fitted parts, shrinkage-fitted
LM-P 09940-00040 200 g Tube parts, and threaded parts.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S 09995-00250 190 g Can metals from galling.
• Use for the drive shaft splines, needle
bearings, various link pins, bolts, etc.
50-8 HB215LC-2
Seizure prevention compound

• Feature: Seizure and galling prevention
compound with metallic super-fine-
LC-G grain, etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust
manifold and the turbocharger, etc.
Grease
SYG2-400LI-A
G2-LI SYGA-16CNLI • Lithium grease with extreme pressure
G0-LI(*) SYG0-400LI-A Various Various lubrication performance, general
*: For cold districts (*) purpose type.
SYG0-16CNLI (*)
• Use for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows- • Do not use this grease for rolling
disulfide grease type bearings like swing circle bearings,
SYG2-400M-A 400 g x 20 container etc. and spline.
LM-G(G2-M) SYGA-16CNM 16 kg Can • Use this grease for work equipment
pins only when installing them, but
do not use it afterward.
Hyper white SYG2-400T • Higher seizure resistance, heat
grease Bellows-
SYG2-16CNT 400 g type resistance, and waterproof than
G2-T molybdenum disulfide grease
SYG0-400T(*) 16 kg container
G0-T(*) • Not conspicuous on machine since
SYG0-16CNT(*) Can color is white.
*: For cold districts
Biogrease
SYG2-400B
G2-B Bellows-
SYGA-16CNB • Since this grease is biodegradable in
G2-BT(*) 400 g type
SYG2-400BT(*) container short period, it has less impact on
*: For use at high 16 kg microorganisms, animals, and plants.
SYGA-16CNBT Can
temperature and
(*)
under high load
• Feature: Silicon-based grease with
wider operating temperature range and
G2-S superior thermal oxidative stability to
— 200 g Tube prevent deterioration of rubber and
ThreeBond 1855 plastic.
• Use for oil seals of the transmission,
etc.
• Feature: Urea (organic) grease with
heat resistance and long life, inclusion
type.
G2-U-S
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
ENS grease
damper.
Caution: Do not mix with lithium
grease.
HB215LC-2 50-9
Primer
Glass • Use to accelerate hardening of
Loctite 712 428-99-80080 100 mN
container instantaneous adhesive.
SUNSTAR Paint • Use as primer for cab side.
Glass (Effective period: 4 months after
Surface Primer 20 mN
container manufacture)
580 SUPER
417-926-3910
SUNSTAR Glass • Use as primer for glass side.
Glass (Effective period: 4 months after
Primer 580 20 mN
container
For adhered window glass

SUPER manufacture)
• Use as primer for painted cab sheet
SUNSTAR Paint metal surface.
Glass
Surface Primer 22M-54-27230 20 mN (Effective period: 4 months after
container
435-95 manufacture)
• Use as primer for black ceramic-
SUNSTAR coated glass surface and for hard
PRIMER 435-41 22M-54-27240 150 mN Steel can polycarbonate-coated surface.
for glass (Effective period: 4 months after
manufacture)
• Use as primer for sash (alumite
SUNSTAR sash Glass surface treatment).
primer GP-402 22M-54-27250 20 mN (Effective period: 4 months after
container
manufacture)
Adhesive
• Use "S" as adhesive for glass in
high temperature months (during
SUNSTAR Polyethy- summer) and "W" in low

Penguin Seal 580 417-926-3910 320 mN lene temperature months (during winter).
SUPER "S" or "W" container (Effective period: 4 months after
manufacture)
• Use as adhesive for glass.
Sika Japan Cartridge (Effective period: 6 months after
20Y-54-39850 310 mN
Sikaflex 256HV manufacture)
SUNSTAR Ecocart • Use as adhesive for glass.
Penguin Super 22M-54-27210 320 mN (special (Effective period: 6 months after
560 container) manufacture)
Caulking material
SUNSTAR • Use to seal glass-to-glass joint.
Cartridge (Effective period: 4 months after
Penguin Seal 417-926-3920 330 mN

No.2505 manufacture)
• Use to seal front window.
SEKISUI Silicone Cartridge (Effective period: 6 months after
20Y-54-55130 333 mN
Sealant 83 manufacture)
• Translucent white seal used for joint

GE TOSHIBA seals between glasses
SILICONES 22M-54-27220 333 mN Cartridge
(Effective period: 12 months after
TOSSEAL381 manufacture)
50-10 HB215LC-2
Specialtoolslist
C Toolswithpartnumber79*T-***-****arenotsupplied(tobelocallymanufactured).
C Necessity
V: Tools are not substituted, must always be equipped (used).
S: Tools extremely useful if available or tools that can be substituted with commercially available tools.
C New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
C Tools marked with 3 in the sketch column have the sketches (See "Sketches of special tools").
New/Redesign
Necessity
Sketch
Q'ty
Work Symbol Part No. Part name Contents of operation
Removal and Removal and installation

13 795-799-6130 Support V 1 of gear
installation of A
supply pump 14 790-101-3000 Push puller S 1 Removal of gear
1 795-799-1131 Gear V 1 Adjusting valve clearance
Removal and
installation of 2 795-799-8150 Remover S 1 Removal of inlet connector
A
injector assembly Removal of injector
3 795-799-6700 Puller V 1
assembly
1 795-799-1131 Gear V 1 Adjusting valve clearance
2 795-799-8150 Remover S 1 Removal of inlet connector
Removal and Removal of injector
installation of 3 795-799-6700 Puller V 1
assembly
cylinder head A
Angle tightening Angle tightening of bolts
assembly 6 790-331-1120 S 1
wrench
Judgment of mounting bolt
7 795-790-4510 Gauge S 1 length for cylinder head
Removal and 1 796-460-1210 Oil stopper S 1
installation of Shutting off of oil in
hydraulic oil cooler R 2 796-770-1320 Adapter S 1 hydraulic tank
assembly
Removal and
installation of
Removal and installation
engine, motor- A 8 796T-401-1110 Plate S 1 3 of engine mount
generator, and main
pump assembly
of engine, motor-
9 795-799-9300 Lifting tool S 1 generator, and main pump
Removal and A assembly
installation of Measurement of insulation
engine, motor- Commercially Megohm tester resistance of motor-
12 V 1
generator, and main available generator
pump assembly
B 1 7875-35-2910 Cap V 2 Protecting connector part
1 796-460-1210 Oil stopper S 1 Shutting off of oil in
R hydraulic tank
2 796-770-1320 Adapter S 1
Commercially
Removal and 18 Ratchet handle S 1 of fan belt and alternator
available
installation of fan A belt
belt Commercially Adapter Removal and installation
19 S 1
available of alternator belt
HB215LC-2 50-11
New/Redesign
Necessity
Sketch
Q'ty
Removal and Installation of engine front

4 795-799-6400 Seal puller V 1
installation of oil seal
A
engine front oil seal Angle tightening Angle tightening of bolts
6 790-331-1120 S 1
wrench
Removal and
installation of Installation of engine rear
A 5 795-799-6500 Seal puller V 1
engine rear oil seal oil seal
Removal and
installation of B 1 7875-35-2910 Cap V 4 Protecting connector part
inverter assembly
Removal and Positioning of inverter and
installation of 4 796T-426-1110 Assembling jig V 1 3 capacitor assembly
inverter and B
capacitor assembly 1 7875-35-2910 Cap V 4 Protecting connector part
Measurement of insulation
Commercially Megohm tester resistance of motor-
A 12 S 1
Removal and available generator
installation of 1 7875-35-2910 Cap V 2 Protecting connector part
motor-generator
2 796T-410-1110 Plate V 1 N 3
and housing Removal and installation
assembly B 3 796T-410-1200 Plate V 1 N 3
of motor-generator and
4 01010-81235 Bolt V 2 housing assembly
5 01643-31232 Washer V 2
Removal and Removal and installation
installation of F 4 01124-51490 Guide bolt V 3 of electric swing motor
electric swing motor assembly
assembly B 1 7875-35-2910 Cap V 1 Protecting connector part
1 796-427-1400 Wrench assembly V 1 of ring nut
2 796-427-1520Installer V 1 Installation of floating seal
3 796T-427-1510Push tool V 1 3
3 790-101-2510Block V 1
3 790-101-3310Plate V 1
3 790-101-2610 Leg V 2
3 790-101-2730 Adapter V 2 Press fit of bearing
3 790-101-2560 Nut V 2
Disassembly and 3 790-101-2570 Plate V 4
assembly of final J Puller (294kN {30
3 790-101-2102 ton}) V 1
drive assembly
3 790-101-1102 Pump V 1
Tightening of cover
4 790-331-1110 Wrench V 1
mounting bolt
Installation of hub
5 796T-427-1710 Guide V 1
assembly
6 790-101-3601 Gear puller S 1
Removal of bearing
6 790-201-2660 Plate S 1
7 792T-423-1350 Push tool S 1 3 Press fit of bearing
Measurement of tangential
8 79A-264-0091 Push-pull scale V 1
force
Removal and
installation of B 1 7875-35-2910 Cap V 1 Protecting connector part
electric swing motor
50-12 HB215LC-2
New/Redesign
Necessity
Sketch
Q'ty
and swing
machinery
assembly
1
796T-426-1130 Plate V 1 3
1790-101-5421 Push tool V 1
Removal of shaft
101010-81240 Spacer V 1
2796-426-1120 Push tool V 1
3
796T-426-1410 Push tool V 1 3 Removal of bearing
Disassembly and 401124-51490 Guide bolt V 3 Press fit of bearing
assembly of swing 5 1 796-426-1710 Collet V 1
machinery F
5 2 796-426-1720 Taper cone V 1
assembly Press fit of oil seal
5 3 796-426-1730 Collar V 1
6 790-201-2710 Spacer S 1
7 790-201-2740 Spacer S 1
8 790-201-2890 Spacer S 1 Press fit of bearing
9 793T-615-1760 Spacer S 1 3
10 790-201-2660 Plate V 1 Installing spirolock
Remover and
1 791-630-3000 V 1
Separation and installer
Cylinder (980 kN Removal and installation
connection of track N 2 790-101-1300 {100 ton}) V 1 of master pin
shoe assembly
3 790-101-1102 Hydraulic pump V 1
Disassembly and
J 791-530-1510 Installer V 1 Installation of floating seal
assembly of idler
791-600-2001 Compressor (A)
1 or Compressor (B)
V 1
791-685-8006
1 790-201-2780 Spacer V 1 Disassembly and
1 791-635-3160 Extension V 1 assembly of idler cushion
Cylinder (686 kN assembly
1 790-101-1600 {70 ton})
V 1
1 790-101-1102 Pump V 1
Disassembly and
assembly of idler M 1 791-640-2180 Guide bolt V 1
cushion assembly 2 790-101-5201 Push tool kit (B) S 1
2 790-101-5241 • Plate 1
Press fit of bushing
2 790-101-5221 • Grip 1
2 01010-51225 • Bolt 1
3 790-201-1500 Push tool kit S 1
3 790-201-1620 • Plate 1
Press fit of dust seal
3 790-101-5021 • Grip 1
3 01010-50816 • Bolt 1
Disassembly and 1 796T-667-1120 Push tool V 1 3 Press fit of bushing
assembly of track K
roller assembly 2 796-670-1020 Installer V 1 Installation of floating seal
Disassembly and 1 793T-613-1380 Spacer S 1 3 Removal of shaft, press fit

assembly of carrier L 2 790-201-2820 Spacer V 1 of bushing
roller assembly 3 790-434-1660 Installer V 1 Installation of floating seal
HB215LC-2 50-13
New/Redesign
Necessity
Sketch
Q'ty
796T-430-1310 Push tool V 1 3

Press fit of shaft
796T-430-1310 Spacer V 1 3
Commercially Impact wrench
Removal and 1 S 1
available
installation of Removal and installation
Z Socket wrench
counterweight Commercially (Width across of counterweight assembly
assembly 2 S 1
available flats: 46mm)
790-101-2501 Push puller S 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
Disassembly and
790-101-2540 • Washer 1
assembly of swivel S Removal of rotor and ring
joint assembly 790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2680 • Adapter 2
790-201-1410 Plate S 1
Removal and 1 796-460-1210 Oil stopper S 1
installation of main R
pump assembly 2 796-770-1320 Adapter S 1
Shutting off of oil in
Removal and 1 796-460-1210 Oil stopper S 1 hydraulic tank
installation of
control valve R
2 796-770-1320 Adapter S 1
assembly
796-946-1310 Guide: φ21.8 mm
2 V 1
(for 723-46-40100)
796-946-1810 Guide: φ21.2 mm
2 V 1
(for 723-46-43100, 723-46-43600)
796-946-1910 Guide: φ21.2 mm
2 V 1
(for 723-46-446101, 723-46-46300)
796-946-2210 Guide: φ20.6 mm
2 V 1
(for 723-46-45100)
796-946-1320 Guide: φ21.8 mm
3 V 1
(for 723-46-40100)
796-946-1820 Guide: φ21.2 mm
3 V 1
Disassembly and (for 723-46-43100, 723-46-43600)
Replacing seal of pressure
assembly of control T 796-946-1920 Guide: φ21.2 mm
3 V 1 compensation valve
valve assembly (for 723-46-46101, 723-46-46300)
796-946-2220 Guide: φ20.6 mm
3 V 1
(for 723-46-45100)
796-946-1420 Guide: φ21.6 mm
3 V 1
(for 723-46-42700)
796-946-1330 Sleeve
4 V 1
(for 723-46-40100)
796-946-1830 Sleeve
4 V 1
(for 723-46-43100, 723-46-43600)
796-946-1930 Sleeve
4 V 1
(for 723-46-46101, 723-46-46300)
4 796-946-2230 Sleeve V 1
50-14 HB215LC-2
New/Redesign
Necessity
Sketch
Q'ty
(for 723-46-45100)
796-946-1430 Sleeve
4 V 1
(for 723-46-42700)
796-900-1200 Remover V 1
796-900-1210 • Sleeve 1
792-900-1520 • Plate 1
• Screw 1
Removal and
installation of work 796-900-1240 • Adapter 1
V 01643-33080 • Washer 1 Removal of boom foot pin
equipment
assembly 01803-13034 • Nut 1
Puller (490 kN {50
790-101-4000 ton} long) V 1
Pump (294 kN {30
790-101-1102 ton}) V 1
Cylinder repair Disassembly and
1 790-502-1003 S 1
stand assembly of work
1 790-101-1102 Pump S 1 equipment assembly
2 790-102-4300 Wrench assembly V 1 Removal and installation
2 790-102-4310 Pin V 2 of piston ring
3 790-720-1000 Expander S 1
Rubber band (for
4 796-720-1670 boom, arm) S 1
4 07281-01279 Clamp S 1 Installation of piston ring
Rubber band (for
4 796-720-1660 arm) S 1
Disassembly and 4 07281-01159 Clamp S 1

assembly of work 5 790-201-1702 Push tool kit V 1
equipment cylinder U • Push tool (for
assembly 5 790-201-1940 boom) 1
• Push tool (for
5 790-201-1930 arm) 1
Press fit of bushing
• Push tool (for
5 790-201-1831 bucket) 1
5 790-101-5021 • Grip 1
5 01010-50816 • Bolt 2
6 790-201-1980 Plate (for boom) V 1
6 790-201-1990 Plate (for arm) V 1
6 790-201-1640 Plate (for bucket) V 1 Press fit of dust seal
6 790-101-5021 Grip V 1
6 01010-50816 Bolt V 1
Removal and 2 793-498-1210 Lifter (suction cup) V 2 Holding glass
installation of
operator's cab glass X
(adhered window 3 20Y-54-13180 Stopper rubber V 2 Fixing glass
glass)
HB215LC-2 50-15
Sketches of special tools (HB205-3531-066-A-00-A)
Note) Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A8: Plate
B4: Assembling jig
50-16 HB215LC-2
B2: Plate
B3: Plate
HB215LC-2 50-17
J3: Push tool
J5: Guide
50-18 HB215LC-2
F1: Plate
F3: Push tool
HB215LC-2 50-19
F9: Spacer
K1: Push tool
50-20 HB215LC-2
L1: Spacer
HB215LC-2 50-21
L5: Push tool
L6: Spacer
50-22 HB215LC-2
Removal and installation of supply pump assembly (HB205-AD70-924-K-00-A)
C Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
13 795-799-6130 Support V 1
A
14 790-101-3000 Push puller S 1
k Stop the machine on a level surface, lower

the work equipment to the ground so that it
is stable, and stop the engine.
k Place the lock lever in LOCK position. 4. Remove KCCV assembly. For details, see
"Removal and installation of KCCV assembly".
k Turn the battery disconnect switch to OFF 5. Remove cotter pin (6), and disconnect stay (7).
position, and remove the key.
C When disconnecting the stay, the engine
k After the engine is stopped, the parts are hood is unlocked. Fix the engine hood to
very hot. Wait until all parts are cooled down. keep it open by using a rope, etc.
6. Remove bolts (8) (2 pieces), and remove
Removal (HB205-AD70-520-K-00-A) bracket (9).
1. Close fuel stop valve (1) under the fuel tank.
7. Remove bolts (10) (2 pieces), and remove fuel

splash prevention cover (11).
2. Remove bolt (2), and remove undercover (3).
8. Remove nuts (12a) (2 pieces) and bolts (12) (2

3. Open engine hood (4). pieces), and remove bracket (13).

HB215LC-2 50-23
15.Disconnect connector (24).

16.Remove clamp (25).
17.Remove spray prevention caps (26) and (27),
and remove high-pressure pipe (28). [*4]
18.Disconnect spill tube (28a).
9. Remove clamp (14).

10.Remove bolts (15) (2 pieces).
11.Remove bolts (16) (2 pieces), and remove
bracket (17).
12.Remove joint bolt (18), and then disconnect fuel

return hose (19). [*1] 19.Remove nuts (29) (3 pieces), and remove
13.Remove joint bolt (20), and then disconnect fuel supply pump assembly (30). [*5]
supply hose (21). [*2]
14.Disconnect fuel filter hoses (22) and (23). [*3]
50-24 HB215LC-2
20. Remove the gear from the supply pump according to

the following procedure. [*6]
1) Fix the gear by using tool A13 and 1/2 inch spindle
handle [1], and loosen nut (31).
a Do not remove nut (31) from the shaft.
a Check that the lock is securely fixed.
Installation (HB205-AD70-720-K-00-A)
q Perform installation in the reverse order to removal.
[*1]
Joint bolt (18) of fuel return hose (19): Width across flats
17 mm
3 Joint bolt (18) of fuel return hose (19):
19.6 to 25.5 Nm {2.0 to 2.6 kgm}
2) Remove gear (32) by using tool A14.
[*2]
Joint bolt (20) of fuel supply hose (21): Width across flats
19 mm
3 Joint bolt (20) of fuel supply hose (21):
25.4 to 34.3 Nm {2.6 to 3.5 kgm}
[*3]
q When installing quick coupling type connectors of fuel
filter hoses (22) and (23), observe the following points.
a Since the internal parts of the fitting of the
disconnected hoses or tubes may be damaged,
do not reuse them. For installation, replace them
with new ones.
a Ensure that mud or dirt is not sticking to the hose
joint part in advance.
a Push the connector and insert it straight (in the
direction (b)) without prying or shaking it.
If it is difficult to insert it, do not push it in forcibly
but pull it out once, and check concave and
convex parts for damage and dirt.
3) Remove nut (31), lock washer (33) and gear (32)

from shaft (34).
4)
[*4]
HB215LC-2 50-25
q Install high-pressure pipe (28) according to the

following procedure.
1. Finger-tighten the sleeve nuts and clamp (25) of
high-pressure pipe (28). (both sides)
2. Tighten the sleeve nuts in the order of the supply
pump side → the common rail side.
Sleeve nut: Width across flats 19 mm
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
Clamp (25): Width across flats 15 mm
3 Clamp (25):
24 ± 4 Nm {2.45 ± 0.41 kgm} [*6]
3. Install fuel spray prevention caps (26) and (27). q Install gear (32) according to the following procedure.
a Direct slits of fuel spray prevention caps a Before installation, clean dusts and foreign
outward and downward. substances on the mating surfaces of shaft (34)
a The fuel spray prevention caps are installed so and gear (32), and keep the mating surfaces dry.
that fuel will not spout over the hot part of the 1. Degrease gear (32) and shaft (34) before
engine and catch fire when it leaks by any installing.
chance. 2. Degrease and install lock washer (33) and nut
[*5] (31), and finger-tighten them lightly.
q Install supply pump assembly (30).
a If grease is applied too much to O-ring (35), it will
ooze out. Do not apply grease too much.(Apply it
only to O-ring groove area of B part.)
a When replacing supply pump mounting stud bolt
(36), apply Loctite to stud bolt when inserting it.
3 Stud bolt (36):
12 ± 2 Nm {1.22 ± 0.2 kgm}
3. While fixing the gear by using tool A13 and

1/2-inch spindle handle [1], tighten nut (31).
Mounting nut (31): Width across flats 27 mm
3 Mounting nut (31):
105 ± 5 Nm {10.7 ± 0.51 kgm}
q 105 ± 5 Nm {10.7 ± 0.51 kgm}
Bleed air from the fuel system. For details, see Testing
and adjusting, "Bleeding air from fuel system".
a Since it is difficult to install the cylinder block side
nuts when installing mounting nuts (29) for supply
pump assembly (30), be sure to use a new socket
for their installation.
a If an old socket is used, nut may fall off or the
thread part of nut is damaged due to excess
clearance between the socket and mounting nut
(29).
24 ± 4 Nm {2.45 ± 0.41 kgm}
50-26 HB215LC-2
Removal and installation of injector assembly (HB205-AE60-924-K-00-A)
C Special tools 3. Open the engine hood (3).
Necessity
Sym-
Q'ty
Part No. Part name
bol
2 795-799-6700 Puller V 1
A 3 795-799-1131 Gear V 1
4 795-799-8150 Remover S 1

k Set the lock lever in LOCK position.

4. Remove KCCV assembly. For details, see
k Turn the disconnect switch to OFF position,
5. Remove cotter pin (6), and disconnect stay (7).
and remove the key.
C When disconnecting the stay, the engine
C Write down the installing positions of pipings not hood is unlocked. Fix the engine hood to
to install them wrongly. keep it open by using a rope, etc.
k After the engine is stopped, the parts are
bracket (9).
very hot. Wait until all parts are cooled down.
Removal (HB205-AE60-520-K-00-A)
1. Remove undercover (1).
7. Disconnect the EGR gas temperature sensor

(14).
8. Remove mounting bolts (17) (3 pieces), and
2. Drain the coolant from drain valve (2). remove EGR piping flange (18). [*6]
9. Disconnect tube clamp (55).
6 Coolant: 10.Loosen hose clamps (15) (2 pieces), and
23 N disconnect hose (16). [*6]
HB215LC-2 50-27
11.Disconnect clamp (19), band (20), and

connectors (21) and (22), move wiring harness
assembly (23) aside.
14.Remove fuel spray prevention caps (32) (8

pieces) of fuel high-pressure pipes (28) to (31).
15.Remove fuel high-pressure pipes (28) to (31).
12.Remove bolts (24) (2 pieces), and remove fuel
splash prevention cover (25).
16.Remove blowby duct (33).

17.Remove nuts (34) (4 pieces), and remove head
cover (35).
13.Remove nuts (26) (2 pieces) and bolts (27) (2
pieces), and remove bracket (27a).
18.Remove harness nuts (36) from the injector.

C Installed position of harness
Color of wiring Cylinder No.
harness
White 1, 3
Black 2, 4
C Remove injector harness connector (37) from

the rocker housing only when required.
19.Remove mounting bolts (38) (8 pieces), and
remove rocker arm assembly (39), crosshead
(40), and the rocker arm support.
50-28 HB215LC-2
C Loosen locknut (41) and loosen adjustment

screw (42) several turns so that an excessive
force is not applied to the push rod when the
rocker arm assembly (39) is installed.
C Record the locations and directions of the
crossheads (40) (shapes of holes "a" and
"b"). (Install them in the recorded directions
when reassembling.)
Installation (HB205-AE60-720-K-00-A)
1. Injector assembly
C When replacing an injector assembly with a
new one, be sure to replace the inlet
connector with a new one as well.
C Check that injector sleeve (48) is free from
scratches and dirt.
20.Remove retaining nut (43), and remove inlet
connectors (44) (4 pieces).
C Clean the surrounding area in advance to
prevent mud and dirt from entering into the
hole of inlet connector (44).
C Use tool A4 to remove inlet connector (44).
21.Remove mounting bolts (45) of injector
assembly (47), and remove injector holder (46).
22.Remove injector assembly (47) by using tool A2.
C Be careful to prevent dirt and foreign matter
from entering the mounting part of the
injector assembly (47). 1) Install O-ring (50) and gasket (51) to injector
(49).
C Replace O-ring and gasket with new
ones.
2) Apply engine oil to O-ring (50) of injector (49)
and the cylinder head side.
2 O-ring (50) of injector (49) and
cylinder head side:
Engine oil (EO15W-40)
HB215LC-2 50-29
3) While aligning convex and concave shapes (A),

install injector holder (46) to injector (49).
7) Apply engine oil to O-ring (C) of inlet connector

(44) and cylinder head side (B).
2 O-ring of inlet connector and cylinder
4) Direct fuel inlet hole of injector assembly (47) head side:
toward air intake manifold, and install it to the
cylinder head.
8) Insert inlet connector (44) to the mounting hole of
5) Tighten injector holder mounting bolt (45) by 3 to injector assembly (47), and tighten retaining nut
4 threads. (43) lightly.
6) Check inlet connector on the following points. If a After tightening the nut lightly, tighten it to the
specified torque. If tightening torque is
any abnormality is found, replace it.
insufficient or too much, it will cause fuel
1] When burrs or wear are found on front-end leakage inside the engine.
part (a) or rear-end part (b) of inlet connector. a Install inlet connector so that its positioning ball
2] When foreign matters are found in the edge (D) becomes as guide groove part on head
filter at rear-end (c) of the inlet connector. side.
3] When cracks or deterioration are found on the Retaining nut (43) (tightening lightly): Width
O-ring of inlet connector upper part (d). across flats 24 mm
3 Retaining nut (43) (tightening lightly):
15 ± 5 Nm {1.53 ± 0.51 kgm}
4] When wear or uneven contact are found on

seat surface (e) at tip-end of the inlet
connector. 9) Tighten mounting bolts (45) of injector holder (46)
a If high-pressure fuel leaks through the inlet alternately.
connector, seat surface is eroded and fine Holder mounting bolt (45): Width across flats 8 mm
3 Holder mounting bolt (45):
streaks or cracks appear.
8 ± 0.8 Nm {0.82 ± 0.08 kgm}
10) Tighten retaining nut (43) of inlet connector (44).
Retaining nut (43) (tightening to the specified
torque): Width across flats 24 mm
3 Retaining nut (43) (tightening to the
specified torque):
50 ± 5 Nm {5.1 ± 0.5 kgm}
50-30 HB215LC-2
a Rotate the crankshaft by using tool A3 to adjust

the valve clearance of each cylinder.
3) After adjusting the valve clearance, check that
lock nut (41) is tightened to the specified torque.
Lock nut (41): Width across flats xx mm
3 Lock nut (41):
24 ± 4 Nm {2.45 ± 0.41 kgm}

4) Install harness mounting nuts (36) to injector
assembly (47).
a Check that wiring harness does not interfere
with rocker arm.
a Installed position of harness
Color of wiring
Cylinder No.
harness
White 1, 3
Black 2, 4

1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}

a If the injector wiring harness connector (37) is
removed, apply liquid gasket to O-ring part (53)
and flange surface (54) of connector when
installing.
2. Rocker arm and crosshead assembly
a As for O-ring, apply liquid gasket (3 mm in
1) Install rocker arm assembly (39), crosshead (40), diameter) until O-ring groove is completely
and the rocker arm support. hidden.
a Shape of hole in (a) and (b) parts of crosshead a When O-ring is damaged, replace it as the
is not identical. So when reusing them for the wiring harness assembly.
2
same intake valve or exhaust valve, be sure to
O-ring part and flange surface of
install them in the same direction.
connector:
Liquid gasket (LG-7)
Connector flange mounting bolt (52): Width across
flats 8 mm
3 Connector flange mounting bolt (52):
10 ± 2 Nm {1 ± 0.2 kgm}
a Check that spherical part of adjustment screw

(42) is fitted securely to socket of push rod, and
then tighten mounting bolt (38).
Mounting bolt (38): Width across flats 10 mm
36 ± 5 Nm {3.7 ± 0.5 kgm}

2) Adjust the valve clearance.
a See Testing and adjusting, "Testing and
adjusting valve clearance".
HB215LC-2 50-31
3. Head cover 1) Lightly tighten high-pressure pipes (28) to (31).

1) Install gasket, and install head cover (35) with Sleeve nut: Width across flats 19 mm
mounting nut (34). 3 Sleeve nut:
Mounting nut (34): Width across flats 13 mm 0.2 to 0.8 Nm {0.02 to 0.08 kgm}
3 Mounting nut (34): 2) Fasten fuel high-pressure pipes (28) to (31) to the
24 ± 4 Nm {2.45 ± 0.41 kgm} specified torque according to the following
2) Install blowby duct (33). procedure.
Mounting bolt: Width across flats 3 mm 1] Connector side: (28) o (29)

3 Mounting bolt: 2] Common rail side: (28) o (29)
7 ± 2 Nm {0.7 ± 0.2 kgm} 3] Connector side: (30) o (31)
4] Common rail side: (30) o (31)
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
5] Install fuel spray prevention caps (32) (8
pieces).
k When installing the fuel spray prevention

caps, direct their slits outward and
downward.
q Perform subsequent installation in the reverse order

4. Fuel high-pressure pipe to removal.
k Do not bend the fuel high-pressure pipe to

correct before installing.
k Be sure to use the genuine fuel high-pressure

pipe clamp and strictly observe the specified
tightening torque.
k Install each fuel high-pressure pipe and wiring

harness at least 10 mm apart from each other.
a A fuel high-pressure pipe must be replaced if

dents such as slits (b) or spots (c) are visually
recognizable in taper seal portion (in 2 mm area
from (a) part) of its connection, or if level
difference in portion (d) (2 mm from tip part of
taper seal portion) due to fatigue is large enough
to catch your fingers, because such fuel
high-pressure pipe can induce fuel leakage.
50-32 HB215LC-2
Removal and installation of cylinder head assembly (HB205-A100-924-K-00-A)
C Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
1 795-799-1131 Gear V 1
2 795-799-8150 Remover S 1
A 3 795-799-6700 Puller V 1
Angle tightening
6 790-331-1120 S 1
wrench
7 795-790-4510 Gauge S 1
k Stop the machine on a level surface, lower 4. Remove the KCCV assembly. For details, see
the work equipment to the ground so that it "Removal and installation of KCCV assembly".
is stable, and stop the engine. 5. Remove the air conditioner compressor
assembly. For details, see "Removal and
k Turn the battery disconnect switch to OFF installation of air conditioner compressor
position, and remove the key. assembly".
k After the engine is stopped, the parts are remove bracket (6).
Removal (HB205-A100-520-K-00-A)
7. Remove the KDOC assembly. For details, see

"Removal and installation of KDOC assembly".
remove bracket (8).
2. Drain the coolant from drain valve (2).
6 Coolant:
23 N
9. Remove heat insulation cover (10).
3. Open the engine hood, and remove cover (4).
HB215LC-2 50-33
15.Remove lubrication return tube mounting bolts

(19) (2 pieces), and disconnect lubrication tube
(20).
16.Remove turbocharger assembly (21).
C Place the plastic bag of exhaust opening of
the exhaust manifold to protect it from dust or
dirt.
10.Disconnect clamp (9). [*1]
17.Disconnect the EGR gas temperature sensor

(22).
18.Loosen hose clamps (23) (2 pieces), remove
mounting bolts (24) (3 pieces) and clamp (126),
and disconnect tube (25). [*3]
11.Remove joint bolts (12), (13), and (14).
12.Loosen clamps (15) and (16). [*2]
13.Remove mounting bolts (17) (4 pieces).
14.Disconnect hose (15a) from the turbocharger
assembly.
19.Disconnect clamp (26).

20.Remove mounting bolt (27).
remove bracket (29).
disconnect tube (31).
23.Remove spill tubes (26a), (26b), and (26c).
50-34 HB215LC-2
24.Remove clamp (80) and tube (81). 28.Remove fan belt (91) according to the following
25.Remove clamp (82), and remove tube (83). procedure.
C When removing the hose clamp, be careful it 1) Set tool A18 and tool A19.
does not exceed the adjustment range of
worm gear.
If it is removed by widening the band by hand,
it may be deformed and cause water leakage.
2) Install set tool A18 and tool A19 to part A

(width across flats: 12.7 mm) of tensioner
assembly (92).
3) Turn tool A19 in the direction opposite to the
winding-up direction (R) to loosen the tension
26.Remove mounting bolts (32) (8 pieces) and
of fan belt (91), and remove fan belt (91).
(32a) (2 pieces), and remove exhaust manifold
(33). [*4]
k Do not attach a pipe to use tool A19. (The
pipe may come off when you turn it, and
that is very dangerous.)
k Before turning tool A19, check that tool

A19 and tool A18 are connected securely
and part (a) of tool A18 is set securely to
part A of tensioner assembly (92). (If you
install tool A18 and tool A19 halfway and
turn them, they come off, and that is very
dangerous since the spring of tensioner
assembly (92) is strong.)
27.Remove mounting bolts (84a) (2 pieces), and k After removing fan belt (91), return
remove EGR cooler assembly (84). tensioner assembly (92) to its original
C When disconnecting, be careful not to drop
the gasket.
k Be careful not to get your fingers caught
between the pulley and fan belt (91)
during work.
HB215LC-2 50-35
32.Disconnect clamp (33), band (34), and

connectors (35), move wiring harness assembly
(37) aside.

remove fuel splash prevention cover (39).
29.Disconnect coolant temperature sensor

connector (WATER TEMPERETURE) (93).
30.Disconnect terminal B (95) and connector E12
(96) from alternator assembly (94).
31.Disconnect wiring harness clamp (97), and
remove alternator assembly (94).
34.Remove nuts (40) (2 pieces) and mounting bolts
(41) (2 pieces), and remove bracket (42).
50-36 HB215LC-2
35.Remove fuel spray prevention caps (10 pieces) 44.Remove harness nuts (51) from the injector.
of fuel high-pressure pipes (43) to (47).
C Installed position of harness
36.Remove fuel high-pressure pipes (43) to (46).
37.Remove tube clamps, and remove fuel high- Color of wiring Cylinder No.
pressure pipe (47). harness
38.Remove spill tube (127). White 1, 3
39.Remove mounting bolts (128) (4 pieces), and Black 2, 4
remove common rail assembly (129).
C Remove injector harness connector (57) from
the rocker housing only when required.
remove rocker arm assembly (53), crosshead
(54), and the rocker arm support.
C Loosen locknut (55) and loosen adjustment
screw (56) several turns so that an excessive
force is not applied to the push rod when the
rocker arm assembly (53) is installed.
C Record the locations and directions of the
crossheads (54) (shapes of holes "a" and
"b"). (Install them in the recorded directions
40.Disconnect air intake heater connector (E01) when reassembling.)
(104).
remove EGR valve, intake connector, and intake
manifold connector assembly (102) as a unit.
42.Remove blowby duct (48).

43.Remove nuts (49) (4 pieces), and remove head
cover (50).
HB215LC-2 50-37
51.Remove mounting bolts (66) (18 pieces), sling

46.Remove retaining nut (58), and remove inlet
cylinder head assembly (67), and remove it.
connectors (59) (4 pieces).
C Clean the surrounding area in advance to 4 Cylinder head assembly:
prevent mud and dirt from entering into the 50 kg
hole of inlet connector (59).
C Use tool A4 to remove inlet connector (59).
47.Remove mounting bolt (60) of injector assembly
(62), and remove injector holder (61).
52.Remove cylinder head gasket (68) from cylinder

head assembly (67).
48.Remove injector assembly (62) by using tool A2.

C Be careful to prevent dirt and foreign matter
from entering the mounting part of the
injector assembly (62).
Installation (HB205-A100-720-K-00-A)
1. Cylinder head assembly

1) Measure stem length (a) of every cylinder
head mounting bolt and check that it is within
the using limit.
49.Remove push rods (63). • Allowable limit of bolt length: Less than
50.Remove mounting bolt (64), and remove rocker 132.1 mm
housing assembly (65). C If a bolt is longer than the allowable limit,
do not reuse it but replace it.
C Measure it by using tool A7.
50-38 HB215LC-2
q When not using an angle tightening tool, put a

2) Install cylinder head gasket (68) to cylinder block.
mark on cylinder head and bolt using a felt-tip pen
a Check that cylinder head mounting surface and
and retighten bolt to 90 ± 5 deg.
inside of cylinders are free from dirt or foreign
matters.
a Check that the holes in cylinder head gasket
(68) are aligned with the holes in the cylinder
head.
3) Install cylinder head assembly (67) in position on
the cylinder block, and finger-tighten mounting
bolts (66) more than 2 to 3 turns.
4 Cylinder head assembly:
50 kg
4) Tighten mounting bolts (66) in the order shown in
the figure as follows.
2. Install rocker housing assembly (65) with mounting
a Apply engine oil to mounting bolt threaded part bolt (64).
and bolt head seat surface.
Mounting bolt: Width across flats 10 mm
2 Threaded part and seat surface of head 3 Mounting bolt:
of mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
Engine oil (EO15W-40) 3. Install push rods (63).
3 Mounting bolt: a Check that push rod is fitted to tappet.
1] 90 ± 3 Nm {9.2 ± 0.3 kgm} a Pour engine oil to push rod socket.
2] 90 ± 3 Nm {9.2 ± 0.3 kgm} 2 Push rod socket:
3] 90 ± 5 deg. (Perform angle tightening Engine oil (EO15W-40)
by using tool A5.)
4. Injector assembly
a When replacing an injector assembly with a new
one, be sure to replace the inlet connector with a
new one as well.
HB215LC-2 50-39
a Check that injector sleeve (69) is free from

scratches and dirt.
4] When wear or uneven contact are found on

seat surface (e) at tip-end of the inlet
1) Install O-ring (71) and gasket (72) to injector (70). connector.
a Replace O-ring and gasket with new ones. a If high-pressure fuel leaks through the inlet
2) Apply engine oil to O-ring (71) of injector (70) and connector, seat surface has fine streaks or
the cylinder head side. cracks.
2 O-ring (71) of injector (70) and cylinder
head side:
3) While aligning convex and concave shapes (A),

install holder (61) to injector (70).
7) Apply engine oil to O-ring (part C) and head side

(part B) of inlet connector (59).
2 O-ring of inlet connector and cylinder
head side:
4) Direct fuel inlet hole of injector assembly (62) 8) Insert inlet connector (59) to injector (70), and
toward air intake manifold, and install it to the tighten retaining nut (58) lightly.
cylinder head. a After tightening each of them lightly, tighten it
5) Tighten holder mounting bolt (60) by 3 to 4 to the specified torque. If tightening torque is
threads. insufficient or too much, it will cause fuel
leakage inside the engine.
6) Check inlet connector on the following points. If
a Install inlet connector so that its positioning ball
any abnormality is found, replace it.
(part D) becomes as guide groove part on head
1] When burrs or wear are found on front-end side.
part (a) or rear-end part (b) of inlet connector
Retaining nut (58) (tightening lightly): Width
2] When foreign matters are found in the edge across flats 24 mm
filter at rear-end (c) of the inlet connector 3 Retaining nut (58) (tightening lightly):
3] When there are cracks or deterioration on the 15 ± 5 Nm {1.53 ± 0.51 kgm}
O-ring of the inlet connector upper (d) part.
50-40 HB215LC-2
㻢㻜
㻡㻥
9) Tighten mounting bolts (60) of holder (61)

a Check that spherical part of adjustment screw
alternately.
(56) is fitted securely to socket of push rod, and
Holder mounting bolt (60): Width across flats
then tighten mounting bolt (52).
8 mm
3 Holder mounting bolt (60):
8 ± 0.8 Nm {0.82 ± 0.08 kgm}
36 ± 5 Nm {3.7 ± 0.5 kgm}
10) Tighten retaining nut (58) of inlet connector (59).
Retaining nut (58) (tightening to the specified 2) Adjust the valve clearance.
torque): Width across flats 24 mm a See Testing and adjusting, "Testing and
3 Retaining nut (58) (tightening to the adjusting valve clearance".
specified torque):
a Rotate crankshaft to adjust valve clearance of
50 ± 5 Nm {5.1 ± 0.5 kgm}
each cylinder by using tool A3.
3) After adjusting the valve clearance, check that
lock nut (55) is tightened to the specified torque.
3 Lock nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4) Install harness mounting nuts (51) to injector

assembly (62).
a Check that wiring harness does not interfere
with rocker arm.
a Installed position of harness
Color of wiring
Cylinder No.
harness
White 1, 3
Black 2, 4
Mounting nut: Width across flats 9 mm

3 Mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}

a If the injector wiring harness connector (57) is
removed, apply liquid gasket to O-ring part (75)
and flange surface (76) of connector when
installing.
Apply liquid gasket of diameter 3mm to O-ring
5. Rocker arm and crosshead assembly part until O-ring groove is completely hidden.
1) Install rocker arm assembly (53), crosshead (54), When O-ring is damaged, replace it as the
and the rocker arm support. wiring harness assembly.
a Shape of hole in (a) and (b) portions of
crosshead is not identical. So when reusing
them for the same intake or exhaust valve, be
sure to install them in the same direction.
HB215LC-2 50-41
2 O-ring part and flange surface of

connector:
Connector flange mounting bolt (57a): Width
across flats 8 mm
3 Connector flange mounting bolt (57a):
10 ± 2 Nm {1 ± 0.2 kgm}
7. EGR valve, air intake connector, air intake manifold

connector assembly
1) Install the EGR valve, air intake connector, and
intake manifold connector assembly (102) as a
unit. Fasten them with bolts(103)(16 pieces).
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
6. Head cover 8. High-pressure pipe
k
1) Install gasket, and install head cover (50) with
Do not bend high-pressure pipe to correct
mounting nut (49).
before installing.
Mounting nut: Width across flats 13 mm
3 Mounting nut: k Be sure to use the Komatsu genuine
24 ± 4 Nm {2.45 ± 0.41 kgm} high-pressure pipe clamps and observe the
specified tightening torque.
2) Install blowby duct (47).
Mounting bolt: Width across flats 3 mm k Install each high-pressure pipe and wiring
3 Mounting bolt: harness at least 10 mm apart from each other.
7 ± 2 Nm {0.7 ± 0.2 kgm} a A high-pressure pipe must be replaced if dents
3) Install spill tube (26a). such as slits "b" or spots "c" are visually
recognizable in taper seal part ( "a" part: 2mm
Joint bolt: Width across flats 17 mm from the tip) of its connection, or if level difference
3 Joint bolt: in part "d" (within 2mm from taper seal end face)
24 ± 4 Nm {2.45 ± 0.41 kgm} due to fatigue is large enough to catch your fingers
because such high-pressure pipe can induce fuel
leakage.
50-42 HB215LC-2
a Do not remove the common rail pressure

sensor (2) from common rail (1) for a
purpose other than replacement.
a Be sure to replace the common rail
pressure sensor removed from the
common rail with a new sensor.
1] Before removing the common rail pressure
sensor, clean the area around it, and
remove dirt, etc. thoroughly.
2] Remove the common rail pressure sensor.
3] Check the common rail pressure sensor
1) Lightly tighten common rail (129) and connector for crack, breakage, damage of
high-pressure pipes (43) to (46). the seal, foreign matter on the pin and
a Apply liquid gasket to threaded part of bolts (2 corrosion, bend and breakage of the pin.
pieces) on the engine side when installing the 4] Install a new common rail pressure
common rail. sensor.
2 Threaded part of common rail 2 Threaded part of common rail
mounting bolt: pressure sensor:
Liquid gasket (LG-7) Gear oil (#90)
Mounting bolt and sleeve nut (lightly tightening): 3 Threaded part of common rail
Width across flats 19 mm pressure sensor:
3 Mounting bolt and sleeve nut (lightly 70 ± 5 Nm {7.1 ± 0.5 kgm}
tightening):
0.2 to 0.8 Nm {0.02 to 0.08 kgm}
2) Tighten fuel high-pressure pipes (43) to (46)
1] Fuel high-pressure pipe ((43): connector side)
→ ((44): connector side) → ((43): common rail
side) → ((44): common rail side)
2] Fuel high-pressure pipe ((45): connector side)
→ ((46): connector side) → ((45): common rail
side) → ((46): common rail side)
Sleeve nut (tightening to the specified torque):
3 Sleeve nut (tightening to the
2] Replace pressure limiter (3) according to the
specified torque):
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
1] Before removing the pressure limiter, thor-
3) Lightly tighten tube clamps (47) (2 pieces) to
oughly remove dirt and dusts on and
fasten fuel high-pressure pipe (127).
around it.
4) Tighten fuel high-pressure pipe (127) in the order
of supply pump side → common rail side. 2] Remove the pressure limiter.
Sleeve nut (tightening to the specified torque): 3] Do not use the pressure limiter if leakage
Width across flats 19 mm exceeds the specified value.
3 Sleeve nut (tightening to the specified 4] Check that there is no damage on
torque): high-pressure sealing surfaces (A) on the
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
pressure limiter and common rail.
5) Tighten mounting bolts (128) of common rail 5] Install the pressure limiter.
(129).
a Excessive tightening may cause
a Handling of common rail pressure sensor and
pressure limiter valve. leakage. Take care not to tighten
excessively.
1] Replace common rail pressure sensor (2)
HB215LC-2 50-43
2 Threaded part of pressure Mounting bolt:

limiter: M10: Width across flats 13 mm
Gear oil (#90) M8: Width across flats 10 mm
3 Mounting bolt:
Pressure limiter: Width across flats 17 mm
3 Pressure limiter: M10: 43 ± 6 Nm {4.38 ± 0.61 kgm}
100 ± 4 Nm {10.2 ± 0.4 kgm} M8: 24 ± 4 Nm {2.45 ± 0.41 kgm}

3 Hose clamp mounting bolt:
5 ± 1 Nm {0.5 ± 0.1 kgm}
a If the hose clamp is deformed, replace it with a
new one. When installing, take care that the
hose will not get caught by the end of the clamp
band.

3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
6) Tighten tube clamps (47) (2 pieces) to specified

torque to fasten fuel high-pressure pipe (127).
Tube clamp mounting bolt of fuel high-pressure
10. Exhaust manifold assembly
pipe (127): Width across flats 19 mm
3 Tube clamp mounting bolt of fuel
1) Install new gasket, install exhaust manifold (33) to
cylinder head (67) and EGR cooler (33d) and
high-pressure pipe (127): lightly tighten it with mounting bolts (32a) and (32).
24 ± 4 Nm {2.45 ± 0.41 kgm} a Adjust the cylinder head, exhaust manifold,
7) Install the fuel spray prevention cap. and EGR cooler by loosening and tightening
the mounting bolts so that there is no phase
k
shift or play in them.
Direct the slits of fuel spray prevention cap
outward or downward when installing it. 2) Tighten exhaust manifold mounting bolts (32) to
the specified torque in the order shown in the
following figure.
3 Mounting bolt:
1] Tighten bolts in the order of [1] to [8] as shown
in the figure to 53 ± 5 Nm {5.4 ± 0.5 kgm}.
2] Retighten bolts [1] to [4] shown in the figure to
53 ± 5 Nm {5.4 ± 0.5 kgm}.
3) Tighten mounting bolt (32a) to the specified
torque.
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
4) Tighten EGR cooler (32b) to bracket to the
specified torque.
9. EGR cooler assembly: Mounting bolt: Width across flats 13 mm
1) Lightly tighten EGR cooler assembly (33d) with 3 Mounting bolt:
bracket (29). 24 ± 4 Nm {2.45 ± 0.41 kgm}
a Tighten exhaust manifold lightly, and tighten it 5) Install tube (73).
to the specified torque. Mounting nut: Width across flats 12 mm
3 Mounting nut:
2) Install tube (33b) to EGR cooler assembly (33d).
18 ± 3 Nm {1.84 ± 0.31 kgm}
50-44 HB215LC-2
5) Install fan belt (91).

1] Set tool A18 and tool A19.
11. Alternator assembly

1) Install coolant temperature sensor connector
(WATER TEMPERATURE) (93).
2) Install alternator (94). 2] Install set tool A18 and tool A19 to part A
(width across flats: 12.7 mm) of tensioner
assembly (92).
3] Install fan belt (91) as rotating tool A19 in the
opposite direction (R) to the winding-up
direction.

A19 and tool A18 are connected securely
and part (a) of tool A18 is set securely to
Mounting bolt (bracket side): Width across flats
part A of tensioner assembly (92). (If you
17 mm
3 Mounting bolt (bracket side):
install tool A18 and tool A19 halfway and
43 ± 6 Nm {4.4 ± 0.6 kgm} turn them, they come off, and that is very
Mounting bolt (plate side): Width across flats dangerous since the spring of tensioner
10 mm assembly (92) is strong.)
3 Mounting bolt (plate side):
24 ± 4 Nm {2.45 ± 0.41 kgm} k After installing fan belt (91), slowly and
3) Install terminal B (95) and connector E12 (96) to carefully restore tensioner assembly (92).
alternator (94).
3 Terminal B (95): k Be careful not to get your fingers caught
5.9 to 9.8 Nm {0.6 to 1.0 kgm} between the pulley and fan belt (91) during
4) Install wiring harness clamp (97). work.
HB215LC-2 50-45

3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4) Install clamp (31a) of tube (31) to the bracket.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
5) Connect tube (31) and EGR piping flange (85)
with hose (86), and fasten it with hose clamp (23).
Hose clamp mounting bolt: Width across flats
9.5 mm
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
6) Install gasket, and install EGR piping flange (85).
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
7) Install tube (26c).
Joint bolt: Width across flats 14 mm
3 Joint bolt:
12 ± 2 Nm {1.2 ± 0.2 kgm}
12. EGR cooler piping

1) Install tube (81).
3 Hose clamp (81a):
5 ± 1 Nm {0.5 ± 0.1 kgm}
a If the hose clamp is deformed, replace it with a
new one.
a When installing, take care that the hose will not
get caught by the end of the clamp band.
3 Tube mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
13. Turbocharger assembly
2) Install tube clamp (81b).
1) Install gasket, and install turbocharger lubrication
Tube clamp: Width across flats 10 mm
3 Tube clamp:
return tube (20).
24 ± 4 Nm {2.45 ± 0.41 kgm} Mounting bolt: Hexagon socket width across flats:
5 mm
3 Mounting bolt:
6
10 ± 2 Nm {1.02 ± 0.2 kgm}

2) Install gasket, and install turbocharger assembly
(21) with mounting nut (21a).
4 Turbocharger assembly:
15 kg
3 Mounting nut:
43 ± 6 Nm {4.4 ± 0.6 kgm}
a Tighten the mounting nuts in diagonal order.
3) Install tube (56).
Mounting bolt (turbocharger side): Width across
flats 14 mm
3) Install gasket and install tube (31) to EGR cooler 3 Mounting bolt (turbocharger side):
side. 9.8 to 12.7 Nm {1.0 to 1.3 kgm}
50-46 HB215LC-2
Sleeve nut (oil cooler side): Width across flats 1] Align hose to its original position (marked
21 mm position).
3 Sleeve nut (oil cooler side) a Reference
35 ± 5 Nm {3.57 ± 0.51 kgm} Air horse insertion depth: 50 mm
4) Install the water circulation tube.
(aftercooler side)
Joint (12): Width across flats 17 mm Air horse insertion depth: 40 mm
3 Joint (12):
(turbocharger side)
24 ± 4 Nm {2.45 ± 0.41 kgm}
Joint (14): Width across flats 14 mm 2] Set bridge (BR) under clamp fastening bolt,
3 Joint (14): and adjust overlap (b) between bridge (BR)
12± 2 Nm {1.22 ± 0.20 kgm} and band to Min. 5 mm.
(b) dimension: Min. 5 mm
2 Clamp fastening bolt threaded part
(BC):
Lubricating oil (ThreeBond
PANDO18B)
a Impact wrench is not allowed to use.
q When reusing hose
Align clamp position to the trace of clamp left
on hose.
3 Clamp tightening bolt:
Min. 6 Nm {0.6 kgm}
q When hose is new
Tighten it until dimension BDG becomes as
shown below.
BDG: 7 to 10 mm
5) Install the tube (113) and fasten it with V clamp

(114).
a Install the tube with its positioning line (A)
being in an upward direction.
3 V-clamp mounting bolt:
5.9~7.8 Nm 6) Install hose (87).
Hose clamp (15) mounting bolt: Width across flats
9.5 mm
3 Hose clamp (15) mounting bolt:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
7) Lightly fasten tube (88) with V-clamp.

a Although the V-clamp is reusable, replace it
with a new one when it is under the following
condition.
q V-clamp is deformed.
q Threads of T-bolt are crushed.

q V-groove is cracked.
q MIKALOR clamp q V-groove is flaked.
a Be sure to use a new clamp.
HB215LC-2 50-47
14. Install the heat insulation cover (89a) with mounting

bolts (89).
Mounting bolt (3 pieces on the L.H.): Width across
flats 12 mm
3 Mounting bolt (3 pieces on the L.H.)
27 to 34 Nm {2.8 to 3.5 kgm}
Mounting bolt (3 pieces on the R.H.): Width across
flats 10 mm
3 Mounting bolt (3 pieces on the R.H.)
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
16. Install KDOC assembly (101). For details, see

15. Install the fuel splash prevention cover.

11.8 to 14.7 Nm {1.2 to 1.5 kgm}
Mounting bolts (38) and (41): Width across flats 17. EGR valve, air intake connector, air intake manifold
12 mm connector assembly
3 Mounting bolts (38) and (41):
1) Install air intake heater connector (E01)(104).
27 to 34 Nm {2.8 to 3.5 kgm}
50-48 HB215LC-2
Mounting nut for air intake heater connector:

3 Mounting nut for air intake heater
connector:
3.4 to 4.6 Nm {0.34 to 0.47 kgm}
19. Install the dipstick pipe (107) together with the bracket
(108).
3 Mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
18. Install the air hose (105) and tighten MIKALOR clamp
(106).
q MIKALOR clamp
a Be sure to use a new clamp.

1) Align hose to its original position (marked
position).
a Reference
Air hose insertion depth: 80 mm (both up and
down)
2) Set bridge (BR) under clamp fastening bolt, and
adjust overlap (b) between bridge (BR) and band
20. Install the air compressor (109) and tighten it with
to Min. 5 mm.
mounting bolts (110) (4 pieces).
dimension: Min. 5 mm
Air conditioner compressor mounting bolt (34): Width
2 Clamp fastening bolt threaded part across flats 13 mm
(BC): 3 Air conditioner compressor mounting bolt
Lubricating oil (ThreeBond (34):
PANDO18B) 24.5 to 29.4 Nm {2.5 to 3.0 kgm}
a See Testing and adjusting, "Testing and adjusting
a Impact wrench is not allowed to use. air conditioner compressor belt tension".
q When reusing hose
Align clamp position to the trace of clamp left on
hose.
3 Clamp tightening bolt:
Min. 6 Nm {0.6 kgm}

q When hose is new
Tighten it until dimension BDG becomes as shown
below.
BDG: 7 to 10 mm
21. Install hoses (120) and (121).

22. Install fan guard (123) with mounting bolt (122).
HB215LC-2 50-49
23. Attach the radiator hose (124), and install the hose
clamp (125) and band (23).
a Fix the band on conduit.

10.8 to 11.8 Nm {1.1 to 1.2 kgm}

to removal.
[*1]
Clamp (9) of tube on turbocharger outlet side: Width
across flats 12 mm
3 Clamp (9) of tube on turbocharger outlet side:
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*2]
Hose clamps (15) and (16) on turbocharger inlet side:
Width across flats 9.5 mm
3 Hose clamps (15) and (16) on turbocharger
inlet side:
24 ± 4 Nm {2.45 ± 0.41 kgm}
q Refilling with coolant
Refill the radiator with coolant to the specified level
through the coolant filler port. Run the engine to
circulate the coolant. Then check the coolant level
again.
6 Radiator:
23.5 ℓ
50-50 HB215LC-2
Removal and installation of radiator assembly (HB205-B220-924-K-00-A)
k Place the machine on a level surface, lower

k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant
temperature drops before starting the work.
k When draining coolant, be careful that

coolant does not contact your skin or enter
your eye. The super coolant mixed in the
coolant is poisonous. If the coolant sticks to 5. Open engine hood (6).
your skin or enters your eye, immediately
rinse with water thoroughly and see a doctor.

Removal (HB205-B220-520-K-00-A)
6. Disconnect hose clamps (7) and (8).

7. Disconnect aeration hose (9) and reservoir tank
hose (10).
8. Disconnect radiator inlet hose (11). [*2]
2. Remove cover mounting bolts (2) (4 pieces),

and remove cover (3).
3. Drain the coolant through drain valve (4). (Inside
diameter of drain hose: 7 mm)
6 Radiator:
23 N
4. Disconnect radiator outlet hose (5). [*1]
9. Remove mounting bolt (12), and remove cover
C Make matchmarks on the hose end and
(13).
radiator side so that they can be reconnected
correctly.
HB215LC-2 50-51
10. Remove mounting bolt (14), and reposition cover (15)

14. Sling radiator assembly (21), and remove it. [*3]
out of the way.
a Be careful not to catch the bottom of the radiator
assembly when slinging it.
4 Radiator assembly (21):
25 kg
11. Remove mounting bolts (16) (4 pieces), and remove

cover (17).
Installation (HB205-B220-720-K-00-A)
[*1] [*2]
2 Hoses (5) and (11):
Liquid gasket (ThreeBond 2720C)
a Hose insertion depth: 45 mm (both up and down)

Hoses (5) and (11): Width across flats 8 mm
3 Hoses (5) and (11):
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
12. Remove radiator mounting bolts (18) (2 pieces).
[*3]
a Check that the heat insulation sealant (sponge) on the

periphery of the radiator is not damaged.
a If the heat insulation sealant (sponge) is damaged,

replace it.
a When installing the radiator assembly, be careful not

to damage the heat insulation sealant (sponge) on the
periphery while lowering.

bracket (20).
50-52 HB215LC-2
C Check that convex portion (A) of the radiator

bottom is correctly aligned with concave portion
(B) on the machine body side from the
undercover side.
• Refilling with coolant

Refill it with the coolant to the specified level
through the coolant filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.
5 Radiator:
23 N
HB215LC-2 50-53
Removal and installation of hydraulic oil cooler assembly (HB205-B8P0-924-K-00-A)
C Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
1 796-460-1210 Oil stopper S 1

R
2 796-770-1320 Adapter S 1


C When using tools R1 and R2, remove the
hydraulic tank strainer and stop the draining
oil by using the tools R1 and R2.
hydraulic circuit referring to Testing and
adjusting, "Releasing remaining pressure
from hydraulic system".


Removal (HB205-B8P0-520-K-00-A)
1. Remove undercovers (1) and (2).
3. Remove plug (5) of hydraulic oil cooler inlet tube

(4), and drain the hydraulic oil from the hydraulic
oil cooler.
C When draining is completed, close plug (5).
2. Remove drain plug (3), and drain the hydraulic

oil from the hydraulic tank. [*1]
6 Hydraulic tank:
132 N
Remove bracket mounting bolts (6).
50-54 HB215LC-2
4. Remove mounting bolts (7) (2 pieces), and 8. Remove mounting bolts (15) (4 pieces), and
disconnect hydraulic oil cooler tube (4). remove cover (16).
5. Open engine hood (8). 9. Remove hydraulic oil cooler mounting bolts (17)
(2 pieces).
remove hydraulic oil cooler outlet tube (19).

(10).
11.Sling hydraulic oil cooler assembly (20). [*1]
4 Hydraulic oil cooler assembly (20):

10 kg
7. Remove mounting bolt (11), and reposition cover

(12) out of the way.
HB215LC-2 50-55
Installation (HB205-B8P0-720-K-00-A)
• Perform installation in the reverse order to

removal.
[*1]
C Check that the heat insulation sealant (sponge)
on the periphery of the hydraulic oil cooler is not
damaged.
C If the heat insulation (sponge) is damaged,
replace it.
C When installing the hydraulic oil cooler assembly,
be careful not to damage the heat insulation
sealant (sponge) on the periphery while lowering
it.
C Check from below that convex part (A) of the
hydraulic oil cooler bottom is correctly aligned
with concave part (B) on the machine side.
• Refilling with oil (Hydraulic tank)

C Check that the hydraulic oil cooler drain plug
is tightened before refilling with oil.
C Refill it with hydraulic oil through the oil filler
port of the hydraulic tank to the specified
level. Run the engine to circulate the oil
through the piping. Then check the hydraulic
oil level again.
5 Hydraulic tank:
132 N
234 N (specified capacity)
50-56 HB215LC-2
Removal and installation of aftercooler assembly (HB205-A9A0-924-K-00-A)
k Place the machine on a level surface, lower 4. Open engine hood (6).
the work equipment to the ground in a stable
posture and stop the engine.


Removal (HB205-A9A0-520-K-00-A)

remove bracket (8).

remove bottom cover (3).
6. Remove mounting bolt (9), and reposition cover
(10) out of the way.

disconnect aftercooler inlet tube (5).
remove cover (12).
HB215LC-2 50-57
8. Remove aftercooler mounting bolts (13) (2 pieces).

Installation (HB205-A9A0-720-K-00-A)
[*1]
Install disconnected aftercooler outlet tube (16) according
to the following procedure.
q Be sure to use a new MIKALOR clamp.
1. Align hose with its original position (marked position).
2. Set bridge (BR) under clamp fastening bolt, and
fasten the clamp so that overlap dimension (b)
between bridge (BR) and band is as following.
Dimension (b): Min. 5 mm
3 Clamp fastening bolt threaded part (BC):
9. Remove clamp (14). Lubricating oil (ThreeBond PANDO18B)
10. Remove MIKALOR clamps (15), and disconnect
a Do not use an impact wrench.
aftercooler outlet tube (16). [*1]
q When reusing tube
a Make marks on the hose end and tube so that they Align clamp position to the trace of clamp left on hose.
can be reconnected correctly. Clamp fastening bolt: Width across flats 13 mm
3 Clamp fastening bolt:
Min. 6 Nm {0.6 kgm}

q For new tube
Tighten it until dimension BDG becomes as shown
below.
BDG: 7 to 10 mm
11. Sling aftercooler assembly (17), and remove it.

4 Aftercooler (17):
15 kg
50-58 HB215LC-2
Removalandinstallationofengine,motor-generator,andmainpump
assembly
C Note the installing positions, connector numbers,
and hose band colors of the wirings and pipings
k The removal and installation in this section not to install them wrongly.
must be performed by persons "who
completed the special training for low- k After the engine is stopped, the parts are
voltage electric work". very hot. Wait until all parts are cooled down.
Before performing work, understand 00
Foreword, Safety, Basic information, "Safety
Removal (HB205-R400-520-K-00-A)
notice 1. Precautions Specific to Hybrid 1. Open left side inspection cover (1).
Equipment" and "Handling Hybrid
C Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
8 796T-401-1110 Plate S 1
A 9 Lifting tool S 1
Commercially Megohm tester
12 V 1
available
B 1 7875-35-2910 Cap V 2
2. Remove nuts (2) (3 pieces) at the top of the
1 796-460-1210 Oil stopper S 1 inverter, and remove cover (3).
R
2 796-770-1320 Adapter S 1

k Discharge the capacitors. For details, see "—

Capacitor discharge procedure—" in 00
Foreword, Safety, Basic information,
"Handling Hybrid Equipment and High-
Voltage Wires".

3. Disconnect one-touch wiring connectors HB01
k Before opening the water filler cap or (CC) ((+) and (-)) (2 pieces) of the capacitor.
draining coolant, check that the coolant C Pull out the connector by pressing the lock
temperature cools down to the temperature part of the connector with your thumb to
safe enough for anyone not to get burn. release the lock.
k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant
temperature drops before starting the work.

coolant is poisonous. If the coolant sticks to
HB215LC-2 50-59
4. Remove undercovers (4), (5), (5a), (6), and (7).

C The cover is a reinforced cover and heavy.
Remove it carefully.
C If the hydraulic tank is not drained, install the

stopper by using tool R1 according to the
1) Remove cover (10).
2) Remove the strainer.
3) Install tool R1 (oil stopper) and tool R2
(adapter).
4) After removing the strainer, remove tool R1
and tool R2 together.
5) Install cover (10).
C Tighten it with several bolts lightly.
5. Close fuel stop valve (8).
7. Place a container to receive oil below oil drain

plug (12) of motor-generator housing (11).
8. Remove oil drain plug (12) to drain the oil.
6 Motor-generator housing (11):

6. Loosen drain plug (9) to drain the oil from the 6.0 N
hydraulic tank.
6 Hydraulic tank:
132 N
50-60 HB215LC-2
6 Electric swing motor case (13):

3.0 N
15.Remove bolts (18) (4 pieces), and remove cover

(19).
16.Remove 5 bolts (20) and cover (21).
10.Drain the coolant from drain valve (14).
6 Radiator (14):
23 N
17.Remove KCCV assembly. For details, see

18.Remove bolts (24) and (25), and remove cover
(26).
11.Remove coolant drain plug (15) of motor-
generator housing, and drain the coolant.

1N
12.Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
13.Remove the counterweight. For details, see
"Removal and installation of counterweight".
14.Remove bolts (16) (5 pieces), and remove cover
(17).
HB215LC-2 50-61

disconnect suction tube (28) from the main
pump assembly.
20.Disconnect branch hoses (29) and (30).
32.Disconnect case drain hose (43), EPC source

pressure hose (44), EPC source pressure hose
(45), pump pressure input hose (46), front pump
load pressure input hose (47), and rear pump
load pressure input hose (48).
21.Disconnect connector V11 (31).
23.Disconnect connector P22 (33).
33.Disconnect rear pump discharge hose (49) and

front pump discharge hose (50).
25.Disconnect connector GM01 (35).
34.Remove starting motor B terminal (51). [*1]

35.Remove starting motor C terminal (52). [*2]
26.Disconnect clip (36).
30.Disconnect hose (40) (if equipped).
31.Remove pilot filter mounting bolts (41) (2 pieces),
and move pilot filter (42) to the right side of the
machine (if equipped).
50-62 HB215LC-2
36.Disconnect connector E08 (53). 45.Remove the fan belt. For details, see "Removal
37.Disconnect connector E10 (54). and installation of fan belt".
38.Disconnect connector P44 (55). 46.Remove fan (67).
39.Remove mounting bolt (56).
47.Remove mounting bolts (68) and (69), and

40.Loosen clamps (57) (2 pieces), and remove remove alternator assembly (70).
hose (57a) and tube (58) together. [*3] 48.Remove alternator terminal AB (71).
49.Remove connector E12 (72).
C Mark the hose and clamp.
50.Disconnect clamp (73), and disconnect radiator

41.Loosen clip (59), and disconnect coolant air vent
lower hose (74). [*6]
hose (60).
42.Loosen clip (61), and disconnect heater hose C Mark the hose and clamp.
(62).
43.Remove clamp (63), and disconnect
turbocharger outlet connector (64). [*4]
44.Remove clamp (65), and disconnect radiator
upper hose (66). [*5]
HB215LC-2 50-63
51.Remove clamps (75) (4 places). 53.Remove mounting bolts (80) (6 pieces), and
52.Loosen mounting bolts (76) (2 pieces each), and

disconnect high voltage wiring (power cable) 54.Remove mounting bolts (82) and (83).
connectors GM03 (77) and GM02 (78). [*7] 55.Disconnect fuel return hose (84). (*8)
56.Disconnect supply pump inlet connector (85).
C After disconnecting the high voltage wiring,
(*9)
make sure to install cap B1 to the connector
57.Disconnect swing motor lubrication supply hose
part.
(86). (*10)
C Cap B1 prevents water and dust from 58.Disconnect swing motor lubrication return hose
entering into the connector part. (87). (*10)
C Do not lose rubber washers (79) installed to
the high voltage wiring connector bolt as a
stopper.
59.Remove mounting bolts (88) (2 pieces each on

upper and lower sides), and remove brackets
(89) and (90).
50-64 HB215LC-2
60.Disconnect connector E24 (91). 67.Loosen mounting bolts (99) and (100) (3 pieces),
61.Disconnect connector CE03 (92). [*11] and remove belt (101).
62.Disconnect ribbon heater terminal E01 (93). 68.Disconnect connector AC03 (102).
63.Disconnect connector K02 (94). 69.Remove mounting bolts (99) and (100) (3
64.Remove clamps (95) and (96). pieces), and remove air conditioner compressor
assembly (103). [*13]
C Move it to the machine body side so that it
does not hinder the work.
65.Disconnect fuel return hose (97). [*12]

66.Disconnect fuel supply hose (98). [*12]
Pull out hose to direction (a) while pressing lock
(L) on both sides. 70.Remove clamps (104) and (105).
71.Loosen clamp (106) (4 pieces), and remove
aftercooler return hose (107). [*14]
72.Disconnect hose clamps (108) and (109).

73.Disconnect aeration hose (110).
74.Disconnect radiator inlet hose (111). [*15]
HB215LC-2 50-65
75. Disconnect motor-generator ground wiring (112). 78. Sling engine, motor-generator, and main pump
assembly (118), and remove it.
76. Remove engine mount bolts (113) (2 pieces).[*16]

77. Remove engine mount bolts (114) (2 pieces).[*17] a Tool A9 is provided as a sling for the engine,
Nuts are not welded except for the alternator motor-generator, and main pump assembly.
mounting side. Therefore, fix nut (115) to prevent it a Check that all the wiring, piping, clamps, etc. are
from rotating by using tool A8, and then remove disconnected, and remove it.
engine mount bolts (116) and (117). 4 Engine, motor-generator, and main pump
assembly:
900 kg
Installation (HB205-R400-720-K-00-A)
[*1]
Starting motor B terminal (51): Width across flats 17 mm
3 Starting motor B terminal (51):
17.7 to 24.5 Nm {1.8 to 2.5 kgm}
[*2]
3 Starting motor C terminal (52):
2.6 to 4.6 Nm {0.27 to 47 kgm}
[*3]
q Align with the mark, and then assemble them.
3 Clamp (57):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*4]
50-66 HB215LC-2
a Although the V-clamp is reusable, replace it with a a Check it thoroughly that the inspection plugs
new one when it is under the following condition. do not come off during measurement (when
q V-clamp is deformed. high voltage is applied). Otherwise it touches
q Threads of T-bolt are crushed. other parts, and then it may cause an electric
q V-groove is cracked. shock.
q V-groove is flaked. 2) Do not touch motor-generator assembly during
measurement. Do not touch the target object for
measurement (MOTOR A) during measurement
(when high voltage is applied). During
measurement, the person performing
measurement should alert other people.
2. Measuring
1) Insulation measurement: Connect the following
items as shown in the following figure.
Between line A and line B
Between line A and line C
Between line B and line C
(Criteria)
q Width across flats of V-clamp fastening nut: 7/16
a Insulation resistance between lines A and B:
inch. (11.1 mm)
Min. 5 MΩ
[*5]
a Insulation resistance between lines A and C:
a Be careful that the rib does not get onto the engine Min. 5 MΩ
side when installing.
a Insulation resistance between lines B and C:
3
Min. 5 MΩ
Clamp (65):
10.8 to 11.8 {1.1 to 1.2 kgm}
[*6]
a Align with the mark, and then assemble them.
a Be careful not to get onto the boss when installing.

3 Clamp (73):
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
[*7]
a Install the connector of the high voltage wiring (power

cable) according to the following procedure. 2) Insulation measurement between phases
Connect the following items as shown in the
a Before installing the connector of the high voltage
figure.
wiring (power cable), measure the insulation
Between phase A and motor case phase
resistance of the motor-generator according to the
Between phase B and motor case phase
following procedure. Between phase C and motor case phase
1. Caution for measuring (Criteria)
a Insulation resistance between phase A and

k High voltage (500 VDC) is applied for
motor case phase: Min. 5 MΩ
insulation resistance measurement. Be careful
of the following. a Insulation resistance between phase B and
motor case phase: Min. 5 MΩ
1) Connection of the inspection plug
a Insulation resistance between phase C and
a Check that inspection plugs P(+) and (-) are motor case phase: Min. 5 MΩ
connected to the target parts for measurement.
HB215LC-2 50-67
Fuel return hose (84): Width across flats 17 mm

3 Fuel return hose (84):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*9]
Supply pump inlet (85): Width across flats 22 mm
3 Supply pump inlet (85):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*10]
Swing motor lubrication supply hose (86):
Swing motor lubrication return hose (87):
3 Swing motor lubrication supply hose (86):
a For the connector of the high voltage wiring Swing motor lubrication return hose (87):
(power cable), match the number in the 35.0 to 63.0 Nm {3.5 to 6.5 kgm}
motor-generator side and marking line. [*11]
1) Replace the O-ring with a new one. 3 Engine controller (92):
2.6 to 3.1 Nm {0.27 to 0.32 kgm}
2) Check that there is no stain or scratch on the cable
[*12]
side plug (P) and O-ring surface.
When installing a connector of quick coupling type,
3) Install connectors (70) and (71). observe the following points.
a Before inserting the cable, check that rubber Since the internal parts of the fitting of the disconnected
washer (T) is installed to the bolt. hoses or tubes may be damaged, do not reuse them.
For installation, replace them with new ones.
a Insert the cable side plug (P) straight into the
motor side power supply terminal socket (S) so Ensure that mud or dirt is not sticking to the hose joint part
that the plug does not touch the motor case. in advance.
Push the connector and insert it straight (in the direction
a When inserting, direct high voltage wiring
(b)) without prying or shaking it.
connection detection contact (Q) toward the
engine. If it is difficult to insert it, do not push it in forcibly but pull
it out once, and check concave and convex parts for
damage and dirt.

Refill the radiator with coolant to the specified level
through the water filler port. Run the engine to
again.
5 Radiator (14):
23 ℓ
a For precautions on the mixing proportion of super
coolant in the coolant, see "Removal and installation
of radiator assembly".
[*8]
50-68 HB215LC-2
q Refilling with oil (Hydraulic tank) 2 Clamp fastening bolt threaded part
Refill the hydraulic tank with oil to the specified level (BC):
through the oil filler port. Run the engine to circulate Lubricating oil (THREEBOND
PANDO18B or equivalent)
the oil through the piping. Then check the oil level
q When reusing hose
again. Align clamp position to the trace of clamp left on
5 Hydraulic tank: hose.
132 ℓ Clamp Fastening bolt: Width across flats 13 mm
3 Clamp Fastening bolt:
234ℓ (specified capacity)
16 to 17 Nm {1.6 to 1.7 kgm}
q Refilling with oil (motor-generator housing)
q When hose is new
Refill the motor-generator housing with oil to the Tighten so that dimension (BDG) is 4 to 7mm.
specified level through the oil filler port. Run the
engine to circulate the oil through the piping. Then
check the oil level again.
6.0 ℓ (T10)
6.5 ℓ (T10) (specified capacity)
q Refilling with oil (Electric swing motor case)
Refill theElectric swing motor case 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
[*16] [*17]
Electric swing motor case (13):
1.6 ℓ (T10) a Bolt lengths are different. Be careful during
2.3 ℓ (T10) (specified capacity) installation.
(The one on engine front side is longer than it on
q Check for fuel leakage (fuel system)
engine rear side.)
Check the fuel system for leakage. For details, see
a Engine mount rubber sizes are different. Be careful
Testing and adjusting, "Testing fuel circuit for
during installation.
leakage". (The one on engine front side is smaller than it on
q Bleeding air (fuel system) engine rear side.)
Bleed air from the fuel system. For details, see Testing A: Front
and adjusting, "Bleeding air from fuel system". B: Rear
q Bleeding air (hydraulic system)
Bleed air from the hydraulic circuit. For details, see
Testing and adjusting, "Bleeding air from hydraulic
system".
[*13]
a Seat the nut before tightening it.

Mounting bolts (99) and (100): Width across flats 19 mm
3 Mounting bolts (99) and (100):
102.9 Nm {10.5 kgm}
[*14]
a Fasten the MIKALOR clamps at both ends of the tube Engine mounting bolt (113) and (114): Width across flats
according to the following procedure. 24 mm
a Be sure to use a new MIKALOR clamp. 3 Engine mounting bolt (113) and (114):
a Do not use an impact wrench. 245 to 308.9 Nm {25 to 31.5 kgm}
[*15]
a Set bridge (BR) under clamp fastening bolt, and adjust
overlap dimension (b) between bridge (BR) and band
to the following.
q Dimension (b): Min. 5 mm
HB215LC-2 50-69
2 Hose (111):
Liquid gasket (ThreeBond 2720C)
a Hose insertion depth: 45 mm (both up and down)
Hose (111): Width across flats 8 mm
3 Hose (111):
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
50-70 HB215LC-2
Removal and installation of fan belt (HB205-B430-924-K-00-A)
C Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
Commercially Adapter
18 V 1
available
A
Commercially
19 Ratchet V 1
available



Removal (HB205-B430-520-K-00-A)
5. Loosen air conditioner compressor clamping bolt

(8) and belt adjustment bolts (9) (2 pieces), and
remove air conditioner compressor drive belt
(10). [*1]
2. Remove bolts (2) (3 pieces), and remove fan

guard (3).
guard (5).
guard (7). 6. Place tools A18 and A19 on auto-tensioner (11).
HB215LC-2 50-71
7. Install set tool A18 and tool A19 to part a (width

across flats: 12.7 mm) of tensioner assembly
(11).
8. Turn tool A19 counterclockwise (R) seen from
the engine front to loosen the tension of fan belt
(12), and remove fan belt (12).


A19 and tool A18 are connected securely 3. Install part (a) of set tool A18 and tool A19 to
and part a of tool A18 is set securely to part P (width across flats: 12.7 mm) of tensioner
part P of tensioner assembly (11). (If you assembly (11).
install tool A18 and tool A19 halfway and 4. Turn tool A19 counterclockwise (R) seen from
turn them, they come off, and that is very the engine front to loosen the tension of fan belt
dangerous since the tension of tensioner (12), and install fan belt (12).
assembly (11) is strong.)
k After removing fan belt (12), return pipe may come off when you turn it, and that
tensioner assembly (11) to its original is very dangerous.)
k Before turning tool A19, check that tool A19
and tool A18 are connected securely and part
(a) of tool A18 is set securely to part P of
between the pulley and fan belt (12)
tensioner assembly (11). (If you install tool
during work.
A18 and tool A19 halfway and turn them, they
come off, and that is very dangerous since
the tension of tensioner assembly (11) is
strong.)
k After removing fan belt (12), return tensioner

assembly (11) to its original position slowly
and carefully.

between the pulley and fan belt (12) during
work.
Installation (HB205-B430-720-K-00-A)
1. Set fan belt (12) to each pulley.

2. Set tool A18 and tool A19.
50-72 HB215LC-2
• Perform subsequent installation in the reverse

order to removal.
[*1]
Adjust the air conditioner compressor belt tension.
For details, see Testing and adjusting, "Testing and
adjusting air conditioner compressor belt tension".
HB215LC-2 50-73
Removal and installation of starting motor (HB205-AK70-924-K-00-A)



Removal (HB205-AK70-520-K-00-A)
5. Remove bolts (5) (2 pieces).
2. Open side cover (2) on the right side of the
machine.
6. Remove bolts (6) (5 pieces) and cover (7).
3. Remove bolts (2a) (3 pieces).
4. Remove bolts (3) (4 pieces), and remove step

(4).

undercover (10).
50-74 HB215LC-2
Installation (HB205-AK70-720-K-00-A)
[*1]
Starting motor B terminal (M10 x 1.5): Width across flats
17 mm
3 Starting motor B terminal (M10 x 1.5):
17.7 to 24.5 Nm {1.8 to 2.5 kgm}
3 Starting motor C terminal (M5 x 0.8):
2.6 to 4.6 Nm {0.27 to 0.47 kgm}
Starting motor mounting bolt (17) (M10 x 1.5), nut: Width
across flats 14 mm
3
9. Remove bolt (11), and remove cover (12).
Starting motor mounting bolt (17) (M10 x 1.5),
nut:
43 ± 6 Nm {4.4 to 0.61 kgm}
10. Remove bolts (13) (2 pieces), and remove bracket

(14).
11. Disconnect terminal B (15) and terminal C (16).[*1]

12. Remove bolts (17) (3 pieces), and remove starting
motor assembly (18).
HB215LC-2 50-75
Removal and installation of engine front oil seal (HB205-A350-924-K-00-A)
C Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
4 795-799-6400 Seal puller V 1

A Angle tightening
6 790-331-1120 S 1
wrench

k Set the lock lever in LOCK position. remove fan (10). [*1]


Removal (HB205-A350-520-K-00-A)
1. Remove the radiator assembly. For details, see

"Removal and installation of radiator assembly".
2. Remove the hydraulic oil cooler assembly. For
details, see "Removal and installation of
hydraulic oil cooler assembly".
3. Remove the aftercooler assembly. For details, 10.Remove fan belt. For details, see "Removal and
see "Removal and installation of aftercooler installation of air conditioner compressor belt
assembly". and fan belt".
4. Remove the hybrid system radiator assembly. 11.Remove crankshaft pulley mounting bolt (11),
For details, see "Removal and installation of and remove crankshaft pulley (12).
hybrid system radiator assembly".
5. Remove mounting bolts (1) (4 pieces) and move
air conditioner condenser (2) so that it does not
hinder the work.
6. Remove bolts (3) (2 pieces), and remove net (4).
12.Remove dust seal (12a).

remove stay (6).
remove stay (8).
50-76 HB215LC-2
C When installing the engine front seal, do not

apply oil or grease to the crankshaft and seal
lip. Also, thoroughly wipe off oil or grease
from the crankshaft.
13.Remove engine front seal (13) according to the

1) Install tool A4 to the crankshaft.
2) Screw in tapping screw [1] of tool A4 to the
seal carrier part of engine front seal (13).
3) Turn the handle clockwise, and remove C The protrusion and facial runout of engine
engine front seal (13). front seal (13) from cover (14) are as follows.
• Protrusion (x): Max. 0.38 mm
• Facial runout (y): Max. 0.25 mm
2. Install dust seal (12a).

C Check the installed dimension (L)
• Installed dimension (L): 12(+0.1/0) mm
C Be careful not to damage the crankshaft

when removing the oil seal.
1. Remove engine front seal (13) by using tool A4.

C Replace the engine front seal with a new 3. Crankshaft pulley
one.
1) Insert dowel pin (a) to the tip of the
C Before installing the engine front seal, check crankshaft.
that the end corner and the seal lip sliding
surface of the crankshaft are free from a flaw,
burr, fin, and rust.
HB215LC-2 50-77

to removal.
[*1]
a After installing fan (10) check tip clearance (d)
between the fan and shroud (15).
If the clearance is out of the standard value range,
loosen mounting bolts (16) (6 pieces), and adjust the
shroud.
q Tip clearance (4 places of top, bottom, right, and left)
(d): Min. 13 mm
2) Check the dowel pin insertion position, and insert

crankshaft pulley and plate to the crankshaft.
3) Tighten mounting bolts (11) according to the
1] Tighten the bolts diagonally with a torque of 55

± 5 Nm {5.6 ± 0.5 kgm}.
2] Loosen bolts by 180 deg.
3] Tighten the bolts diagonally with a torque of 55
± 5 Nm {5.6 ± 0.5 kgm}.
4] Tighten the bolts by 90 deg. ± 5 deg. in a diag-
onal order. (Use angle tightening tool A6)
(When angle tightening tool A6 is not used)

1] After performing steps 1] to 3], put marks on
the crankshaft pulley and bolts.
2] Retighten the bolts 90 ± 5 deg. in a diagonal
order.
50-78 HB215LC-2
Removal and installation of engine rear oil seal (HB205-A510-924-K-00-A)
C Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
A 5 795-799-6500 Seal puller V 1
Removal (HB205-A510-520-K-00-A)
1. Remove the main pump assembly. For details,

see "Removal and installation of main pump
assembly". 5. Removal of engine rear oil seal
2. Remove the motor-generator and housing 1) Install tool A5 to the crankshaft.
assembly. For details, see "Removal and 2) Screw tapping screw [2] of tool A5 into the
installation of motor-generator and housing seal carrier of engine rear oil seal (5).
assembly". 3) Turn the handle clockwise, and remove
3. Remove bolts (1) (10 pieces), and remove engine rear oil seal (5).
coupling (2).
C Install the rear oil seal according to the following

procedure.
1. Set rear oil seal (5) to pilot [3].
C Replace the engine rear oil seal with a new
one.
C Do not remove pilot [3] attached to rear seal
(5) until it is inserted into the crankshaft.
C Before installing the engine rear oil seal,
degrease, clean and dry the crankshaft
sealing face and the seal lip face to prevent
4. Remove the flywheel according to the following oil leakage.
procedure.
1) Remove flywheel mounting bolts (3) (2
pieces) in diagonal positions, and install
guide bolts [1]. [*1]
2) Sling flywheel (4), and remove the remaining
mounting bolts.
3) Pull out flywheel (4) toward you.
4) Remove guide bolt (1), sling flywheel (4), and
remove it.
4 Flywheel:
15 kg
2. Install pilot [3] to crankshaft (6), and insert

engine rear oil seal (5) into flywheel housing (7).
3. Push in engine rear oil seal (5) further, and
remove pilot [3].
HB215LC-2 50-79
4. Install engine rear seal (5) to the proper depth in

a Tighten the bolts while preventing rotation of the
flywheel housing (7) by using tool A5.
flywheel by using lock [4].
a When inserting engine rear seal (5), be careful
that there are no bend etc. on it.
a Protrusion of engine rear seal (5) from flywheel

housing (7)
(X): Max. 0.38 mm
a (6) in the figure below indicates the crankshaft.
q Measurement of radial runout
a Radial runout: Max. 0.13 mm

1. Install dial gauge [5] on the stand, and set it to
flywheel housing (7).
2. Set the probe of the dial gauge perpendicularly to
the spigot joint part (a) or outside perimeter of the
flywheel.
3. Rotate the flywheel 1 turn, and measure the
difference between the maximum readings of the
pointer runout of dial gauge [5].
a When the flywheel rotated 1 turn, check that

the pointer of dial gauge [5] indicates the same
value as it of the starting rotation.
q Measurement of facial runout
a Facial runout: Max. 0.20 mm

1. Similarly to the measurement of radial runout, set
[*1] dial gauge [5] so that its probe is at a right angle
with the end face (b) near the outside perimeter of
a Tighten flywheel assembly mounting bolts (3) (8
the flywheel.
pieces) in the order [1] to [8] as shown in the figure
below. a Perform the measurement with the crankshaft
Flywheel assembly mounting bolt: Width across flats 18 pulled to either the front or rear side of the
mm engine to prevent errors caused by backlash.
3 Flywheel assembly mounting bolt: 2. Rotate the flywheel 1 turn, and measure the
137 ± 7 Nm {13.97 ± 0.71 kgm} difference between the maximum readings of the
pointer runout of dial gauge [5].
50-80 HB215LC-2
3. Rotate the flywheel 1 turn, and measure the

difference between the maximum readings of
the pointer runout of dial gauge [5].
C When the flywheel rotated 1 turn, check
that the pointer of dial gauge [5] indicates
the same value as it of the starting
rotation.
order to removal.
HB215LC-2 50-81
Removal and installation of fuel cooler assembly (HB205-B7W0-924-K-00-A)


k Drain the fuel since the fuel does not stop

flowing through the fuel tank return hose
when the fuel level is high.
4. Disconnect fuel hoses (4) and (5). [*1]
6 Fuel tank (when the tank is full):
C Prepare an oil container to receive fuel
400 N
flowing out of the fuel hose.
Removal (HB205-B7W0-520-K-00-A)
C When disconnecting the fuel hose, fix elbows
1. Open side cover (1) on the left side of the (6) and (7) on the fuel cooler side, and then
machine. disconnect the hose.
C If the elbow is not fixed to disconnect the
hose, the force may be applied to the fuel
cooler assembly and the assembly may be
damaged.
5. Remove cover mounting bolt (9), and remove

cover (10).
6. Remove fuel cooler assembly mounting bolts (8)

(2 pieces), and remove fuel cooler assembly
(12).
50-82 HB215LC-2
(Position of fuel cooler assembly (12) after

removal of the counterweight is shown.)
Installation (HB205-B7W0-720-K-00-A)

order to removal.
[*1]
C When installing the hose, be sure to fix elbows
(4) and (5) on the fuel cooler assembly side by
using another wrench, and tighten it so that the
force is not applied to the fuel cooler assembly.
C If the wrench is not used, the force may be
applied to the fuel cooler assembly and it may
be damaged.
HB215LC-2 50-83
Removal and installation of fuel tank assembly (HB205-AD10-924-K-00-A)


Removal (HB205-AD10-520-K-00-A)
5. Remove handrail (6).

C Handrail (6) bottom mounting bolt is provided
also inside the tool case.

machine, open fuel drain valve (2), and drain the
fuel.

6. Disconnect connector L02 (7).
400 N
7. Remove R.H. headlamp (8). [*3]

4. Remove plate (4) and handrail (5). 8. Remove bolts (9) (4 pieces), and remove battery
box (10).
4 Battery box (10):

35 kg
50-84 HB215LC-2
9. Remove bolts (11) (4 pieces), and remove cover (12).
Installation (HB205-AD10-720-K-00-A)
10. Disconnect clamp (13) and connector P21 (14).
[*1]
Fuel supply hose (15) and fuel return hose (16): Width
across flats 22 mm
3 Fuel supply hose (15) and fuel return hose
(16):
54 to 93 Nm {5.5 to 9.5 kgm}
[*2]
235 to 285 Nm {23.5 to 29.5 kgm}
11. Disconnect fuel supply hose (15) and fuel return hose [*3]
(16). [*1] R.H. headlamp (8) mounting bolt: Width across flats
12. Loosen clip (17), and disconnect fuel drain hose (18). 19 mm
13. Remove mounting bolts (19) (8 pieces), sling fuel tank 3 R.H. headlamp (8) mounting bolt:
(20), and remove it. [*2] 17.6 to 19.6 Nm {1.8 to 2.0 kgm}
4 Fuel tank: q Check for fuel leakage (fuel system)
180 kg After refilling with oil, check the fuel system for
leakage. For details, see Testing and adjusting,
"Testing fuel circuit for leakage".
q Bleeding air (fuel system)
Bleed air from the fuel system. For details, see Testing
and adjusting, "Bleeding air from fuel system".
HB215LC-2 50-85
Removal and installation of engine hood assembly (HB205-H540-924-K-00-A)
Removal (HB205-H540-520-K-00-A)
1. Open engine hood (1), sling it, and hold it to

prevent it from being closed.
5. Remove mounting bolts (7) (4 pieces), open

hinges (8) (2 places), and disconnect them from
engine hood (1). [*1] [*2]
2. Remove gas springs (2) and (3).

3. Remove stay (5).
6. Sling engine hood (1), and remove it.
4 Engine hood:
50 kg
4. Close engine hood (1) temporarily, and remove

hinge cover (6) on the rear of the engine hood.
Installation (HB205-H540-720-K-00-A)
C Close the engine hood while it is slung and
held. • Perform installation in the reverse order to
removal.
[*1]
Adjustment procedure for installation of the engine
hood
1. Tighten hinge (8) of engine hood (1) with
mounting bolts (7) (4 pieces).
50-86 HB215LC-2
C Lightly tighten the bolts until the engine hood • Looking into hole (B), clearance (b) between
does not move in all directions when bracket (13) and inside surface of the engine
opening/closing it. hood does not interfere.
C After installing the engine hood, sling and
hold it to prevent it from falling off.
5. If the clearance between bracket and inside of

the engine hood interferes, check that brackets
(12) and (13) installed to frame (11) are installed
2. Slowly lower engine hood (1), bring catch (9) within the range of the dimensions.
close to pin (10) on the machine body side, and X: 177.5 ± 1 mm
check the installation status. Y: 89 ± 1 mm
3. Adjust the front and rear of engine hood (1) so 6. If adjustment is required, loosen the engine
that spring box (14) of catch (9) becomes hood mounting bolts (4 pieces) and move the
approximately vertical. engine hood to adjust the clearance.
C Repeat steps 2. to 5. until you can open/
close the engine hood smoothly.
7. After adjustment, tighten mounting bolt (7) of
hinge (8) to the specified torque.
4. Look into holes (A) and (B) of the closed engine

hood, and check the clearance inside the engine
hood.
• Looking into hole (A), clearance (a) between
bracket (12) and inside surface of the engine
hood must be 1 mm or more. [*2]
Catch adjustment procedure
HB215LC-2 50-87
C Adjust the lock part of catch (9) when installing

the engine hood according to the following
procedure.
1. Loosen mounting bolt (15) of catch (9).
2. Hook catch hook (16) to the bump part of pin

(10) on the frame side with the lever of catch (9)
opened horizontally.
3. Make a mark on the under surface position of

the catch seat with the lever of catch (9) kept
horizontally and pulled up to the top.
4. Align with the marked position, and then tighten
mounting bolt (15).
5. Check that catch (9) can be locked smoothly.

C Repeat steps 1. to 4. until you can lock catch
(9) smoothly.
50-88 HB215LC-2
Removal and installation of KDOC assembly (HB205-A9H2-924-K-00-A)

k Stop the machine on a level surface, lower the
work equipment to the ground so that it is stable,
and stop the engine.
k Turn the disconnect switch to OFF position, and

remove the key.
k After the engine is stopped, the parts are very hot.

Wait until all parts are cooled down.
Removal (HB205-A9H2-520-K-00-A) 4. Remove U-bolts (6). [*2]
1. Remove plate mounting bolts (1) (6 pieces), and

remove plate (2).
5. Sling KDOC assembly (7), and remove it.

Installation (HB205-A9H2-720-K-00-A)
2. Remove mounting bolts (3) (4 pieces), and remove q Perform installation in the reverse order to removal.
bracket (4). [*1]
44.1 to 53.9 {4.5 to 5.5 kgm}
[*2]
U-bolt 1st stage: Width across flats 19 mm
3 U-bolt 1st stage:
14.7 to 34.3 Nm {1.5 to 3.5 kgm}
U-bolt 2nd stage: Width across flats 19 mm
3 U-bolt 2nd stage:
20.1 to 49 Nm {2.05 to 5.0 kgm}
3. Remove mounting bolts (5) (4 pieces). [*1]
HB215LC-2 50-89
Removal and installation of KCCV assembly (HB205-A180-924-K-00-A)



k If hoses are wrongly assembled, it may

result in engine damage. So be careful when 4. Remove step (4).
assembling hoses.
Removal (HB205-A180-520-K-00-A)
1. Remove bolt (1), and remove undercover (2).
5. Remove joint bolt (5), and disconnect coolant

outlet hose (6). [*1]
6. Loosen clip (7), and disconnect blowby gas
outlet hose (8). [*2]
7. Remove joint bolt (9), and disconnect coolant

inlet hose (10). [*3]
3. Remove mounting bolts (3a) (3 pieces).
50-90 HB215LC-2
4) Disconnect connector P57 (23).

5) Remove hose clamps (24) (2 pieces), and
remove hose (18).
6) Remove hose clamps (25) (2 pieces), and
remove hose (19).
8. Loosen clip (11), and disconnect blowby gas

inlet hose (12). [*4]
9. Loosen clip (13), and disconnect oil drain hose
(14). [*5]
10.Remove bolts (15) (2 pieces), and remove

KCCV ventilator assembly (16) together with
bracket (17).
11.Disconnect KCCV ventilator assembly (16) from
bracket (17).
13.When replacing the following hoses, remove

them according to the following procedure. [*3]
[*5]
• Coolant inlet hose (10)
12.When replacing the following hoses, remove • Oil drain hose (14)
them according to the following procedure. [*1]
[*4] 1) Remove clamps (26) and (27).
• Coolant outlet hoses (6) and (18) C Clamp (27) is tightened together with
• Blowby gas inlet hoses (12) and (19) hoses (10) and (14).
1) Remove clamp (20). 2) Remove hose clamps (28) (2 pieces), and
2) Remove hose clamps (21) (2 pieces), and remove hose (10).
remove hose (6). 3) Remove clamp (29).
3) Remove hose clamps (22) (2 pieces), and 4) Remove hose clamps (30) (2 pieces), and
remove hose (12). remove hose (14).
HB215LC-2 50-91
5) Remove hose clamps (31) (2 pieces), and remove

hose (32).
k If KCCV drain hose (14 and coolant inlet hose (10
are wrongly assembled, the engine may be
damaged. So be careful not to assemble wrongly.
[*1] [*3]
Joint bolts (5) and (9): Width across flats 17 mm
3 Joint bolts (5) and (9):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*2] [*4] [*5]
q Install coolant inlet hose (10) according to the
Hose insertion depth (a): 30 mm
Between hose tip and clamp (b): 5 mm
Hose clamp (28): Width across flats 7 mm
3 Hose clamp (28):
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
14. When replacing the following hoses, remove them

according to the following procedure. [*2]
q Blowby gas outlet hose (8)
Remove hose clamps (7) (2 pieces), and remove hose
(8). Remove hose clamps (7) (2 pieces), and remove
hose (33).
50-92 HB215LC-2
q Install coolant outlet hose (6) according to the

a The following is the method of replacing hose (6)
between KCCV ventilator assembly (16) and
intermediate block (34).
3 Hose clamp (21):
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
q Install blowby outlet hose (8) and (33) according to the

Hose insertion depth (d): 25 mm
Hose insertion depth (e): 35 mm
3 Hose clamp (7):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}

between engine and intermediate block (34).
3 Hose clamp (24):
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
HB215LC-2 50-93
3 Hose clamp (25):

4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
q Install blowby inlet hose (12) according to the


intermediate block (24).
Between hose tip and clamp (f): 3 mm
Between hose tip and clamp (g): 5 mm
3 Hose clamp (22):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
q Install oil drain hose (14) according to the following

procedure.

check valve (35).
3 Hose clamp (30):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}

between engine and intermediate block (34).
between check valve (35) and engine.
Hose insertion depth (h): 17 mm
50-94 HB215LC-2

3 Hose clamp (31):
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
HB215LC-2 50-95
Removal and installation of air cleaner assembly (HB205-A910-924-K-00-A)

k Stop the machine on a level surface, lower the
work equipment to the ground so that it is stable,
k Turn the disconnect switch to OFF position, and

remove the key.
Removal (HB205-A910-520-K-00-A)
1. Open side door (1) on the left side of the machine.
6. Remove air cleaner assembly mounting bolts (6) (4
pieces).
2. Remove connector cover (2).
7. Remove air cleaner assembly (7).

[*1]
Clamp (5): Width across flats 9.5 mm
3 Clamp (5):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
q Install the air cleaner hose according to the following
procedure.
3. Disconnect connector (3). Band position (a): 10 mm
Connector No.(3): P55 Hose insertion depth (b): 45 mm
4. Disconnect spill tube (4).

5. Disconnect clamp (5). [*1]
50-96 HB215LC-2
Removal and installation of EGR (Exhaust Gas Recirculation) valve

assembly (HB205-A9K1-924-K-00-A)


Removal (HB205-A9K1-520-K-00-A)
4. Remove the KCCV assembly. For details, see
1. Remove undercover (1). "Removal and installation of KCCV assembly".
5. Remove pin (4), and disconnect lock bar (5).
C When disconnecting the lock bar, fix the
engine hood to prevent it from falling down.
bracket (7).
2. Drain the coolant from drain valve (2).
6 Coolant:
23 N
7. Disconnect the EGR gas temperature sensor

connector EXHAUST GAS TEMP (8).
8. Remove bolt (9).
9. Remove mounting bolts (10) (3 pieces).
10.Loosen clamps (11) (2 pieces), and remove
EGR piping flange (13) from hose (12). [*1]
11.Disconnect connector VFT (14).
HB215LC-2 50-97

EGR valve assembly (16).
Installation (HB205-A9K1-720-K-00-A)
[*1]
Clamp: Width across flats 9.5 mm
3 Clamp:
10.5 ± 05. Nm {1.1 ± 0.05 kgm}
Bolt (M8 x 1.25): Width across flats 10 mm
3 Bolt (M8 x 1.25):
24 ± 4 Nm {2.45 ± 0.41 kgm}
Refill it with coolant to the specified level through the
coolant filler port of the radiator. Run the engine to
again.
5 Radiator:
23 ℓ
50-98 HB215LC-2
Removal and installation of EGR (Exhaust Gas Recirculation) cooler

assembly (HB205-A9L0-924-K-00-A)


Removal (HB205-A9L0-520-K-00-A)
4. Remove bolts (3a) (3 pieces).
5. Remove bolts (4) (4 pieces), and remove step

2. Drain the coolant from drain valve (2). (5).
6 Radiator:
23 N
6. Loosen clamps (6) (2 pieces),, and remove tube

(8) from hose (7). [*1]
HB215LC-2 50-99
7. Remove joint bolt (9). 14. Remove mounting bolt (21), and remove tube (8).
8. Remove joint bolt (10), and remove tubes (11) and
(12).
15. Remove mounting bolts (23) (2 pieces).

9. Remove mounting bolts (13) (2 pieces). EGR cooler (26).
10. Remove bolt (14).
11. Remove clamp (15), and remove tube (17) from hose
(16).
Installation (HB205-A9L0-720-K-00-A)
12. Remove mounting bolt (18). [*1]
13. Loosen clamp (19), and remove tube (20). Clamp: Width across flats 9.5 mm
3 Clamp:
10.5 ± 0.5. Nm {1.1 ± 0.05 kgm}
Bolt (M8 x 1.25): Width across flats 10 mm
3 Bolt (M8 × 1.25):
24 ± 4 Nm {2.45 ± 0.41kgm}
3 Bolt (M10 × 1.5):
43 ± 6 Nm {4.39 ± 0.61kgm}
50-100 HB215LC-2
Joint (M10 x 1.0): Width across flats 14 mm

3 Joint (M10 × 1.0):
12± 2Nm {1.22 ± 0.20kgm}
Refill it with the coolant to the specified level through
the coolant filler port. Run the engine to circulate the
coolant through system. Then check the coolant level
again.
5 Coolant:
23ℓ
HB215LC-2 50-101
Hybrid system
Draining coolant, refilling with coolant, and bleeding air for hybrid
system (HB205-PQJA-200-K-00-A)
C The removal and installation in this section do your eye.
not require the "completion of the special
training for low-voltage electric work". The super coolant mixed in the coolant is
poisonous. If the coolant sticks to your skin
k Never disconnect any high-voltage wiring or enters your eye, immediately rinse with
(power cable) during removal and installation water thoroughly and see a doctor.
in this section.
2. Open left side inspection cover (2).
SM: Electric swing motor

HR: Hybrid radiator 3. After checking that the temperature of water filler
WP: Hybrid water pump cap (3) of the hybrid radiator (HR) is low enough
for bare hands to touch, open water filler cap (3)
HI: Inverter
slowly.
HC: Capacitor
(2): Water filler cap
(4): Drain valve
(5): Swing motor air bleeding plug
(6): Coolant filler port
(7): Swing motor elbow plug (in)
(8): Swing motor elbow plug (out)
(9): Overflow hose
Drain
k Stop the machine on a level ground, lower
the work equipment to the ground, and stop 4. Remove undercover (4).
the engine.
k Before opening the water filler cap or

draining coolant, check that the coolant
temperature cools down to the temperature
safe enough for anyone not to get burn.
Hybrid system
50-102 HB215LC-2
Hybrid system
5. Place a container to receive coolant below the drain

hose, and loosen water pump drain plugs (5) to drain
the coolant.
6 Hybrid radiator:
6.0 ℓ
3. Pour coolant from water filler (6) of the hybrid radiator

slowly (taking approximately 5 minutes) up to the
upper side gauge (SG) position.
5 Hybrid radiator: 3.9 ℓ
a Be careful not to spill coolant out from the water

Refilling with coolant and bleeding air filler of the hybrid radiator.
a Make sure to use Komatsu genuine Super Coolant a The mixing proportion of super coolant must be
(AF-NAC) as coolant. minimum of 30% in volume ratio.
a Determine the ratio of water in the coolant by

a Use tap water as dilution water.
checking the lowest ambient temperature in the
k Undiluted super coolant is flammable. Be careful past and checking the mixing proportion table
of open flame. below.
Actually, set a temperature approximately 10°C
lower than the lowest temperature.
1. Install capacitor drain valves (5).
Capacitor drain valve: Width across flats 14 mm
(Exchange capacity in the hybrid system radiator: 5.5 ℓ)
3 Capacitor drain valve:
88 to 8.82 Nm {0.6 to 0.9 kgm}
Min.
Mixing ratio -15 -20 -25 -30 (-35) (-40)
–10
Amount of
super coolant 1.6 1.9 2.3 2.5 2.8 (3.0) (3.2)
(ℓ)
Water quantity
3.6 3.3 3.1 2.8 2.6 2.4 2.2
(ℓ)
Volume
30 36 41 46 50 (54) (58)
ratio(%)
2. Install cover (4).
4. Close water filler cap (3), turn on the starting key

switch to rotate the water pump (WP), and turn
HB215LC-2 50-103
Hybrid system
off the key switch in 2 minutes to stop the water Total replacement of hybrid coolant
pump (WP).
C When changing the mixing proportion of super
coolant, or when it is required to replace all the
k Never start the engine. coolant because of a problem such as
C If the time from refilling with coolant to turning lubrication oil of the swing motor mixed into the
on the starting switch is taken too long, air coolant, replace the coolant according to the
accumulates in the water pump suction side following procedure.
causing the water pump defective suction. 1. Drain the coolant from the water pump, capacitor,
Turn on the starting switch promptly after and capacitor case. For details, see "Drain".
refilling. 2. Loosen clamps (10) of the return tube and hose
C Touch the water pump (WP) directly with from the swing motor, and disconnect tube (11).
hands to see if the hybrid system water C Before disconnecting tube (11), provide a
pump (WP) is rotating. (Pump driving sound container to receive drained coolant below
is too low to hear for determination.) the disconnection part above.
3. Take measures to prevent spraying of coolant
such as installing a heavy-duty plastic bag on
the disconnected tube (11) side.
4. Close water filler cap (2) and supply
compressed air (for impact wrenches, etc.) into
disconnected hose (12) to discharge all the
coolant forcibly (to prevent spraying of coolant).
C Make sure to close the radiator cap
mentioned above before performing it.
6 Discharged coolant amount:

7.0 N
5. Connect the disconnected hose, and install the
clamp.
6. Supply the specified coolant according to steps
3 to 6 in "Refilling with coolant and bleeding air"
above to clean the circuit.
7. Repeat above steps 1 to 4 (Clean the inside and
drain the coolant). If necessary, repeat steps 6
and 7 (Clean the inside and drain the coolant).
8. Insert and connect the disconnected hose into
the original position of the tube, and tighten the
clamp to the specified torque.
3 Hose clamp:
5. The water level drops when the water pump 3.9 to 4.9 Nm {0.4 to 0.5 kgm}
rotates. Supply coolant several times until it gets 9. Perform the following steps 1 to 9 (Procedures
to the upper side gauge (SG). for refilling with coolant and bleeding air after
6. Loosen the radiator cap to complete air complete drain) to refill with the specified coolant
bleeding. and bleed air.
7. Air may remain in the coolant circuit. Perform the 1) Add coolant through water filler port (6) of the
following work. hybrid radiator slowly (taking approximately 5
1) In 8 hours after completing the work, check minutes). (5.7 N)
the coolant level of the hybrid radiator. C Be careful not to spill coolant out from the
2) If the coolant level is low, supply coolant until water filler of the hybrid radiator.
it gets to the upper side gauge (SG).
C The mixing proportion of super coolant
must be minimum of 30% in volume ratio.
50-104 HB215LC-2
Hybrid system
C Determine the ratio of water in the coolant

by checking the lowest ambient
temperature in the past and checking the
mixing proportion table below.
Actually, set a temperature approximately
10°C lower than the lowest temperature.
(Exchange capacity in the hybrid system radiator:
5.5 N)
Min. (– (–
Mixing ratio –10 –15 –20 –25 –30 35) 40)
Amount of
super 1.6 1.9 2.2 2.5 2.7 (2.9) (3.1)
coolant (N)
Water
quantity (N) 3.6 3.3 3.1 2.8 2.6 2.4 2.2
Volume ratio
(%) 30 36 41 46 50 (54) (58)
2) Open water filler cap (2), turn on the key

switch to rotate the water pump, and turn off
the key switch 1 minute later to stop the
water pump.
3) The water level drops when the water pump
rotates. Supply coolant until it gets to the
upper side gauge (SG).
4) Close water filler cap (2), turn on the key
switch to rotate the water pump, and turn off
the key switch 20 minutes later to stop the
water pump.
5) Open water filler cap (2). If the coolant level
is low, supply coolant until it gets to the upper
side gauge (SG).
6) Tighten the water filler cap (2) to complete air
bleeding.
7) Some air may remain in the coolant circuit.
Check the coolant level after the work
(approximately 8 hours), and supply coolant
until it gets to the upper sight gauge (SG).
HB215LC-2 50-105
Hybrid system
Removal and installation of hybrid radiator assembly (HB205-PQHD-924-K-00-A)
• The removal and installation in this section do

training for low-voltage electric work".


your eye.
k The super coolant mixed in the coolant is

or enters your eye, immediately rinse with
water thoroughly and see a doctor.
5. Remove capacitor drain plugs (5), and drain the
Removal (HB205-PQHD-520-K-00-A) coolant. [*1]
6 Hybrid radiator:
2. Open side cover (2) on the left side of the
machine. 6.0 N
3. Open water filler cap (3) of the hybrid system 6. Remove nuts (6) (3 pieces), and remove cover
radiator. (7).
50-106 HB215LC-2
Hybrid system
7. Remove clamps (8). 12.Loosen clamps (16) and (17), and remove filler
8. Disconnect clip (9). hose (18).
• Protect the radiator core portion by 13.Remove bolt (19).
corrugated fiberboard, etc. to prevent the 14.Loosen clamp (20), and disconnect radiator
radiator core from being damaged when upper hose (21). [*2]
disconnecting clamps (8) and clip (9).

9. Disconnect connectors P18 (10) and HK05 (11). remove air conditioner condenser assembly (23).
10.Remove bolt (12), and remove bracket (13). [*3]
C Do not remove the air conditioner hose, and
move it so that it does not hinder the work.
11.Remove clamp (14), and disconnect radiator

lower hose (15).
16.Remove bolts (24), and remove hybrid radiator
assembly (25). [*4]
HB215LC-2 50-107
Hybrid system
Installation (HB205-PQHD-720-K-00-A)
[*1]
Capacitor drain plug (5): Width across flats 14 mm
3 Capacitor drain plug (5):
5.88 to 8.82 Nm {0.6 to 0.9 kgm}
[*2]
3 Clamp (20):
3.91 to 4.89 Nm {0.27 to 0.47 kgm}
[*3]
2 Threaded portion of air conditioner condenser
assembly mounting bolt (22):
Liquid adhesive (LT-2)
10.0 to 15.0 Nm {1.0 to 1.5 kgm}
[*4]
14.7 to 34.0 Nm {1.5 to 3.5 kgm}
q Refilling with coolant and bleeding air
a Refill with coolant and bleed air in the hybrid

radiator. For details, see "Procedures for draining
coolant, refilling with coolant, and bleeding air for
hybrid system".
50-108 HB215LC-2
Hybrid system
Removal and installation of hybrid water pump assembly (HB205-PQGV-924-K-00-A)
C The removal and installation in this section do

training for low-voltage electric work".

position, and remove the key. 4. Remove cover (5).

your eye.
k The super coolant mixed in the coolant is

Removal (HB205-PQGV-520-K-00-A)
coolant. [*1]
1. Open engine hood (1). 6 Hybrid radiator:

2. Open side covers (2) and (3) on the left side of
6.0 N
the machine.
6. Disconnect connector M06 (7).

3. Open water filler cap (4) of the hybrid system
7. Disconnect washer hose (8).
radiator.
washer tank (10).
HB215LC-2 50-109
Hybrid system

Refill with coolant to the specified level through the
hybrid radiator filler port of the radiator. Run the
engine to circulate the coolant. Then check the
coolant level again.
5 Hybrid radiator:
5.5ℓ
a Refill the hybrid radiator with coolant and bleed

air. For details, see "Procedures for draining
9. Disconnect connector HK01 (11).
hybrid system".
10. Remove clip (12), and disconnect capacitor hose (13)

between water pumps.
11. Remove clip (14), and disconnect water pump hose
(15) between hybrid radiators.
hybrid system water pump (17).
Installation (HB205-PQGV-720-K-00-A)
[*1]
Capacitor drain plug (6): Width across flats 14 mm
3 Capacitor drain plug (6):
5.88 to 8.82 Nm {0.6 to 0.9 kgm}
50-110 HB215LC-2
Hybrid system
Removal and installation of inverter assembly (HB205-PQGK-924-K-00-A)
Removal (HB205-PQGK-520-K-00-A)
k The removal and installation in this section 1. Drain coolant from the hybrid system radiator
must be performed by persons "who according to the following procedure.
completed the special training for low-
1) Open engine hood (1).
voltage electric work".
2) Open side cover on the left side of the
Before performing work, understand 00 machine.
notice 1. Precautions Specific to Hybrid
C Special tools
Necessity
Sym-
bol
Part No. Part name Q'ty
B 1 7875-35-2910 Cap V 4

Capacitor discharge procedure—" in 00 3) Open water filler cap (3) of the hybrid system
Foreword, Safety, Basic information, radiator.
Voltage Wires".
k Disconnect the one-touch connectors ((+)

and (-) cable terminals) (2 pieces) (see step
8).
k Place the machine on a level ground, lower

the work equipment to the ground, and stop
the engine.

hydraulic circuit and set the lock lever to
LOCK position. For details, see "Releasing 4) Remove bottom cover (4).
remaining pressure in hydraulic circuit" in
Testing and adjusting.



your eye. 5) Remove capacitor drain plugs (5), and drain
The super coolant mixed in the coolant is coolant.
or enters your eye, immediately rinse with 6 Hybrid radiator:
water thoroughly and see a doctor. 6.0 N
HB215LC-2 50-111
Hybrid system
(17): HC06
(18): HC05
(19): HC04
(20): HC03
make sure to install tool B1.
C Tool B1 prevents water and dust from
entering into the connector part.

remove cover (7).
8. Disconnect connectors (21) to (25). [*2]

(Connector No.)
(21): HC02
(22): HC01
(23): P18
(24): HK05
3. Remove nuts (9) (3 pieces) at the top of the
(25): HP01
inverter, and remove cover (10).

bracket (12).
5. Disconnect connectors HB01 (13a) and (13b).
C Pull out the connector by pressing the lock
part of the connector with your thumb to
release the lock.
C When disconnecting the clamp and wiring,
protect the hybrid radiator core portion from
damages by using corrugated fiberboard,
etc.
6. Remove high voltage wiring (power cable)
clamps (14), (15), and (16). 9. Disconnect swing motor hose (27) between
7. Disconnect high voltage wiring (power cable) inverters and inverter hose (28) between
connectors (17) to (20). [*1] capacitors from inverter assembly (29).
(Connector No.): (From left)
50-112 HB215LC-2
Hybrid system
2. Insert the cable side plug straight into the motor

side power supply terminal socket (S) so that the
plug does not touch the case.
a Make sure that black marking faces upward.

a Insert power cable removal and installation
detection contact (Q) with having the cable
facing the bottom.
High voltage wiring (power cable) plug mounting
bolt: Width across flats 5 mm
3 High voltage wiring (power cable) plug
mounting bolt:
bracket (33). 8.8 to 10.8 Nm {0.9 to 1.1 kgm}
11. Remove mounting bolts (30) (4 pieces). [*2}

12. Install eyebolts to cover mounting part (A).
13. Sling inverter assembly (31), and remove it.
4 Inverter assembly:
35 kg
[*2]
3 Wiring connectors (21) and (22):
2.6 to 3.1 Nm {0.27 to 0.32 kgm}
Tightening torque of inverter mounting bolt: Width across
flats 17 mm
3 Tightening torque of inverter mounting bolt:
Installation (HB205-PQGK-720-K-00-A)
59 to 74 Nm {6.0 to 7.6 kgm}
[*1] q Refilling with coolant and bleeding air
q Install the connector of the high voltage wiring (power a Refill with coolant and bleed air in the hybrid
cable) according to the following procedure. radiator. For details, see "Procedures for draining
1. Check that there is no stain or scratch on the cable coolant, refilling with coolant, and bleeding air for
side plug (P). hybrid system".
HB215LC-2 50-113
Hybrid system
Removal and installation of inverter and capacitor assembly (HB205-RA21-924-K-00-

A)
Removal (HB205-RA21-520-K-00-A)
k The removal and installation in this section k Disconnect the one-touch connectors ((+)
must be performed by persons "who and (-) cable terminals) (2 pieces) from
completed the special training for low- capacitor (see step 12).
Before performing work, understand 00 1. Drain coolant from the hybrid radiator according
Foreword, Safety, Basic information, "Safety to the following procedure.
Equipment" and "Handling Hybrid 6 Hybrid radiator:
Equipment and High-Voltage Wires". 6.0 N
C Special tools 1) Open engine hood (1).
Necessity
Sym-
Q'ty
Part No. Part name

bol
1 7875-35-2910 Cap V 4
B
3 796T-426-1110 Assembling jig V 1

Voltage Wires".
2) Open side cover on the left side of the
k Stop the machine on a level ground, lower machine.
the work equipment to the ground, and stop 3) Open water filler cap (3) of the hybrid system
the engine. radiator.

LOCK position. For details, see "Releasing


safe enough for anyone not to get burn. 4) Remove bottom cover (4).

your eye.
The super coolant mixed in the coolant is
50-114 HB215LC-2
Hybrid system
5) Remove capacitor drain plugs (5), and drain 5. Disconnect overflow hose (12).
coolant. 6. Remove reservoir tank (13).
2. Remove mounting bolts (6) (4 pieces), and 7. Remove mounting bolts (14) (3 pieces), and
remove cover (7). remove bracket (15).
8. Disconnect connector HB01 (16) and (16a).
C Insert corrugated fiberboard, etc. between
the hybrid radiator and inverter assembly to
prevent the hybrid radiator from being
damaged.
part of the connector with your thumb to
release the lock.
9. Remove high voltage wiring (power cable)
clamps (17), (18), and (19).
10.Disconnect high voltage wiring (power cable)
connectors (20) to (23). [*1]
3. Remove nuts (9) (3 pieces) at the top of the (Connector No.): (From left)
inverter, and remove cover (10). (20): HC06
(21): HC05
(22): HC04
(23): HC03
entering the connector portion.
C When disconnecting the clamp and wiring,
damages by using corrugated fiberboard,
etc.
4. Disconnect connector HK01 (11).
HB215LC-2 50-115
Hybrid system
11.Disconnect wiring connectors (24) to (28). [*2] 15.Remove mounting bolts (30) (2 pieces), and
(Connector No.) remove bracket (31).
(24): HC02
(25): HC01
(26): CN-P18
(27): HK05
(28): HP01
16.Remove mounting bolt (32), loosen hose clamp

(33), and disconnect hybrid radiator lower hose
(34). [*3]
17.Remove clamp (35), and disconnect hose (36)
from inverter (37).
18.Disconnect capacitor hose (38) between water
pumps.
remove hose fixing bracket (40) from inverter
and capacitor assembly (41).
12.Remove power cable clip (48).

13.Remove harness clip (49).
50-116 HB215LC-2
Hybrid system
20. Disconnect ground cable (42). Installation (HB205-RA21-720-K-00-A)

21. Remove mounting nuts (43) (2 pieces). [*4]
[*1]
Connector mounting bolt: Width across flats 5 mm
3 Connector mounting bolt:
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
[*2]
3 Clamp:
3.9 to 4.9 Nm {0.4 to 0.5 kgm}
[*3]
a Replace capacitor and inverter assembly mounting

nut (01596-01211) (4 pieces) with a new one. (Used
22. Disconnect ground cable (44). nuts will become loosened and the torque is
23. Remove mounting nuts (45) (2 pieces). deteriorated.)
Tightening torque: Width across flats 19 mm
3 Tightening torque:
35 to 44 Nm {3.5 to 4.5 kgm}
Tighten them diagonally in the order of [1] to [4] in the
figure below.
24. Sling inverter and capacitor assembly (41), and

remove them by using the eyebolts at corners (4
places) of the capacitor bottom.
a Place a cloth between the inverter and capacitor

assembly and lifting tool not to make scratches on
the inverter and capacitor assembly. [*4]
4 Inverter, capacitor assembly: After loosening the rubber mount mounting bolt, position
125 kg the rubber mount according to the following procedure.
1. Install rubber mount (46) and finger-tighten mounting
a Do not loosen mounting bolts (47) (4 pieces) of
rubber mounts (46). bolts (47).
HB215LC-2 50-117
Hybrid system
2. Install tool B3.

3. Determine the position of nut (47) with tool B3,
and tighten rubber mount mounting bolt (46).
• Refilling with coolant and bleeding air

Refill the hybrid radiator with coolant and bleed
air. For details, see "Procedures for draining
hybrid system".
50-118 HB215LC-2
Hybrid system
Procedure for draining and refilling generator lubricating oil (HB205-PQJZ-200-K-00-A)
a The removal and installation in this section do not

require the "completion of the special training for
low-voltage electric work".
k Never disconnect any high-voltage wiring (power

cable) during removal and installation in this
section.
k Stop the machine on a level ground, lower the

work equipment to the ground, and stop the
engine.
2. Install undercover (1) of the motor-generator part.
k Set the lock lever to LOCK position.

Drain
1. Remove lower cover (1) of the motor-generator.
3. Open side cover (4) on the right side of the machine.
2. Place a container to receive oil below oil drain plug (3)

of motor-generator housing (2).
6 Motor-generator housing:
6.0 l
4. Open oil filler port (5), refill with the oil up to the
specified capacity.
6.0 l
6.5 ℓ (specified capacity)
Oil filler port: Width across flats 32 mm
3 Oil filler port:
93.1 to 122.5 Nm {9.5 to 12.5 kgm}
a Check the oil level with the oil gauge.
Refilling with oil

1. Tighten drain plug (3).
HB215LC-2 50-119
Hybrid system
C Start the engine to circulate the oil through

the lubrication circuit. Check the oil level
again, and refill oil.
Oil level inspection procedure

1. Remove oil gauge (6) and wipe off oil on the
gauge with a cloth, etc.
2. Insert oil gauge (6) fully into the guide.
3. Remove oil gauge (6). It is normal if oil is in the
range specified in the figure (marks (H)-(L)).
4. Supply oil if it is below (L) of oil gauge (6).
5. If it is over (H) of oil gauge (6), loosen drain plug
to drain excess oil.
50-120 HB215LC-2
Hybrid system
Removal and installation of tandem pump assembly (HB205-RA11-924-K-00-A)
C The removal and installation in this section do

not require the completion of the special training
for low-voltage electric work.
k Never disconnect any high-voltage wiring
(power cable) during removal and installation
in this section.

4. Loosen oil drain plug (4), and drain the oil. For
details, see "Procedures for draining and filling
lubricating oil". [*1]
k After the engine is stopped, the parts are 6.0 N
Removal (HB205-RA11-520-K-00-A)
5. Open engine hood (5a).
2. If the fuel level is above the return hose, open

fuel drain valve (2) to drain the fuel.

400 N
6. Disconnect connector E24 (5).

7. Disconnect clamp (6).
8. Disconnect KCCV hose clamp (7).
9. Disconnect the wiring and hoses from the fuel
supply pump assembly according to the
C Record the disconnected parts of hoses and
the fixed parts of clamps.
3. Remove bottom cover (3). C Cover the tips of the disconnected hoses
with cloth.
HB215LC-2 50-121
Hybrid system
1) Remove fuel hose clamp (8). [*2]
Installation (HB205-RA11-720-K-00-A)
2) Disconnect hose (9) from the prefilter. [*3] q Perform installation in the reverse order to removal.
3) Disconnect fuel return hose (10) from the engine. [*1]
Oil drain plug (4): Width across flats 32 mm
3 Oil drain plug (4):
58.8 to 78.4 Nm {6.0 to 8.0 kgm}
Target value: 68.6 Nm {7.0 kgm}
6l
6.5 l(specified capacity)
[*2]
a Clamp the fuel hose at the removed part.
[*3]
Hose tightening bolt: Width across flats 19 mm
3
10. Disconnect 4 lubricating oil hoses (11) to (14) (4 Hose tightening bolt:
pieces). [*4] 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
(11): Hose to the swing motor
[*4]
(12): Hose from the swing motor
(13): Hose to the motor-generator a Ensure that mud or dirt is not sticking to the hose
fitting or interior.
(14): Hose from the motor-generator
Lubricating oil hose sleeve nut:
a Record the disconnected parts of hoses. Hose to the swing motor (11): Width across flats 22 mm
a Cover the tips of the disconnected hoses with Hose from the swing motor (12): Width across flats 27 mm
cloth. Hose to the motor-generator (13):
a Do not remove elbows (11a) to (14a). [*5] Width across flats 27 mm
When loosening or removing for replacement, Hose from the motor-generator (14):
record the mounting direction. Width across flats 32 mm
3 Lubricating oil hose sleeve nut:
Hose to the swing motor (11):
54 to 93 Nm {5.5 to 9.5 kgm}
Hose from the swing motor (12):
84 to 132 Nm {8.5 to 13.5 kgm}
Hose to the motor-generator (13):
84 to 132 Nm {8.5 to 13.5 kgm}
Hose from the motor-generator (14):
128 to 186 Nm {13.0 to 19.0 kgm}
[*5]
a If elbows (11a) to (14a) are loosened or removed,
11. Remove bolts (15) (2 pieces), and remove tandem
install them in the direction recorded in the removal
pump assembly (16). [*6]
procedure.
50-122 HB215LC-2
Hybrid system
Hose mounting elbow:

Swing motor discharge port (11a):
Swing motor suction port (12a):
Motor-generator discharge port (13a):
Motor-generator suction port (14a):
3 Hose mounting elbow:
Swing motor discharge port (11a):
25 to 29 Nm {2.6 to 3.0 kgm}
Swing motor suction port (12a):
25 to 29 Nm {2.6 to 3.0 kgm}
Motor-generator discharge port (13a):
35 to 63 Nm {3.6 to 6.4 kgm}
Motor-generator suction port (14a):
59 to 98 Nm {6 to 10 kgm}
[*8]
a Before installing the pump assembly, install O-ring
(17) and shaft (18) to the pump side.
a Make sure that the mounting direction of the pump
assembly is correct.
Tandem pump assembly mounting bolt (15): Width across
flats 17 mm
3 Tandem pump assembly mounting bolt (15):
59 to 74 Nm {6 to 7.5 kgm}
HB215LC-2 50-123
Hybrid system
Removal and installation of motor-generator and housing assembly (HB205-

RA22-924-K-00-A)

k The removal and installation in this section
must be performed by persons "who Removal (HB205-RA22-520-K-00-A)
voltage electric work". 1. Remove undercovers (1), (2), (3), and (4).
Before performing work, understand 00 C The cover is a reinforced type and heavy.
Foreword, Safety, Basic information, "Safety Remove it carefully.
C Do not disconnect the motor-generator rotor

from the engine for quality assurance reasons.
C Special tools
Necessity
Sym-
Q'ty
Part No. Part name

bol
1 7875-35-2910 Cap V 2
2 7875-12-5520 Plate V 1
B 3 796T-410-1200 Plate V 1
4 01010-81235 Bolt V 2
5 01643-31232 Washer V 2

k Discharge the capacitors. For details, see

"Capacitor discharge procedure" in 00
Voltage Wires". 2. Drain the coolant through drain valve (5). (Inside
diameter of drain hose: 7 mm)
and remove the key. 6 Radiator:
23 N

coolant is poisonous. If the coolant sticks to
C Write down the installing positions, connector

numbers, and hose band colors of the wirings 3. Remove coolant drain plug (6) of motor-
and pipings not to install them wrongly. generator housing, and drain the coolant.
50-124 HB215LC-2
Hybrid system

remove KDOC bracket (12).
1N

4. Place a container to receive oil below oil drain remove bracket (14).
plug (8) of motor-generator housing (7).
5. Remove oil drain plug (8), and drain the oil.

6.0 N
11.Disconnect clamps (15) and (16).

12.Disconnect coolant return hose (17) and cooling
supply hose (18).
14.Disconnect lubricating oil filler hose (20).
C After draining the oil, install the drain plug 15.Disconnect lubricating oil inlet port hose (40)
having been removed. from hybrid system oil cooler (41).
6. Remove main pump assembly. For details, see
"Removal and installation of main pump
assembly".
7. Remove the KDOC assembly. For details, see
HB215LC-2 50-125
Hybrid system

make sure to install cap B1 to the connector
part.
C Cap B1 prevents water and dust from
entering into the connector part.
C Do not lose rubber washers (T) installed to
the high voltage wiring connector as a
stopper.

18.Remove blowby gas hose (24).
20.Disconnect ground cable (28).

21.Disconnect lubricating oil outlet hose (29).
19.Loosen mounting bolts (25) (2 pieces each), and

disconnect high voltage wiring (power cable)
connectors GM03 (26) and GM02 (27) (2
pieces). [*1]
22.Support the engine by using jack [1].
50-126 HB215LC-2
Hybrid system
23.Remove engine mount brackets (30) (right and 27.Install the guide bolts.
left). 28.Remove all the remaining mounting bolts (33).
24.Remove engine mount bolts (31) (right and left). 29.Install forcing taps [3] (2 pieces) to the position
(b).
25.Sling motor-generator and housing assembly

(32), and hold it.
C Install tool B3 to KDOC bracket mounting
hole (a) in 2 places with tool B4 and tool B5.
30.Pull out motor-generator housing assembly (32)

while tightening top and bottom forcing taps [3]
alternately and evenly.
31.Sling motor-generator housing assembly (32),
26.Leave several bolts in position, but remove all and remove them.
other mounting bolts (33).
4 Motor-generator housing assembly
(32):
195 kg
Installation
• Install motor-generator and housing assembly
1. Install the dowel pin to rear flange (34).
2. Install guide bolt [2] to rear flange (34).
HB215LC-2 50-127
Hybrid system
3. Apply liquid gasket on the mating face of rear

flange (34) and motor-generator housing.
2 Rear flange mating surface:
C Before applying liquid gasket, clean the
mating surface of rear flange (34) and motor-
generator housing.
C Apply liquid gasket (LG-7) in diameter (t)
without a break.
t = 1 to 2 mm
C The liquid gasket (LG-7) is quick drying.
Apply it immediately before installing the
motor-generator and housing assembly.
C If it is left for 5 minutes or more after liquid
gasket (LG-7) is applied, the surface of the
gasket will be hardened, causing oil leakage
after motor-generator and housing assembly
(32) is installed.
C For P and Q parts, apply the gasket at a point
5mmfromrearflangenottooverlapforcing
tapEofmotor-generatorhousing.
C 6LQFHWKHPDWLQJIDFHVRIWKHPRWRUJHQHUDWRU
KRXVLQJDQGUHDUIODQJHDUHSDUWO\GLIIHUHQWLQ
SRUWLRQ5DSSO\JDVNHWWRWKHGLPHQVLRQV
VKRZQLQWKHILJXUHDQGSUHYHQWLWIURP
SURWUXGLQJ
4. Sling motor-generator and housing assembly

(32), and install them.
5. Insert tool B2 into the spline part of the motor-
generator.
C While turning tool B2 clockwise and
counterclockwise, push in motor-generator
and housing assembly (32) along the guide
bolt until the entire mating surface of motor-
generator and housing assembly (32)
touches the rear flange.
6. Remove tool B2.
50-128 HB215LC-2
Hybrid system
7. Tighten mounting bolts (33) (21 pieces) lightly.

8. Remove guide bolt [2], and tighten the remaining
2 bolts lightly.
9. Tighten mounting bolts (33) (23 pieces) to the
specified torque in the order shown in the figure.
98 to 123 Nm {10.0 to 13.1 kgm}

order to removal.
[*1]
C Install the connector of the high voltage wiring
(power cable) according to the following
procedure.
C Before installing the connector of the high
voltage wiring (power cable), measure the
insulation resistance of the motor-generator
1. Caution for measuring
k High voltage (500 VDC) is applied for

insulation resistance measurement. Be
careful of the following.
1) Connection of the inspection plug
C Check that inspection plugs P(+) and (-)
are connected to the target parts for
measurement.
C Check it thoroughly that the inspection
plugs do not come off during
measurement (when high voltage is
applied). Otherwise it touches other parts,
and then it may cause an electric shock.
2) Do not touch motor-generator assembly
during measurement. Do not touch the target
object for measurement (MOTOR A) during
measurement (when high voltage is applied).
HB215LC-2 50-129
Hybrid system
During measurement, the person performing a For the connector of the high voltage wiring (power
measurement should alert other people. cable), match the number in the motor-generator side
2. Measuring and marking line.
1) Insulation measurement 1. Replace the O-ring with a new one.
Connect the following items as shown in the 2. Check that there is no stain or scratch on the cable
following figure. side plug (P) and O-ring surface.
Between line A and line B 3. Install connectors (18) and (19).
Between line A and line C a Before inserting the cable, check that rubber washers
Between line B and line C
(T) is installed to the bolt.
(Criteria)
a Insert the cable side plugs (P) straight into the motor
a Insulation resistance between lines A and B:
side power supply terminal socket (S) so that the plug
Min. 5 Mz
does not touch the motor case.
a Insulation resistance between lines A and C:
a When inserting, direct high voltage wiring connection
Min. 5 Mz
detection contact (Q) toward the engine.
a Insulation resistance between lines B and C:
Min. 5 Mz
High voltage wiring connector bolt: Width across flats

5 mm
2) Insulation measurement between phases 3 High voltage wiring connector bolt:
Connect the following items as shown in the 8.8 to 10.8 Nm {0.9 to 1.1 kgm}
figure.
Between phase A and motor case phase
Refill it with the coolant to the specified level through
Between phase B and motor case phase
the coolant filler port. Run the engine to circulate the
Between phase C and motor case phase
coolant through system. Then check the coolant level
(Criteria)
a Insulation resistance between phase A and again.
motor case phase: Min. 5 Mz 5 Radiator:
a Insulation resistance between phase B and 23 ℓ
motor case phase: Min. 5 Mz
a Insulation resistance between phase C and
motor case phase: Min. 5 Mz
50-130 HB215LC-2
Hybrid system
Removal and installation of electric swing motor assembly (HB205-PQHH-924-K-00-A)
Removal (HB205-PQHH-520-K-00-A)
k The removal and installation in this section 1. Open side cover (1) on the left side of the
must be performed by persons "who machine.
C Special tools
Necessity
Sym-
bol
Part No. Part name Q'ty
2. Remove nuts (2) (3 pieces), and remove cover

F 4 01124 – 51490 Guide bolt V 1 (3).
B 1 7875–35–2910 Cap V 1

Voltage Wires".

k Stop the machine on a level surface, lower 3. Disconnect one-touch wiring connectors HB01
the work equipment to the ground so that it (CC) ((+) and (–) cable terminals) (2 pieces) of
is stable, and stop the engine. the capacitor.
k Set the lock lever in LOCK position. part of the connector with your thumb to
release the lock.
position, and remove the key. C When disconnecting the clamp and wiring,
k Before opening the water filler cap or damages by using corrugated fiberboard,
draining coolant, check that the coolant etc.

your eye.
HB215LC-2 50-131
Hybrid system
5. Loosen oil drain plug (5), and drain the oil. 8. Remove mounting bolt (8), and remove cover
(9).
6 Electric swing motor case: 9. Remove clamp (10).
1.6 N 10.Remove clamp (11), and disconnect hose (12).
6. Remove cover (6) under the capacitor. 11.Remove clip (13).

12.Disconnect swing motor connector PM01 (14).
14.Remove bolts (16) (2 pieces), and disconnect
high voltage wiring (power cable) PM02 (17). [*2]

coolant. [*1]
6 Hybrid radiator:
N
6.0N
50-132 HB215LC-2
Hybrid system
15. Remove clamp (18), and disconnect lubricating oil 20. Remove mounting bolts (M14) (30) (6 pieces). [*4]
inlet hose (19). a Before removing the bolts, make matchmarks (X)
16. Remove bolts (20) (2 pieces), and remove bracket on the electric swing motor side and swing
machinery side.
(21).
a Do not remove bolts (M10) (a) (6 pieces) for motor
structure.
21. Install eyebolts [1] to the eyebolt mounting screw parts
(G) (2 places diagonally).
a Eyebolt thread diameter: 8 mm
22. Sling electric swing motor (31), and remove it.
4 Electric swing motor assembly (31):
70 kg
17. Remove clips (24) and (23), and disconnect coolant

outlet hose (22) and coolant inlet hose (25).
18. Disconnect lubricating oil outlet hose (26) and
lubricating oil drain hose (27). [*3]
Installation (HB205-PQHH-720-K-00-A)
[*1]
Capacitor drain plug: Width across flats 14 mm
3 Capacitor drain plug:
5.88 to 8.82 Nm {0.6 to 0.9 kgm}
[*2]
19. Remove mounting bolts (28) (4 pieces), and remove q Install the connector of the high voltage wiring (power
bracket (29). cable) according to the following procedure.
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.
HB215LC-2 50-133
Hybrid system
3. Insert the cable side plug straight into the motor a For the phase relationship between electric
side power supply terminal socket (S) to prevent swing motor assembly (31) and swing
the plug on the cable side from touching the case. machinery assembly (33), use the positions of
a Make sure that black marking faces upward. motor water filler port (34) and machinery
dipstick pipe (35) as a guide to align the phases
and implement the motor.
detection contact (Q) with having the cable facing
the bottom. a Align motor flange convex portion (J) with
Mounting bolt: Width across flats 5 mm brake spring cover concave portion (K) on the
3 Mounting bolt: machinery side.
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
[*3]
3 Sleeve nut:
84 to 132 Nm {8.5 to 13.5 kgm}
[*4]
q Install the electric swing motor assembly to the swing
machinery according to the following procedure.
1. Degrease the mating surface (H) of the electric
swing motor and No.1 ring gear (32).
2. Install tools F4 (guide bolt) (3 pieces) to electric 4. Install mounting bolts (30) (3 pieces), and tighten
swing motor mount bolt mounting positions (I) (3 them lightly.
places) of No.1 ring gear (32).
5. Remove tool F4, and evenly tighten the 6 bolts in
total including the remaining 3 mounting bolts.
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
q Refilling with coolant, oil and bleeding air
a Refill it with coolant and bleed air in the hybrid
hybrid system".
5 Hybrid radiator:
6.0 ℓ
5
3. Install electric swing motor assembly (31) to swing
Swing machinery
machinery assembly (33) along with the
6.5ℓ (TO30)
matchmarks (x) put before installation.
50-134 HB215LC-2
Hybrid system
5 Electric swing motor case:

N (TO10)
1.6N
HB215LC-2 50-135
Power train system
Power train system (ALL-C100-001-K-50-A)
Removal and installation of travel motor and final drive assembly

(PC220-DF10-924-K-00-A)
a Take care that the hose mounting block is not
k Park the machine on a level place, lower the work damaged.
equipment to the ground stably, and stop the 4 Travel motor and final drive assembly:
engine. 350 kg
k Set the lock lever in the Lock position.

k Release the remaining pressure in the hydraulic
circuit. For details, see Testing and adjusting,
"Releasing remaining pressure from hydraulic
circuit".
Removal (PC200_10-DF10-520-K-00-A)
1. Remove the sprocket, referring to the section
"Removal and installation of sprocket(PAGE 50-168)".
Installation (HB205-DF10-720-K-00-A)
[*1]
Travel motor and final drive assembly mounting bolt:
HB205-2, HB215-2: Width across flats 24 mm
HB215LC-2, HB205LC-2: Width across flats 24 mm
3 Travel motor and final drive assembly
mounting bolt:
q HB205-2, HB215-2
245 to 309 Nm {25 to 31.5 kgm}
3. Disconnect the travel speed selector hose (2), the
motor hoses (3) and (4), and the drain hose (5). q HB215LC-2, HB205LC-2
265 to 309 Nm {27 to 31.5 kgm}
q Refilling with oil
Refill with oil to the specified level through the oil filler
port. Run the engine to circulate the oil through the
piping, and check the oil level again.
q Bleeding air
Bleed air from the travel motor circuit. For details, see
Testing and adjusting, "Bleeding air from hydraulic
system".
4. Sling the travel motor and final drive assembly (6).

5. Remove the 18 mounting bolts and sling and remove
the travel motor and final drive assembly (6). [*1]
Power train system

50-136 HB215LC-2
Power train system
Disassembly and assembly of final drive (HB205-DF10-926-K-00-A)
C Special tools 3. Washer

Remove washer (2).
Necessity
4. No. 1 planetary carrier assembly
Sym-
Q'ty
Part No. Part name 1) Remove No. 1 planetary carrier assembly
bol
(3).
1796-427-1400 Wrench assembly V 1
2796-427-1520 Installer V 1
796T-427-1510 Push tool V 1
790-101-2510 Block V 1
790-101-3310 Plate V 1
790-101-2610 Leg V 2
790-101-2730 Adapter V 2
3 01580-11613 Nut V 2
790-101-2570 Plate V 2
J 01643-31645 Washer V 2
Puller (294 kN {30
790-101-2102 ton})
V 1
790-101-1102 Pump V 1 2) Disassemble No.1 planetary carrier
4 790-331-1110 Wrench V 1
5 796T-427-1710 Guide V 1 1] Drive pin (4) into shaft (5), and remove
790-101-3601 Gear puller S 1 shaft (5) from No.1 planetary carrier (6).
6
790-201-2660 Plate S 1 C After removing shaft (5), remove pin
7 792T-423-1350 Push tool S 1 (4) from shaft (5).
8 79A-264-0091 Push-pull case V 1 2] Remove thrust washer (7), No.1
planetary gear (8), needle bearing (9),
Disassembly (HB205-DF10-530-K-00-A) and thrust washer (10).
1. Draining oil
Remove the drain plug, and drain the oil in the
final drive case.
6 Final drive case

• HB205-2, HB215-2: 3.8 N
• HB215LC-2: 5.4 N
2. Remove the mounting bolts (20 pieces). Sling
cover (1) by using eyebolts [1], and remove it.
4 Cover:
20 kg
C If ring gear (12) is lifted together, tap the ring 5. No.1 sun gear shaft
gear lightly with a plastic hammer to separate Remove No.1 sun gear shaft (11).
it.
HB215LC-2 50-137
Power train system
6. Ring gear
Remove ring gear (12).
4 Ring gear:
45 kg
7. Thrust washer
Remove thrust washer (13).
8. No.2 sun gear
Remove No. 2 sun gear (14).
11.Ring nut
1) Remove lock plate (24).
9. Thrust washer
Remove thrust washer (15).
10.No.2 planetary carrier assembly
1) Remove No.2 planetary carrier assembly
(16).
2) Remove ring nut (25) by using tool J1.
2) Disassemble the No.2 planetary carrier

assembly according to the following
procedure. 12.Hub assembly
1] Drive pin (17) into shaft (18), and remove 1) Sling hub assembly (26) by using eyebolts
shaft (18) from No.2 planetary carrier [2], and remove it from the travel motor.
(19).
4 Hub assembly:
C After removing shaft (18), remove pin
80 kg
(17) from shaft (18).
2] Remove thrust washer (20), No.2
planetary gear (21), needle bearing (22),
and thrust washer (23).
50-138 HB215LC-2
Power train system
14.Remove bearing (34) by using tool J6.

2) Remove bearing (27).
C The bearing may be removed without using
the puller.
3) Remove bearing outer races (29) and (30)

from hub (28).
Assembly (HB205-DF10-710-K-00-A)
C Clean the parts completely and inspect them for

any foreign material or damage. Apply power
line oil (TO30) to the sliding surface before
assembly.
1. Hub assembly
1) Press-fit bearing outer races (29) and (30)
into hub (28) by using tool J7.
13.Remove floating seals (32) and (33) from travel

motor (31).
C Floating seal (32) is installed to the hub
assembly (26) and travel motor sides.
2) By using tool J2, install floating seal (33) to

hub assembly (26).
C Install the floating seal after degreasing
and drying the O-ring and O-ring
contacting surface completely.
HB215LC-2 50-139
Power train system
C When installing the floating seal, use tool C When installing the floating seal, use tool J2
J2 and make sure to press the O-ring. and make sure to press the O-ring.
C After installing the floating seal, measure C After installing the floating seal, measure
protrusion (Ba to Bd) of the floating seal protrusion (Ba to Bd) of the floating seal from
from the housing at the measuring point the housing at the measuring point shown in
shown in the figure below. the figure below.
C Check that the difference between C Check that the difference between maximum
maximum value (B-max) and minimum value (B-max) and minimum value (B-min) of
value (B-min) of the values from Ba to Bd the values from Ba to Bd is 1 mm or less.
is 1 mm or less. • B-max - B-min < 1 mm
• B-max - B-min < 1 mm
C After installing the floating seal, thinly apply
3) After installing the floating seal, thinly apply
power line oil to the sliding surface.
power line oil to the sliding surface.
2 Sliding surface:
2 Sliding surface:
Power line oil (TO30)
Power line oil (TO30)
4. Set hub assembly (26) to the travel motor by

2. Install bearing (34) to travel motor (31).
using tool J5 as a guide.
C Heat the inner race of bearing (34) to 50 to
70°C with a heater.
C After bearing (34) is installed and cooled, hit
it with a rod to check by sound that it is
inserted to the end.
3. Install floating seal (33) to travel motor (31) by
using tool J2.
C Install the floating seal after degreasing and
drying the O-ring and O-ring contacting
surface completely.
50-140 HB215LC-2
Power train system
5. Set hub assembly (26) to the travel motor by

using eyebolts [2].
4 Hub assembly:
80 kg
7] Measure dimension (a) under the

condition described in step 6].
C After measuring dimension (a),
remove tool J3.
6. Lightly tap and install bearing (27) by using the

push tool.
8] Measure the thickness of ring nut (25)

and name it (b) dimension.
9] Subtract (b) from (a) and name it (c).
10]Tighten ring nut (25) until dimension (d)
7. Ring nut
becomes the following by using tool J1.
1) Install the ring nut according to the following (d) dimension: c (+0.06/-0.04) mm
procedure.
1] Rotate the hub for 2 to 3 turns.
2] Press the inner race part of bearing (27)
by using tool J3 and push tool [5].
C Pressing force:
29.4 to 38.2 kN {3.0 to 3.9 ton}
3] While pressing the bearing inner race,
rotate the hub to both directions 5 times
or more in total.
4] Stop pressing.
5] Press in the bearing again.
C Pressing force:
17.7 to 21.6 kN {1.8 to 2.2 ton} 2) Measure the tangential force in the rotation
6] Rotate the hub for 2 to 3 turns. direction of the hub against the motor case
by using tool J8.
C Tangential force:
Max. 490 N {50 kg}
C A tangential force is the maximum force
at the start of rotation.
HB215LC-2 50-141
Power train system
C When installing the shaft, keep

rotating No.2 planetary gear (21). Be
careful not to damage the thrust
washer.
3) Install lock plate (24).

C Install the lock plate so that the splines
(part A) of the motor and the lock plate
are in full contact.
2 Threaded part of mounting bolt: 3] Insert pin (17).
Adhesive (LT-2) C When inserting the pin, take care that
claws (f) (3 places) on the periphery
C Do not apply the adhesive (LT-2) to the
are not placed on the thin-wall parts
threads of the nut.
(g) of No. 2 planetary carrier. The thin-
wall part may be on the opposite side
depending on carriers. Check each
carrier and be careful that the claws of
the pin will not be placed on the thin-
wall side. Also, avoid grooves if any.
C After assembling No.2 planetary
carrier assembly, check that No.2
planetary gear (21) rotates smoothly.
C Punch the pin part (B) of the carrier
after inserting the pin.
8. No.2 planetary carrier assembly

1) Assemble the No.2 planetary carrier
assembly according to the following
procedure.
C Replace thrust washers (20) and (23) as
well as pin (17) with new ones.
C There is a punch mark during pin
insertion on the end surface of carrier
side hole (e). Remove protrusions to the
hole inside diameter of the punch mark in
advance.
1] Install needle bearing (22) to No.2
planetary gear (21) and fit upper and
lower thrust washers (20) and (23), then
set the gear assembly to No.2 planetary
carrier (19).
2] Align the pin hole positions of shaft (18)
and the carrier, and lightly tap shaft (18)
with a plastic hammer to install it.
50-142 HB215LC-2
Power train system
4 Ring gear:
45 kg
C Degrease the mating faces of the ring gear
and hub. Do not apply liquid gasket on the
mating faces.
C Align the bolt holes of the ring gear and hub.
2) Install No.2 planetary carrier assembly (16).

C Align the 4 gear shaft ends of No.2
planetary carrier assembly (16) with the 4
dimples on the motor case end surface to
install.
9. Thrust washer
Install thrust washer (15).
14.No.1 planetary carrier assembly
1) Assemble the No.1 planetary carrier
C Replace thrust washers (7) and (10) as
well as pin (4) with new ones. (Pin (4):
See step 3])
side hole (h). Remove protrusions to the
hole inside diameter of the punch mark in
advance.
10.No.2 sun gear 1] Install needle bearing (9) to No.1
Install No.2 sun gear (14). planetary gear (8) and fit upper and lower
11.No.1 sun gear shaft thrust washers (7) and (10), then set the
Install No.1 sun gear shaft (11). gear assembly to No.1 planetary carrier
12.Thrust washer (6).
Install thrust washer (13).
2] Align the pin hole positions of shaft (5)

13.Ring gear and the No.1 planetary carrier, and lightly
tap shaft (5) with a plastic hammer to
1) Install O-ring to the hub side.
install it.
2) Install ring gear (12) to the hub.
HB215LC-2 50-143
Power train system
a When installing the shaft, keep rotating

No.1 planetary gear (8). Be careful not to
damage the thrust washer.
3] Insert pin (4).
a When inserting the pin, take care that
claws (f) (3 places) on the periphery are
not placed on the thin-wall parts (g) of No.
1 planetary carrier. The thin-wall part may
be on the opposite side depending on
carriers. Check each carrier and be careful
that the claws of the pin will not be placed
on the thin-wall side. Also, avoid grooves if
any.
a After assembling the carrier, check that
No.1 planetary gear (8) rotates smoothly.
a Punch the pin part (C) (2 places) of the
carrier after inserting the pin.
16. Cover
1) Install cover (1) by using eyebolt [1].
4 Cover:
20 kg
2 Mating face of the cover and ring gear:
a Do not apply liquid gasket (LG-6) to the tap.
2) Install No.1 planetary carrier assembly (3).

15. Washer
2) Tighten the mounting bolts (20 pieces) by using
Install washer (2).
tool J4.
a After installing washer (2), measure dimension (i)
from the upper end face of No.1 planetary gear (8) Mounting bolt: Width across flats 19 mm
to that of ring gear (12) to check for the correct 3 Mounting bolt
assembly condition. 1st time: 98 Nm {10 kgm}
a If dimension (i) is not within the range of 2.11 ± 2nd time: 80 to 90 deg. (rotation angle)
0.97 mm, it is not assembled correctly. Check
again.
50-144 HB215LC-2
Power train system
17.Refilling with oil

Tighten the drain plug and supply power line oil
(TO30) from the oil filler port.
5 Final drive case

• HB205-2, HB215-2: 3.8 N
• HB215LC-2: 5.4 N
C Do a final check of the oil level at the
determined position after installing the final
drive assembly to the chassis.
HB215LC-2 50-145
Power train system
Removal and installation of swing motor and swing machinery

assembly (HB205-J120-924-K-00-A)
Removal
k The removal and installation in this section 1. Open side cover (1) on the left side of the
must be performed by persons "who machine.
C Special tools
Necessity
Sym-
Q'ty
Part No. Part name

bol
2. Remove nuts (2) (3 pieces), and remove cover
F 4 01124 – 51490 Guide bolt V 1 (3).
B 1 7875–35–2910 Cap V 1

Voltage Wires".

k Stop the machine on a level surface, lower 3. Disconnect one-touch wiring connectors HB01
the work equipment to the ground so that it (CC) ((+) and (–) cable terminals) (2 pieces) of
is stable, and stop the engine. the capacitor.
k Set the lock lever in LOCK position. part of the connector with your thumb to
release the lock.
position, and remove the key. C When disconnecting the clamp and wiring,
k Before opening the water filler cap or damages by using corrugated fiberboard.

your eye.
50-146 HB215LC-2
Power train system

(10).
5. Loosen oil drain plug (5), and drain the oil.
1.6 N
6. Loosen oil drain plug (6), and drain the oil.
6 Swing machinery case:

6.5 N
11.Remove clip (12).

13.Remove swing motor clamp PM01 (14).
14.Remove bolts (15) (2 pieces), and disconnect
high voltage wiring (power cable) PM02 (16). [*2]
7. Remove cover (7) under the capacitor.
8. Remove capacitor drain valves (8), and drain the

coolant. [*1]
6 Hybrid radiator:
N
6.0N
HB215LC-2 50-147
Power train system
15. Remove clamp (17), and remove lubricating oil inlet 22. Remove mounting bolts (30) (12 pieces).
hose (18). 23. Install eyebolts [1] and sling [2] to 3 places on the
16. Remove bolts (19) (2 pieces), and remove bracket periphery of portion (g).
(20). 24. Sling and remove electric swing motor and swing
machinery assembly (31).
4 Electric swing motor and swing machinery
assembly (31):
290 kg
17. Remove clips (21) and (22), and remove coolant

outlet hose (23) and coolant inlet hose (24).
18. Disconnect lubricating oil outlet hose (25) and
lubricating oil drain hose (26). [*3]
Installation (HB205-J120-720-K-00-A)
[*1]
Capacitor drain valve: Width across flats 14 mm
3 Capacitor drain valve:
5.88 to 8.82 Nm {0.6 to 0.9 kgm}
[*2]
q Install the connector of the high voltage wiring (power
cable) according to the following procedure.
1. Check that there is no stain or scratch on the cable
side plug (P).
19. Disconnect swing parking brake release pressure
2. Apply grease (G2-LI) lightly on insertion seal part (R)
hose (27).
of the flange.
20. Disconnect machinery oil drain hose (28).
3. Insert the cable side plug straight into the motor side
power supply terminal socket (S) to prevent the plug
on the cable side from touching the case.
a Make sure that black marking faces upward.
50-148 HB215LC-2
Power train system

detection contact (Q) with having the cable facing
the bottom.
3 Mounting bolt:
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
[*3]
3 Sleeve nut:
84 to 132 Nm {8.5 to 13.5 kgm}
a Refill with coolant and bleed air in the hybrid
hybrid system".
5 Hybrid radiator:
5.5 ℓ
6.5 ℓ (TO30)
7.1 ℓ (TO30)(specified capacity)
1.6 ℓ (TO10)
2.3 ℓ (TO10)(specified capacity)
HB215LC-2 50-149
Power train system
Disassembly and assembly of swing machinery assembly (PC200_10-J120-926-K-01-A)
C Special tools C Make matchmarks (P) on the cases of

electric swing motor assembly (9) and
Necessity
swing machinery assembly (10).
Q'ty
Symbol Part No. Part name
796T-426-1130 Plate V 1
1 790-101-5421 Push tool V 1
01010-81240 Bolt V 1
2 796-426-1120 Push tool V 1
3 796T-426-1410 Push tool V 1
4 01124-51490 Guide bolt V 3
1 796-426-1710 Collet V 1
F
5 2 796-426-1720 Taper cone V 1
3 796-426-1730 Collar V 1
6 790-201-2710 Spacer S 1
7 790-201-2740 Spacer S 1
8 790-201-2890 Spacer S 1
9 793T-615-1760 Spacer S 1
10 790-201-2660 Plate V 1
Disassembly (PC200_10-J120-530-K-01-A)
1. Set the electric swing motor and swing

machinery assembly to the block.
2) Sling electric swing motor assembly (9), and

remove it.
4 Electric swing motor assembly:

71 kg
5. Remove No.1 sun gear (11).
remove cover (13).
2. Draining oil from swing machinery k The spring may pop out when cover (13)
Loosen the drain plug, and drain the oil from the is removed. Remove it carefully and
swing machinery case. slowly.

6.5 N
3. Accessory
1) Disconnect clamp (1) and remove hose (2).
2) Remove mounting bolts (3) (2 pieces) and
(4) (2 pieces), and remove bracket (5).
3) Remove mounting bolts (6) (4 pieces), and
remove oil filler pipe (7).
1) Remove mounting bolts (8) (6 pieces).
7. Remove spring (14).

8. Remove No.1 ring gear mounting bolts (15) (6
pieces).
50-150 HB215LC-2
Power train system
5] Remove plate (21), planetary gear (22),

bearing (23), plate (24), and collar (25).
6] Reverse No.1 carrier assembly (17).
7] Remove holder (26).
C Be careful not to lose ball (27).
9. Sling No.1 ring gear (16), and remove it.
10.No.1 carrier assembly

1) Remove No.1 carrier assembly (17).
11.Put air pressure from swing parking brake port

(Q) by using air gun [1] to remove piston (29).
k Apply air pressure of 5 to 6kg/cm2.
k Put air pressure while holding piston (29)

so that it doesn't pop up suddenly.
2) Disassemble No.1 carrier assembly

1] Reverse carrier assembly (17).
2] Remove spirolock (18).
C While lifting the abutment joint of
spirolock (18) with a flat-head
screwdriver [2] having a thin tip, turn
the screwdriver one round clockwise,
and remove spirolock (18).
3] Remove collar (19).
4] Remove shaft (20) from the carrier
assembly with the push tool.
• Shaft press-fit force (for reference):
12.2 to 30.0 kN {1,240 to 3,050 kg}
HB215LC-2 50-151
Power train system
12.No. 2 sun gear assembly 14.Remove mounting bolts (36) (6 pieces), sling
1) Disassemble the No.2 sun gear assembly case (37), and remove it.
1] Remove snap ring (31) and plate (32)
from No.2 sun gear (30).
2] Remove swing parking brake gear (33)
from No. 2 sun gear (30).
15.Remove No. 2 sun gear (30).

1) Remove No.2 carrier assembly (38).

13.Remove 3 plates and 2 discs in the order of 1] Remove snap ring (39), thrust washer
plate (34) and disc (35). (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).
50-152 HB215LC-2
Power train system

3) Remove shaft (47) from carrier (46) by using
push tool F6.
• Shaft press-fit force (for reference): 1] Push in pin (52), and drive out shaft (53)
11.2 to 25.8 kN {1,140 to 2,630 kg} from carrier (54).
C After removing the shaft, remove pin
(52).
2] Remove thrust washers (55), planetary
gear (56), and bearing (57).
3] Remove plate (58).
17.Remove No.3 sun gear (48).

18.Remove the mounting bolts and bracket (75),
and remove No.2 ring gear (49).
19.Remove holder mounting bolt (50).

1) Remove No.3 carrier assembly (51). 21.Shaft and case assembly
1) Reverse shaft and case assembly (59).
2) Remove cover mounting bolts (60).
HB215LC-2 50-153
Power train system
3) Reverse shaft and case assembly (59) again,

and set it to the press.
4) Remove shaft assembly (61) from shaft and
case assembly (59) by using push tool F7.
23.Remove bearing (67) from case (66).

C Place an appropriate tool on the
circumference (thick line: Q part) of the outer
race, and lightly tap the tool with a hammer
alternately and evenly on the circumference
to remove the bearing gradually.
C Remove it horizontally because the bearing
becomes stuck when the outer race is tilted.
22.Shaft assembly
1) Remove shaft (62) by using push tools F8
and F7.
2) Remove bearing (64) and oil seal (65) from
cover (63).
Assembly (PC200_10-J120-710-K-01-A)
C Clean the parts, and check that they are free

from dirt or damage. Then apply power line oil to
the sliding surface, and assemble them.
C Do not reuse the removed bearing, oil seal, and
snap ring. Use new ones.
1. Oil seal
Install oil seal (65) to cover (63) by using tool F1.
50-154 HB215LC-2
Power train system
a Be careful of the direction (top and bottom) of the Mounting bolt: Width across flats 17 mm
oil seal. 3 Mounting bolt:
2 Outer periphery of oil seal: 59 to 74 Nm {6 to 7.5 kgm}
Liquid gasket (LG-6) a Be careful that liquid gasket (LG-6) does not stick
a When press-fitting, be careful so that liquid gasket to the drain port part (DP).
(LG-6) does not stick to the lip part of the oil seal. a Align the drain machining part of the cover with the
drain port part (DP).
a If tool F1 is not used, use a push tool that can push

outer periphery (A) of oil seal (65) evenly. 4. Shaft and case assembly
a Be careful that oil seal (65) does not tilt. 1) Set case assembly (68) to shaft (62).
2 Oil seal lip:
Grease (G2-LI)
a Place the case assembly without touching the
oil seal.
2) Tap the inner race of bearing (64) and insert it by
using tools F3 and F10 and hammer [7].
a Loosen lifting tool [8].
k Put it in until the shaft does not come off
when lifted.
2. Press-fit bearing (64) to case (66) by using push tool

[9].
a Use a new bearing.
3) Set it to the press.

4) Press-fit the inner race of bearing (64) by using
tools F3, F10, and [10].
a Insert push tool [10] in case if the case
3. Install cover assembly (69) to case assembly (68). assembly tilts significantly.
2 Cover mounting surface: a When case assembly (68) tilts, tap the flange
Liquid gasket (LG-6) part lightly to correct it.
HB215LC-2 50-155
Power train system
C Immediately before oil seal (65) is 1) Assemble No. 3 carrier assembly according
inserted into shaft (B) part, keep case to the following procedure.
assembly (68) horizontally so that case
assembly (68) is at the center of shaft
(62), and be careful not to damage the oil
(54) side hole (h). Remove protrusions to
seal lip part.
the hole inside diameter of the punch
mark in advance. (See step 5]).
1] Assemble plate (58) to carrier (54).
2] Assemble bearing (57) and top and
bottom thrust washers (55) (2 pieces)
to planetary gear (56).
3] Set the planetary gear assembly to
carrier (54).
4] Align the pin hole positions of shaft

(53) and the carrier by tapping with a
plastic hammer, and install shaft (53).
C When installing the shaft, keep
rotating the planetary gear. Be
5. Bearing
careful not to damage the thrust
Press fit bearing (67) by using tools F2 and F10.
washer.
C Press-fit the bearing by pressing the bearing 5] Insert pin (52).
inner race and outer race simultaneously. Do
C Be sure that 3 claws (a) on the
not press only the inner race part to press-fit.
periphery of the pin are not placed
• Press fitting force of bearing (for reference): on the thin-wall parts (b) of carrier.
9.4 to 35.5 kN {960 to 3,620 kg}
In actual items, the thin-wall parts
C After press-fitting the bearing, check that the may be in the opposite side.
case rotates smoothly. Check the actual item and be
careful that the claws of the pin are
not be placed on the thin-wall side.
6. No.3 carrier assembly
50-156 HB215LC-2
Power train system
a Punch 2 places (C) around pin hole of

the carrier after inserting the pin.
2) Install No.3 carrier assembly (51) with bolt (50).

2 Threaded part of mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
3) Install O-ring (70) to case (66).
2) Install bracket (75) to part (k).

a Bolt lengths are different only in part (k). Be
careful during installation.
7. No.3 sun gear

Install No.3 sun gear (48).
8. No.2 ring gear
1) Install No.2 ring gear (49) by using eyebolt (M10 x
1.5).
9. Install O-ring (71).
a Degrease the mating face of No.2 ring gear
(49) and case (66).
a Do not apply liquid gasket on the mating face
of No.2 ring gear and case.
a Position matchmark part (c) of the No.2 ring
gear and the convex part (d) of the case flange
part as shown in the figure to install it.
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
HB215LC-2 50-157
Power train system
C Check the shape of the cross section

of the snap ring and direct sharp edge
side (S) toward the shaft end surface.

1) Assemble No. 2 carrier assembly according
1] Press-fit shaft (47) to the arrow direction
(1st) into carrier (46) until the snap ring
groove is visible.
2] After installing the snap ring (45), press it
back from the opposite side (2nd
direction) until the snap ring comes into
close contact with carrier P surface. Take
care not to push excessively.
11.2 to 25.8 kN {1,140 to 2,630 kg}
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.
C Replace snap rings (39) and (45) with
new ones.
C When installing each snap ring, limit
its abutment joint (N) to the following
dimension.
N < 9.5 mm
2) Install No.2 carrier assembly (38).

3) Install No.2 sun gear (30).
11.case
50-158 HB215LC-2
Power train system
Install case (37) according to the following procedure. a When installing the plate and disc to the case,
1) When installing case (37), set its convex portion align the spline cutout portions G, H, and I of the
(a) and convex portion (b) of the flange as shown disc. The positional relationship between the plate
arcs A, B, C, D, E, and F, and G, H, and I can be
in the figure.
arbitrary.
a Degrease the mating face of No.2 ring gear
(49) and case (37).
a Do not apply liquid gasket on the mating face
of No.2 ring gear (49) and case (37).
2) Install mounting bolts (36) (6 pieces).
3 Mounting bolt:
59 to 74 Nm {6.0 to 7.5 kgm}
13. No.2 sun gear

1) Assemble No.2 sun gear (30) according to the
1] Install swing parking 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 When assembling swing parking brake
12. Install plates (34) (3 pieces) and discs (35) (2 pieces). gear (33), make sure that it is not upside
a Do not clean the disc with trichloroethylene or down.
parts cleaner. Do not blow with strong air. a When installing plate (32), make sure that
a Before installing the disc, apply clean lubricating it is not upside down.
oil (TO30) on the surface.
a Install the plate and disc in the order shown in the
figure.
HB215LC-2 50-159
Power train system
C When installing snap ring (31), do not C Take care not to damage the O-ring during
widen its abutment joint more than installation.
necessity.

14.Install piston (29). 1) Assemble No.1 carrier assembly according
C At this time, position notch (e) of piston (29)
1] Install holder (26) with ball (27) as a unit.
and cut out part (a) of case (37) as shown in
2] Install collar (25), plate (24), bearing (23),
the figure.
planetary gear (22), and plate (21) to
shaft (20) in this order.
3] Reverse the shaft and planetary gear
assembly, and press-fit it into carrier (17).
C Install the shaft so that the groove part
(g) of the shaft and the center part (h)
of the carrier are in the directions in
the figure.
C Press-fit it so that distance (j) between
the carrier end surface and shaft end
surface is 5.2 to 6.1mm.
12.2 to 30.0 kN {1,240 to 3,050 kg}
50-160 HB215LC-2
Power train system
C Check that the spirolock is in close

contact with collar (19).
C After assembly, make sure that

dimensions (i) and (j) are as
follows.
(i): 7.9 to 8.5 mm
(j): 5.2 to 6.1 mm
4] Reverse carrier assembly (17).

5] Install collar (19).
6] Install the spirolock according to the
C Do not reuse the removed spirolock.
Replace it with a new one.
1] Set spirolock (18) to tool F5-2 (taper
cone).
2) Install No.1 carrier assembly (17a).
2] Install tool F5-1 (collet) to tool F5-2,
and set it so that the end surface of
tool F5-2 comes into close contact
with the end surface of shaft (20).
3] Press in tool F5-1 until the end
surface of tool F5-1 hits the spirolock.
4] Set tool F5-3 on the end surface of
tool F5-1.
5] Insert spirolock (18) into the shaft
groove by tapping tool F5-3 lightly by
using a plastic hammer.
C Be careful not to push in collar (19)
too much when inserting.
16.Sling No.1 ring gear (16), and install it.
17.Install mounting bolts (15) (6 pieces).
2 Threaded part of mounting bolt:
Adhesive (LT-2)
HB215LC-2 50-161
Power train system
Mounting bolt: Width across flats 8 mm a When installing the plate, avoid any dent or
3 Mounting bolt: scratch on the contact face with the ball.
59 to 74 Nm {6.0 to 7.5 kgm}
18. Install spring (14).
21. Install the electric swing motor assembly according to

the following procedure.
a Degrease the mating face of electric swing motor
19. Install cover (13) with mounting bolts (12) (7 pieces).
assembly (9) and swing machinery assembly (10).
3
a Do not apply liquid gasket on the mating face of
Mounting bolt:
the electric swing motor assembly and swing
59 to 74 Nm {6 to 7.5 kgm} machinery assembly (10).
20. Install No.1 sun gear (11). 1) Install tool F4 (guide bolt) (M14 x 2 x 90 mm) to
a Before installing No.1 sun gear (11), check that electric swing motor mount bolt mounting part (Q)
plate (11a) is installed. (3 places) of No.1 ring gear (16).
a If there is no plate, install a plate before installing
No.1 sun gear (11).
a When installing No.1 sun gear (11), apply oil
(TO30) on the under surface (K) of the plate.
2) Sling electric swing motor assembly (9) by

aligning with the matchmark (P) on the electric
swing motor and No.1 ring gear marked during
disassembly.
50-162 HB215LC-2
Power train system

3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
23. Install hose (2) and fix it with clamp (1).
24. Install bracket (5), and fix it with bolts (3) (2 pieces)
and (4) (2 pieces).
Bracket mounting bolt (3): Width across flats 13 mm
Bracket mounting bolt (4): Width across flats 17 mm
3 Bracket mounting bolt (3):
27 to 34 Nm {2.8~3.5 kgm}
3 Bracket mounting bolt (4):
59 to 74 Nm {6~7.5 kgm}
a When installing a new electric swing motor
assembly or No.1 ring gear, match the oil filler
pipe mounting surface (S) and electric swing
motor piping port surface (T), and install
electric swing motor assembly (9) by using tool
F4.
4 Electric swing motor assembly:
71 kg
25. Check the mounting angle (15 deg.) and tightening

torque of elbow (3a) for drain.
Elbow mounting nut: Width across flats 32 mm
3 Elbow mounting nut:
128 to 186 Nm {13.0 to 19.0 kgm}
3) Install electric swing motor mounting bolts (8)(3

pieces) and tighten them lightly.
4) Remove tool F4, and evenly tighten the 6 bolts in
total including the remaining mounting bolts (3
pieces).
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
26. Install drain hose.

a When installing the hose, set the drain plug
downward.
Drain hose: Width across flats 32 mm
3 Drain hose:
128 to 186 Nm {13.0 to 19.0 kgm}
27. Refilling with oil
Tighten the drain plug and supply power line oil
(TO30) through the oil filler port up to the specified
level.
3 Drain plug: 19.6 to 24.5 Nm {2.0 to 2.5 kgm}
5 Swing machinery case: 6.5 ℓ

22. Fix oil filler pipe (7) with mounting bolts (6) (4 pieces).
a Check the oil level with the oil level gauge.
HB215LC-2 50-163
Power train system
Removal and installation of swing circle assembly (PC220-J110-924-K-00-A)
Removal (HB205-J110-520-K-00-A)
1. Remove the revolving frame assembly. For details,
see "Removal of revolving frame assembly".
2. Sling swing circle assembly (1) at 3 points, remove
mounting bolts, and then remove it. [*1]
4 Swing circle assembly:
270 kg
Installation (HB205-J110-720-K-00-A)
[*1]
a Install it to the track frame with the inner race soft zone
position (S) mark: (a) and outer race soft zone position
(S) mark: (b) in the right side of the machine body as
shown below.
2 Amount of grease filled in grease bath:
Grease (G2-LI)14.6 l
2 Threaded part of swing circle mounting bolt:
Adhesive (LT-2)
a Perform the angle tightening for the swing circle
mounting bolt.
Swing circle mounting bolt: Width across flats 30 mm
3 Swing circle mounting bolt:
1. Initial torque: 191.2 ± 19.6 Nm {19.5 ± 2
kgm}
2. After that, turn bolt by 48 ± 5 deg.
50-164 HB215LC-2
Separation and connection of track shoe assembly (PC220-DTL0-924-K-00-A)
C Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
Remover and
1 791-630-3000 V 1
installer
N 2 790-101-1300 Cylinder (980 kN V 1
{100 ton})
3 790-101-1102 Hydraulic pump V 1
Separating track (PC220-DTL0-520-K-00-A)
1. Turn the upper structure by 90 deg. 4. By using tool N, remove master pin (2). [*2]
2. Loosen lubricator (1), and then slacken the C With guide pin (GP), push out master pin (2).
tension of the track. [*1]
k Since the internal pressure of the

adjustment cylinder is very high, do not
loosen the lubricator more than one turn.
If the grease does not come out
sufficiently, start the engine and move the
machine backwards and forwards.
5. Change the location of guide pin (GP).

1) Lift the tracks with the work equipment
extended against ground.
2) Move away blocks [1] that were set under the
track below the idler and sprocket.
3) Move guide pin (GP) to the front of the idler.
4) Relieve the extended work equipment, and
3. Position master pin (2). lower the machine.
5) Place block [1] under track (3) in front of the
1) Lift the tracks with the work equipment idler.
extended against ground.
2) Position master pin (2) in around the center
of lower track and between two track rollers.
3) Put blocks [1] under the track below the idler
and sprocket.
6. Pull out guide pin (GP), and move the machine

back slowly to separate track (3). [*3]

HB215LC-2 50-165
C Put some blocks between the track and the

track frame to prevent damages.
Connecting track (PC220-DTL0-720-K-00-A)
Perform connection in the reverse order to

separation.
[*1]
C See Testing and adjusting, "Testing and
adjusting track shoe tension".
[*2]
C 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 equivalent
C 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
NIGTIGHT LYK-2 from Nippon Grease
Co., Ltd.: part no. 44392708 or equivalent
C Press fit master pin (2) and push guide pin (GP)
out.
C Using tool N, press fit master pin (2), so that the
protrusion amount (a) of the master pin is the
dimension designated below.
Protruding amount of master pin
a: 2.5 ± 1 mm
50-166 HB215LC-2
[*3]
1. Using bar [2], roll up track (3) while the machine
moves forward slowly.
2. As for latter half of the operation, use a forklift

truck or the work equipment, to pull wire [3] to fix
the track.
HB215LC-2 50-167
Removal and installation of sprocket (PC220-DT60-924-K-00-A)

Removal (PC220-DT60-520-K-00-A) Installation (PC220-DT60-720-K-00-A)
1. Separate the track shoe assembly. For details, see Perform installation in the reverse order to removal.
"Separation and connection of track shoe assembly". [*1]
2. Swing the work equipment 90 deg., push up the 2 Threads of sprocket mounting bolt:
chassis with the work equipment and place blocks [1] Adhesive (LT-2)
between the track frame and the track. Sprocket mounting bolt: Width across flats 27 mm
3. Remove sprocket (2), by slinging according to the 3 Sprocket mounting bolt:
following procedure. 441 to 490 Nm {45 to 50 kgm}
1) Remove mounting bolts (1). [*1]
a Before removing the final mounting bolt, place

block [2] under sprocket (2).
2) Put sprocket (2) on block [2], make a clearance
from final drive (3), and lead sling [3] in between.
4 Sprocket:
40 kg
50-168 HB215LC-2
Removal and installation of idler and idler cushion assembly (PC220-DTA0-924-K-00-

A)
Removal (PC200_10-DTA0-520-K-00-A)
1. Separate the track shoe assembly. For details,

see "Separation and connection of track shoe
assembly".
2. By using bar [1], move idler and idler cushion
assembly (1) forward to a position where it can
be lifted.
Installation (PC220-DTA0-720-K-00-A)
Perform installation in the reverse order to removal.
3. Lift idler and idler cushion assembly (1), pull it

forward to remove it from track frame (2).
4 Idler and idler cushion assembly:

235 kg
4. Disconnect idler cushion assembly (4) from idler

assembly (3).
4 Idler assembly:
105 kg
4 Idler cushion assembly:

130 kg
HB215LC-2 50-169
Disassembly and assembly of idler assembly (PC200_10-DT90-926-K-00-A)
C Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
J 791-530-1510 Installer V 1
Figure of structure
3. By using tool J, install floating seals (3) to idler

(4) and the assembly of shaft (5) and support
(2).
C Completely clean, degrease, and dry the
contact surfaces (hatched area shown in the
figure) of the floating seal and the O-ring.
C Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.
C After inserting the floating seals, check that
the inclination is less than 1 mm and the
protrusion (a) is within the range of 7 to 11
mm.
Disassembly (HB205-DT90-530-K-00-A)
Assembly (PC200_10-DT90-710-K-00-A)
1. Press fit bushings (9) and (10) to idler (4).
2. Install shaft (5) with O-ring (12) to support (2),

and insert dowel pin (1). 4. Install the assembly of shaft (5) and support (2)
to idler (4).
50-170 HB215LC-2
5. Turn it over, and supply oil between shaft (5) and idler 7. Install shaft (5) with O-ring (11) to support (7), and
(4). insert dowel pin (8).
5 Amount of oil to be sealed (EO-30DH): a See figure of structure.
245 to 255 cc 8. Supply oil and tighten plug (13).
Plug (13): Width across flats 22 mm
3 Plug (13):
157 to 255 Nm {16 to 26 kgm}
6. By using tool J, install floating seal (6) to idler (4) and

support (7).
a Completely clean, degrease, and dry the contact
surfaces (hatched area shown in the figure) of the a When mounting the idler assembly on the
floating seal and the O-ring. machine, make sure that plug (13) faces right side
a Apply oil to the sliding surface of the floating seal, of the machine.
and take care not to have any dirt stuck on it.
a After inserting the floating seals, check that the
inclination is less than 1 mm and the protrusion (a)
is within the range of 7 to 11 mm.
HB215LC-2 50-171
Disassembly and assembly of idler cushion assembly (HB205-DTBP-926-K-00-A)
Disassembly (PC200_10-DTBP-530-K-00-A)
1. Remove piston assembly (2) from idler cushion

assembly (1).
2. Disassembling idler cushion assembly
1) Set idler cushion assembly (1) to tool M1.
C Load at installed length of spring: 137.3
kN {14,010 kg}
4) Install cylinder (7) and yoke (6), plate (7a) to

spring (5). Install the assembly to tool M1.
2 Sliding surface of cylinder:
Grease (G2-LI)
2) Apply hydraulic pressure gradually to

compress the spring and remove lock plate
(3) and nut (4).
C Compress the spring until the nut
becomes loose.
C Release the hydraulic pressure slowly to
release the compression of the spring.
C Free length of spring: 556 mm
3) Remove yoke (6), plate (7a) and cylinder (7) 5) Apply hydraulic pressure slowly to compress
from spring (5). the spring, and then tighten nut (4) so that
4) Remove snap ring (8), dust seal (9) and the installed length of the spring is dimension
bushing (10), in turn from cylinder (7). (a) and secure it with lock plate (3)
3. Further disassembly of piston assembly (2)
C Installed length (a) of spring: 433 mm
1) Remove lock plate (12) from piston (11), and
then remove valve (13).
2) Remove snap ring (14), then remove U-
packing (15) and ring (16).
Assembly (PC200_10-DTBP-710-K-00-A)
1. Assembly of piston (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).
2. Assembly of idler cushion 6) Remove idler cushion assembly (1) from tool
1) Using tool M2, press fit bushing (10) into M1.
cylinder (7). 3. Install piston assembly (2) to idler cushion
2) Using tool M3, install dust seal (9) to cylinder assembly (1).
(7). 2 Sliding surface of cylinder: :
3) Secure them by using snap ring (8).
Grease (G2-LI)
50-172 HB215LC-2
2 Wear ring:
Grease (G2-LI)
C Install the piston assembly with the valve
installed position facing outward.
C Pump 300 cc of grease (G2-LI) into the
cylinder and bleed air. Check that grease
comes out of the grease hole.
HB215LC-2 50-173
Disassembly and assembly of track roller assembly (HB205-DTD0-926-K-00-A)
C Special tools 7. Remove bushings (9) and (10) from roller (4).
N-
e-
c-
Sym- e-
Part No. Part name
bol s- Q'ty
si-
ty
1 796T-667-1120 Push tool S 1
K
2 796-670-1020 Installer V 1
C Figure of structure
Assembly (HB205-DTD0-710-K-00-A)
1. By using push tool K1, press-fit bushings (9) and

(10) to roller (4).
2. Install O-ring (11), install collar (8) to shaft (5)
and install pin (7).
3. Install floating seal (6a) to collar (8) by using tool

K2.
C Clean, completely degrease and dry the
floating seal and O-ring contacting surface
(hatched area).
Disassembly (HB205-DTD0-530-K-00-A) C Take care that dirt dose not stick to the
1. Remove plug (13), and drain the oil from the contact face of the floating seal.
track roller assembly. C After inserting the floating seal, check that
the tilt of the seal is 1 mm or less and the
5 Oil (EO30-DH): projection dimension (a) of the seal is in the
190 to 200 cc range of 7 to 11 mm.
2. Remove pin (1) to remove collar (2). 4. Install floating seals (6b) and (3b) to roller (4) by
3. Remove floating seals (3) from collar (2) and using tool K2.
roller (4).
C For installation of floating seals (6b) and (3b),
4. Pull out roller (4) from shaft (5) and collar (8)
see the precautions in step 3.
assembly.
5. Remove floating seals (6) on the other side from
roller (4), and the assembly of shaft (5) and
collar (8).
6. Remove pin (7), and remove collar (8) from shaft
(5).
50-174 HB215LC-2
9. Supply oil and tighten plug (13).

5 Amount of oil (EO30-DH):
190 to 200 cc
3 Plug (13):
10 to 20 Nm {1 to 2 kgm}
a When installing the track roller assembly on the
machine, make sure that plug (13) faces outward.
5. Install drive shaft (5) to roller (4).

6. Reverse roller (4) and shaft (5) assembly.
7. Install floating seal (3a) to collar (2) by using tool K2.

a For installation of floating seal (3a), see the
precautions 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 O-ring (12), then install collar (2) to shaft (5)
with pin (1).
HB215LC-2 50-175
Disassembly and assembly of carrier roller assembly

Special tools to be used when you disassembly and assembly the carrier roller assembly
Symbol Part No. Part name Q'ty Sketch Remarks
1 793T-613-1380 Spacer 1 Q Removal of shaft, press fit of
2 790-201-2820 Spacer 1 bushing
Press fit of bushing, supporting

3 793T-417-1310 Spacer 1 Q
L the shaft
4 790-434-1660 Installer 1 Installation of floating seal
5 796T-430-1310 Push tool 1 Q
Press fit of shaft
6 796T-430-1320 Washer 1 Q
a Figure of structure
Disassembly
1. Remove plug (9) to drain the oil from carrier roller assembly (1).
6 Amount of oil: 75 to 85 cc
2. Push the shaft end surface to remove shaft (2) from carrier roller
assembly (1), and disassemble the following by using push tool
L1.
q Roller (4), ring (5) assembly, shaft (2), cover (3)
q Press-fitting force (for reference): Min. 59 kN {6,000 kg}
a Press fitting of shaft (2) and ring (5) and press-fitting of roller
(4) and cover (3) are removed simultaneously.
a Shaft (2) is pulled out together with the underlying cover (3).
50-176 HB215LC-2
3. Remove ring (5) from roller (4).

4. Remove floating seal (6) from ring (5).
a Take care not to damage the seal surface.
5. Remove floating seal (7) from roller (4).

a Take care not to damage the seal surface.
6. Remove bushing (8) from roller (4) by using push tools L1 and
L2.
Assembly
1. By using push tools L1 and L2, press-fit bushing (8) to roller (4).
a Press-fit from the cover (3) side.
HB215LC-2 50-177
2. Floating seal
1) Install floating seal (7) to roller (4) by using tool L4.
2) Install floating seal (6) to ring (5) by using tool L4.
a Clean, completely degrease and dry the floating seal and
O-ring contacting surface (hatched area).
Take care that dirt dose not stick to the contact face of
the floating seal.
a Install the floating seal by using tool L4, and make sure
to press the O-ring to insert it.
a After inserting the floating seal, check that the tilt of the
seal is 1 mm or less and the projection dimension (a) of
the seal is in the range of 7 to 11 mm.
3. Install roller (4) and ring (5) to shaft (2).

a Apply oil to the sliding surface of the floating seal, and take
care that dirt dose not stick to it.
50-178 HB215LC-2
4. Insert washer L6 between push tool L5 and roller (4) so

that the step between roller (4) and ring (5) is 1.8 ± 0.2
mm, and press-fit ring (5) to shaft (2).
a Thickness of washer L6 1.8 ± 0.2 mm
a Support shaft (2) from underside by using push tool
L3.
5. Press-fit cover (3) to roller (4) by using push tool L1.

a Degrease, clean, and dry the contact surface of
roller (4) and cover (3).
q Press-fitting force (for reference): Min. 59 kN
{6,000 kg}
6. After filling carrier roller assembly (1) with oil, tighten

plug (9).
5 Amount of oil (EO30-DH): 75 to 85 cc
3 Plug (9): 10 to 20 Nm {1 to 2 kgm}

HB215LC-2 50-178-1
50-178-2 HB215LC-2
Removal and installation of revolving frame assembly (PC220-H110-924-K-00-A)
k Park the machine on a level ground, lower 4 Boom cylinder assembly:

the engine. 180 kg

hydraulic circuit. For details, see Testing and
from hydraulic circuit".
C Note connector numbers and installed positions

before disconnecting wirings and hoses.
C Fit a plug or flange to the disconnected hydraulic
hose to prevent oil from flowing out.
Removal (PC220-H110-520-K-01-A)
1. Remove the work equipment assembly. For

details, see "Removal of work equipment
assembly".
2. Remove counterweight assembly. For details,
see "Removal of counterweight assembly".
3. Disconnect boom cylinder hoses (1) (4 pieces).
C Plug the hoses.
6. Remove hoses (8) to (13) (6 pieces) from the

center swivel joint assembly.
• (8): Center swivel joint (port D) to swing
motor (port T)
• (9): Center swivel joint (port E) to solenoid
valve
• (10): Center swivel joint (port B) to control
4. Set slings to boom cylinder assembly (2). valve L.H. travel (port A2)
5. Remove plate (3) and pin (4), sling boom • (11): Center swivel joint (port D) to control
cylinder assembly (2), and remove it. valve R.H. travel (port B5)
• (12): Center swivel joint (port A) to control
C Remove the boom cylinder on the opposite
valve L.H. travel (port B2)
side in the same way.
• (13): Center swivel joint (port C) to control
valve R.H. travel (port A5)
7. Pull out pin (14) on the center swivel joint side,
and disconnect lock plate (15) from the center
swivel joint.
HB215LC-2 50-179
Installation (PC220-H110-720-K-00-A)
[*1]
Hoses are connected to the following places.
q Hose (6): Swing motor port (T)
q Hose (7): Travel speed increase solenoid valve
q Hose (8): Control valve port (B2)
q Hose (9): Control valve port (B5)
q Hose (10): Control valve port (A2)
q Hose (11): Control valve port (A5)
[*2]
8. Remove the mounting bolts (32 pieces), sling 2 Swivel circle mating surface:
revolving frame assembly (16) and remove it. Liquid gasket (LG-6)
2
[*1] Threads of revolving frame mounting bolt:
a Adjust the front, back, right and left balance of the Adhesive (LT-2)
revolving frame assembly by using the lever block. q In case of angle tightening
a When removing the revolving frame assembly, be Initial torque: Width across flats 32 mm
careful not to hit the center swivel joint assembly. 3 Initial torque:
294.2 ± 29.4 Nm {30 ± 3 kgm}
4
3 Then, rotate the bolt by 60±6°.
Revolving frame assembly:
6,800 kg
q Refilling of oil (hydraulic tank)
Supply oil through the oil filler port to the specified
level. Run the engine to circulate the oil through the
system. Then, check the oil level again.
q Bleeding air
Bleed air from the hydraulic pump circuit. For details,
see Testing and adjusting, "Bleeding air from
hydraulic circuit".
50-180 HB215LC-2
Removal and installation of counterweight assembly (HB205-H700-924-K-00-A)


Removal (HB205-H700-520-K-00-A)
1. Open side cover (1) on the right side of the

machine.
5. Sling counterweight assembly (3), and
disconnect it. [*2]
C When disconnecting the counterweight
assembly, take care not to hit against the
machine body.
4 Counterweight assembly (3):

• HB205, HB205LC:
3160 kg
• HB215, HB215LC
3880 kg
2. Disconnect connector A40 (2).
Reference: Removal of rearview monitor

3. Install the eyebolt to the eyebolt installation assembly
places, and set slings to counterweight 1. Remove cover (1).
assembly (3).
2. Remove bolt (2), and remove cover (6).

4. Remove mounting bolts (4) (4 pieces) by using
socket wrench Z3. [*1]
HB215LC-2 50-181
a If shims are inserted, check and record their

places and quantity.
(Take care that shims (7) installed to cover (6)
may come off with cover (6). )
Installation (HB205-H700-720-K-00-A)
[*1]
2 Threaded part of counterweight assembly (3)
mounting bolt (4):
Adhesive (LT-2)
Counterweight assembly (3) mounting bolt (4): Width
across flats 46 mm
3 Counterweight assembly (3) mounting bolt (4):
1.52 to 1.91 kNm {155 to 195 kgm}
[*2]
q Installation and adjustment of counterweight
a Adjust the step from the exterior cover (top and bottom
gaps) with shims.
q Shim part number: 206-46-31450
a Install it so that the clearances between side cover (5)

and counterweight (6), and between revolving frame
(7) and counterweight (6) (longitudinal direction) are
10 ± 5 mm evenly. Take care that the difference
between the clearances at point (S) and point (T)
should be 3 mm or less.
a Set the lateral difference (a) between side cover (5)

and counterweight (6) to 9 ± 4 mm.
a Set the lateral difference (b) between revolving frame

4. Remove the connector A45 (4), and remove rearview (7) and counterweight (6) to 5 mm or less.
camera assembly (5).
a Set the vertical difference (c) between cover (8) on the
top surface and counterweight (6) to 5 mm or less.
a Reference figure (enlarged R.H. side view from the

rear of the machine)
50-182 HB215LC-2
[*3]
Installation and adjustment of rearview camera
cover
C By using shims (7), adjust the difference
between the vertical clearances between the
counterweight and cover (6) to 2 mm or less.
C Hang shim (7) on cover (6) or insert it from
outside to the cover after inserting the bolt
temporarily.
HB215LC-2 50-183
Hydraulic system
Hydraulic system
Removal and installation of center swivel joint assembly (PC220-J8E0-924-K-00-A)
k Park the machine on a level ground, lower

the engine.


before disconnecting wiring and hoses.
C Fit a plug or flange in the place of the hydraulic
hose is disconnected from to prevent oil from 3. Disconnect bottom hoses (3) to (8). [*2]
flowing out.
• Hose (3): Port (DR1)
• Hose (4): Port (DR1)
Removal (HB205-J8E0-520-K-00-A) • Hose (5): Port (B1)
1. Swing the upper structure to the right by 45 deg. • Hose (6): Port (D1)
stop it, and then remove undercovers (1) (2 • Hose (7): Port (A1)
pieces). • Hose (8): Port (C1)
C Swing it to drain oil from the hydraulic tank.

C For details on using the oil stopper not to
drain the oil in the hydraulic tank, see
"Removal and installation of main pump
assembly".
4. Disconnect bottom hoses (9) and (10). [*2]

• Hose (9): Port (E1)
• Hose (10): Port (E1)
5. Cotter pin (13) is provided to pin (12) of stopper
plate (11). Remove cotter pin (13).
C Perform the work from the bottom side of the
2. Remove drain plug (2) to drain the oil from the machine body.
hydraulic tank. [*1]
C To remove easily from the top side, lightly
6 Hydraulic tank: push up pin (12).
132 N
50-184 HB215LC-2
Hydraulic system
6. Disconnect top hoses (14) to (19). [*2] 9. Sling center swivel joint (20), and remove it.
q Hose (14): Port (DR2) 4 Center swivel joint (20):
q Hose (15): Port (E2) 40 kg
q Hose (16): Port (B2)
q Hose (17): Port (D2)
q Hose (18): Port (A2)
q Hose (19): Port (C2)
7. Pull out pin (12), and disconnect stopper plate (11)
from center swivel joint (20).
Installation (HB205-J8E0-720-K-00-A)
[*1]
q Refilling with oil (Hydraulic tank)
5 Hydraulic tank:
132 l
Drain plug (2): Width across flats 24 mm
3 Drain plug (2):
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
[*2]
The connecting destinations of the hoses are as shown
below.
q Hose (3): L.H. travel motor port (T)
8. Remove mounting bolts (21) (4 pieces) of center q Hose (4): R.H. travel motor port (T)
swivel joint (20). q Hose (5): L.H. travel motor port (PA)
q Hose (6): R.H. travel motor port (PB)
a Do not remove center swivel joint holder (22).
q Hose (7): L.H. travel motor port (PB)
a When removing center swivel joint holder (22), q Hose (8): R.H. travel motor port (PA)
mark it to indicates its original position and
q Hose (9): L.H. travel motor port (P)
direction. [*3]
q Hose (10): R.H. travel motor port (P)
q Hose (14): Swing motor port (T)
HB215LC-2 50-185
Hydraulic system
• Hose (15): Travel speed increase solenoid valve

• Hose (16): Control valve port (B2)
• Hose (17): Control valve port (B5)
• Hose (18): Control valve port (A2)
• Hose (19): Control valve port (A5)
[*3]
When center swivel joint stand (22) is removed,
install center swivel joint stand (22), bolts (23) (4
pieces), washers (24) (8 pieces), and nuts (25) (4
pieces) to the dimensions shown in the figure to
obtain swing center (C).
• Air bleeding
Bleed air from the hydraulic pump circuit. For
details, see Testing and adjusting, "Bleeding air
from hydraulic system".
50-186 HB215LC-2
Hydraulic system
Disassembly and assembly of center swivel joint assembly (HB205-J8E0-926-K-00-A)
C Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
790-101-2501 Push puller S 1

790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
790-101-2540 • Washer 1
S
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2 5. Remove slipper seal (10) from rotor (8).
• Adapter 6. Remove snap ring (11) and oil seal (12) from
790-101-2680 2
rotor (8).
790-201-1410 Plate S 1
7. Remove dust seal (13) from cover (14).
C Figure of structure Assembly (HB205-J8E0-710-K-00-A)
1. Install plug (15) to shaft (9).

3 Plug (15):
33.3 ± 3.9 Nm {3.4 ± 0.4 kgm}
C Clean, degrease, and dry the threaded part
of plug (15) and install it.
C After installing plug (15), check that plug (15)
is below the end surface of shaft (9).
2. Install slipper seal (10) to rotor (8).
3. Install oil seal (12) and snap ring (11) to rotor (8).
2 Oil seal lip:
Grease
2 to 3 mNN
4. Install dust seal (13) to cover (14).
2 Dust seal lip:
Grease
N
2 to 3 mN
5. Install cover (14) to shaft (9).
2 Inside cover:
Grease
3 to 5 mN N
6. Set shaft (9) to a block, install rotor (8) by
Disassembly (HB205-J8E0-530-K-00-A) tapping it lightly with a plastic hammer by using
1. Remove elbows (1) and (2), tee (3) and union a push tool.
(4). 2 Rotor and shaft contact surface:
Grease (G2-LI)
3. Remove snap ring (6) and ring (7).
4. Push out shaft (9) from rotor (8) by using tool S. C When installing rotor (8), be careful not to
damage dust seal (13) and oil seal (12).
7. Install ring (7) and fix it with snap ring (6).
8. Install O-ring (16), and install cover (5).
3 Cover (5) mounting bolt:
31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
HB215LC-2 50-187
Hydraulic system
9. Install elbows (1) and (2), tee (3) and union (4).
Elbow (1): Width across flats 32 mm
3 Elbow (1):
128 to 186 Nm {13 to 19 kgm}

Elbow (2), tee (3): Width across flats 19 mm
3 Elbow (2), tee (3):
35 to 63 Nm {3.5 to 6.5 kgm}
50-188 HB215LC-2
Hydraulic system
Removal and installation of hydraulic tank assembly (PC220-PM30-924-K-00-A)

the engine.


C Fit a plug or flange to disconnected hydraulic
hose to prevent oil from flowing out.
4. Remove step (4), handrail (5) (6 bolts), plate (6)
Removal (PC200_10-PM30-520-K-01-A) tightened together with the handrail, cover (7) (3
1. Swing the upper structure to the right by 45 deg. bolts), cover (8a) (5 bolts), and cover (8b) (4
stop it, and then remove undercovers (1) (3 bolts).
pieces). C After removing the mounting bolt of clamps
C Swing the upper structure, and then remove (4a), remove bolts (4b) (4 pieces), and
the hydraulic tank mounting bolt and suction remove step (4).
tube.
2. Remove drain plug (2), and drain the oil from the
hydraulic tank. [*1]
6 Hydraulic tank:
132 N

machine body, and remove cover (3) (5 bolts)
with rubber sheet.
HB215LC-2 50-189
Hydraulic system
5. Remove mounting bolts (10) (5 pieces) that are 8. Remove cover (9) by pulling up it.
fixing cover (9), and remove mounting bolts (12)
C Be careful not to be caught by the harness or
(2 pieces) that are fixing cover (9a).
hose.
C Remove cover (9) after removing frame (14).
6. Remove mounting bolts (14a) (4 pieces) that are
fixing frame (14).
9. Remove clamp (15) (1 bolt), and move it away

from the hydraulic tank.
Remove cover (13) (4 bolts).
10.Disconnect hoses (20) to (25).

• Hose (20): To attachment circuit
7. Remove frame (14) (9 bolts). • Hose (21): To control valve
• Hose (22): To solenoid valve
4 Frame (14): • Hose (23): To center swivel joint
11 kg • Hose (24): To PPC valve
• Hose (25): To main pump
50-190 HB215LC-2
Hydraulic system
11. Remove hoses (26) to (28), and brackets (29) and

(30).
Installation (PC200_10-PM30-720-K-01-A)
q Hose (26): To control valve
[*1]
q Hose (27): To control valve
q Refilling with oil (Hydraulic tank)
q Hose (28): To oil cooler
5 Hydraulic tank:
132 l
Drain plug (2): Width across flats 24 mm
3 Drain plug (2):
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
[*3]
Suction tube mounting bolts (31): Width across flats
19 mm
12. Remove suction tube mounting bolts (31) (4 pieces), 3 Suction tube mounting bolts (31):
and hydraulic tank mounting bolts (32)(6 pieces). [*3] 29.4 to 49.0 Nm {3 to 5 kgm}
a Be sure to prepare the oil pan since the remaining Hydraulic tank mounting bolt (32): Width across flats
hydraulic oil may flow out when the suction tube is 24 mm
3
removed. Hydraulic tank mounting bolt (32):
235 to 285 Nm {23.5 to 29.5 kgm}
q Air bleeding
Bleed air from the hydraulic pump circuit. For details,
see Testing and adjusting, "Bleeding air from
hydraulic system".
13. Sling hydraulic tank assembly (16), and remove it.

4 Hydraulic tank (16)
140 kg
HB215LC-2 50-191
Hydraulic system
Removal and installation of main pump assembly (PC220-C200-924-K-00-A)
C Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
1 796-460-1210 Oil stopper S 1

R
2 796-770-1320 Adapter S 1
k Park the machine on a level place, swing the

upper structure by 45 deg. clockwise, lower
the work equipment to the ground stably, and
2. Loosen drain valve (6), and drain the oil from the
stop the engine.
hydraulic tank.
k Set the lock lever in the LOCK position.
6 Hydraulic tank:
k Release the remaining pressure in the 132 N
k Turn the battery disconnect switch to the

OFF position and remove the key.
C Tag the hoses to show their installed positions

for the prevention of wrong installation.
Removal (HB205-C200-520-K-00-A)
1. Remove undercovers (1) to (4).

C The cover is a reinforced cover and heavy. C If the hydraulic tank is not drained, install the
Remove it carefully. stopper by using tool R10 according to the
1) Remove the cover.
2) Remove the strainer.
3) Install tool R1 (oil stopper) and tool R2
(adapter).
4) Install tool R1 and tool R2 together after the
strainer is removed.
5) Install the cover.
C Tighten it with several bolts lightly.
50-192 HB215LC-2
Hydraulic system

remove cover (8).
8. Remove mounting bolts (18), and remove

bracket (19).
remove cover (10).
remove cover (12).
9. Disconnect case drain hose (20), EPC source

pressure hose (21), EPC source pressure hose
(22), pump pressure input hose (23), front pump
load pressure input hose (24), and rear pump
load pressure input hose (25).
6. Disconnect front pump PC-EPC connector V11
(13), rear pump PC-EPC connector V12 (14),
LS-EPC connector V19 (15), and hydraulic oil
temperature sensor P22 (16).
10.Disconnect discharge hoses (37) (2 pieces).
7. Disconnect motor-generator connector GM01

(17).
HB215LC-2 50-193
Hydraulic system
11.Disconnect front pump swash plate sensor 17.Remove main pump assembly mounting bolts
connector P27 (26) and rear pump swash plate (36a) (2 pieces), and remove bracket (38). [*2]
sensor connector P28 (27).
12.Remove clip (28).
18.Sling the main pump assembly, hold it, and

remove main pump assembly mounting bolts
(36) (12 pieces). [*1]
14.Remove mounting bolts (30) (2 pieces), and 19.Sling the main pump assembly, and remove it.
move bracket (31) to the machine body side.
4 Main pump assembly:
190 kg

disconnect suction tube (33) from the main
pump assembly.
16.Disconnect rear pump branch hose (34) and Installation (HB205-C200-720-K-00-A)
front pump branch hose (35). • Perform installation in the reverse order to
removal.
[*1]
Under head of mounting bolt (36):
5 mm
[*2]
50-194 HB215LC-2
Hydraulic system
Under head of mounting bolt (36a):

70 mm
• Refilling with oil
Refill the hydraulic tank 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 Hydraulic tank:
132 N
234 N (specified capacity)
HB215LC-2 50-195
Hydraulic system
Removal and installation of control valve assembly (PC220-C030-924-K-01-A)
k Place the machine on a level ground, lower 4. Remove the following cover and partition plates.
the work equipment to the ground, and stop • Control valve top cover (4)
the engine. • Partition plates (5a), (5b), (5c), and (5d)
between the control valve and engine

and remove the key.
C Write down the installing positions, connector

numbers, and hose band colors of the wirings
and pipings not to install them wrongly.
C Fit a plug or flange in the place where a
hydraulic hose is disconnected from to prevent • Partition plate (6) between the control valve
oil from flowing out. and engine
Removal (HB205-C030-520-K-00-A)
1. Swing the upper structure by 45 deg. (For

draining hydraulic oil from hydraulic tank)
5. Disconnect hose (7) to the L.H. travel motor.

6. Disconnect PLS1 port hose (8).
C Color band color: None
7. Disconnect PLS2 port hose (9).
3. Loosen drain plug (3) to drain the oil from the C Color band color: None
hydraulic tank. [*1] 8. Disconnect hoses and tubes in the control valve
front side.
6 Hydraulic tank: • A row: From top to bottom
132 N (refill capacity) A1 port (bucket head side)(hose)
235 N (specified capacity) A2 port (L. H. travel motor reverse) (tube-
hose)
A3 port (boom bottom)(tube)
A5 port (R.H. travel motor reverse)(hose)
A6 port (arm head)(hose)
• B row: From top to bottom
B1 port (bucket bottom side)(tube-hose)
B2 port (L. H. travel motor forward) (tube -
hose)
B3 port (boom head)(tube)
B5 port (R. H. travel motor forward) (tube -
hose)
B6 port (arm bottom)(hose)
50-196 HB215LC-2
Hydraulic system
C For A2 port (L.H. travel motor reverse),

B1 port (bucket bottom side), and B5 port
(R.H. travel motor forward), disconnect
the tube and hose, and then remove the
tube from the control valve.
C For B2 port (R.H. travel motor), remove
tube (10) according to the following
procedure.
1) Disconnect hose (11) from tube (10).
2) Remove clamps (12) (2 pieces), and remove
bracket (13).
3) Remove tube (10).
• (20): B6 port (arm bottom hose)(described
C Remove A3 port (boom bottom) tube (14) previously)
and B3 port (boom head) tube (15) according • (21): T1 port (return tube)
1) Remove boom tube mounting clamp (16).
2) Disconnect hones (17) (2 pieces) from the
bracket.
3) Disconnect boom hoses (18) (4 pieces).
4) Remove boom tube mounting clamps (19) (2
pieces).
5) Remove tubes (14) and (15).
9. Disconnect the wiring connectors and hoses

after the control valve (engine side) according to
1) Disconnect the sensor side connectors (22)
and (23) from the clip.
2) Disconnect merge-divider EPC connector
V23 (22) and merge-divider EPC connector
V24 (23).
3) Disconnect clamp (24).
4) Disconnect brackets (25) and (26) from the
control valve.
5) Disconnect front pump pressure sensor

connector P25 (27) and rear pump pressure
sensor connector P26 (28).
6) Disconnect hoses (29) to (33).
• (29): PP1 port hose (from rear pump)
HB215LC-2 50-197
Hydraulic system
• (30): PP2 port hose (from front pump)

• (31): T port hose (to hydraulic tank)
• (32): PPS2 port hose (to front pump
control)
• (33): PR port hose (to solenoid valve)
12.Open clip (64), and disconnect connector V25

(65).
13.Disconnect pressure sensor inlet hose (66).
14.Disconnect PPC source pressure hose (67).
15.Disconnect oil cooler supply hose (68).
16.Remove relay block bracket (69).
10.Disconnect the hoses on the right side of the
control valve according to the following
procedure.
1) Disconnect PPC hoses (34) to (39).
• (34): (Attachment)
• (35): P2 port hose (bucket curl PPC)
• (36): P4 port hose (L.H travel PPC)
• (37): P6 port hose (boom lower PPC)
• (38): P10 port hose (R.H travel PPC)
• (39): P12 port hose (arm IN PPC)
2) Disconnect PST port hose (solenoid valve)
(40).
17.Remove clip (70), and disconnect TS port hose

(71).
18.Disconnect PST travel junction hose (72).
11.Disconnect the hoses on the left side of the

control valve according to the following
procedure.
1) Disconnect PPC hoses (41) to (48).
19.Remove cover (50).
• (41): PX1 (main relief pressure selector)
• (42): (Attachment selector)
• (43): (Attachment)
• (44): P1 port hose (Bucket DUMP)
• (45): P3 port hose (L.H travel PPC)
• (46): P5 port hose (boom lower PPC)
• (47): P9 port hose (R.H travel PPC)
• (48):P11 port hose (Arm OUT PPC)
2) Disconnect PX2 port hose (main relief
pressure selector) (49).
50-198 HB215LC-2
Hydraulic system
20. Remove hoses (51) to (57).

(Color band color: None)
Installation (PC200_10-C030-720-K-01-A)
q (51): None
[*1]
q (52): Red
Hydraulic tank drain plug: Width across flats 24 mm
(53): None
3
q
Hydraulic tank drain plug:
q (54): None
58.8 to 78.5 Nm {6.0 to 8.0 kgm}
q (55): Red/Yellow
q (56): Brown q Refilling with oil (Hydraulic tank)
q (57): None Refill with oil to the specified level through the oil filler
21. Disconnect the following connectors (58) (6 pieces). port. Run the engine to circulate the oil through the
(From top) piping. Then check the oil level again.
q V06 6 Hydraulic tank:
q V05 132 l (refill capacity)
q V04 234 l (specified capacity)
q V03 q Air bleeding
q V02 See Testing and adjusting, "Bleeding air from each
q V01 part".
22. Disconnect clamp (59).
23. Move solenoid valve assembly (60) away from control
valve bracket (61).
24. Remove 4 mounting bolts (62) of the control valve.
25. Sling control valve assembly (63), and remove it.

4 Control valve assembly:
235 kg
255 kg (1ATT)
HB215LC-2 50-199
Hydraulic system
Disassembly and assembly of control valve assembly (HB205-C030-926-K-00-A)
C This section explains only the precautions for assembling the control valve assembly.
C Special tools
Ne-
Symbol Part No. Part Name cessi- Q'ty
ty
796-946-1310 Guide H21.8 mm
■ 1
(for 723-46-40100)
796-946-1810 Guide H21.2 mm
■ 1
(for 723-46-43100, 723-46-43600)
2
796-946-1910 Guide H21.0 mm
■ 1
(for 723-46-46101, 723-46-46300)
796-946-2210 Guide H20.6 mm
■ 1
(for 723-46-45100, 723-46-45700)
796-946-1320 Guide H21.8 mm
■ 1
(for 723-46-40100)
796-946-1820 Guide H21.2 mm
■ 1
(for 723-46-43100, 723-46-43600)
796-946-1920 Guide H21.0 mm
3 ■ 1
T (for 723-46-46101, 723-46-46300)
796-946-2220 Guide H20.6 mm
■ 1
(for 723-46-45100)
796-946-1420 Guide H21.6 mm
■ 1
(for 723-46-42700)
796-946-1330 Sleeve
■ 1
(for 723-46-40100)
796-946-1830 Sleeve
■ 1
(for 723-46-43100, 723-46-43600)
796-946-1930 Sleeve
4 ■ 1
(for 723-46-46101, 723-46-46300)
796-946-2230 Sleeve
■ 1
(for 723-46-45100)
796-946-1430 Sleeve
■ 1
(for 723-46-42700)
Procedure for replacing pressure compensation valve seal (PC220-L6D4-924-K-00-A)
C Since many types of pressure compensation

valves are installed, put a mark on each and
record the installed position when removing
them.
1. Remove piston (2), plug (3) and spring (4) from
pressure compensation valve (1).
2. Remove seals (5) and (6) from piston (2).
C There are many types of pistons.

3. Place tool T1 on piston (2), put seal (5) on the
tool, and then push the seal down slowly in such
50-200 HB215LC-2
Hydraulic system
a way that it expands evenly to install it in

position.
C Put the seal on the tool and push it down to
the flat part of the tool. Then you may install
the tool to the piston to push in the seal
further.
6. Fit plug (3) and spring (4) to piston (2), then

install pressure compensation valve (1).
C After the installation, push piston (2) by hand
and check that the piston returns with the
spring force alone.
4. Repeat the same process to install another seal

(6). Place tool T2 on the same end of piston (2).
Slowly push seal (6) down in such a way that it
expands evenly to install it in position.
C Put the seal on the tool and push it down to
the flat part of the tool. Then you may install
the tool to the piston to push in the seal
further.
5. Install settling tool T3 on piston (2) and keep it

installed for approximately one minute so that
seals (5) and (6) fit in.
C Check that there is no extrusion or cut on the
seal.
HB215LC-2 50-201
Hydraulic system
Assembly of control valve assembly (HB205-C030-530-K-00-A)
C Install filters (9) at the bottom of ports (PLS1)

and (PLS2) in the direction shown in the figure
below. (Be careful with positioning of caulked
part (10).)
C Apply engine oil on the sliding surfaces on the

parts before assembling them.
C When installing spool (7) to the valve chest,
make sure that drilled hole (H1) faces the
direction shown in the figure.
C Similarly for cross section L-L.
• When installing spool (8) to the valve chest,

make sure that drilled hole (H2) faces the
direction shown in the figure.
C Similarly for cross sections H-H, K-K, and M-M.
50-202 HB215LC-2
Hydraulic system
HB215LC-2 50-203
Hydraulic system
q Control valve top and bottom cover block Boom hydraulic drift prevention valve mounting bolt:
2 Mating faces (11) of top and bottom cover Width across flats 8 mm
blocks of control valve: 3 Boom hydraulic drift prevention valve
Loctite 222 or equivalent mounting bolt:
a Tighten the mounting bolts of the top and bottom 58.8 to 73.6 Nm {6 to 7.5 kgm}
cover blocks of the control valve in the order q Arm quick return valve
shown in the figure below. (A o D o C o B)
a Tighten the arm quick return valve mounting bolts
Mounting bolt of top and bottom cover blocks of
in the same order as the cover blocks of the
control valve: Width across flats 22 mm control valve.
3 Mounting bolt of top and bottom cover Arm quick return valve mounting bolt: Width across
blocks of control valve: flats 8 mm
156.9 to 176.5 Nm {16 to 18 kgm} 3 Arm quick return valve mounting bolt:
58.8 to 73.6 Nm {6 to 7.5 kgm}
q Arm hydraulic drift prevention valve
a Tighten the arm hydraulic drift prevention valve

mounting bolts in the same order as the cover
blocks of the control valve.
Arm hydraulic drift prevention valve mounting bolt:
3 Arm hydraulic drift prevention valve
mounting bolt:
58.8 to 73.6 Nm {6 to 7.5 kgm}
a After assembly, plug φ12 hole (13) to prevent oil and
q Merge-divider valve
2
detergent liquid from entering the hole.
Merge-divider valve mating face (12):
q Pressure compensation valve
Loctite 222 or equivalent
a Install the pressure compensation valves by
a Tighten the merge-divider valve mounting bolts in
checking the marks put during removal.
the same order as the cover blocks of the control
Pressure compensation valve: Width across flats
valve.
30 mm
3
Merge-divider valve mounting bolt: Width across flats
Pressure compensation valve:
22 mm
3
372.7 to 411.9 Nm {38 to 42 kgm}
Merge-divider valve mounting bolt:
156.9 to 176.5 Nm {16 to 18 kgm} q Main relief valve assembly
q Variable back pressure valve a Perform the testing and adjusting after installing
the main relief valve assembly to the control valve.
a Tighten the variable back pressure valve For details, see Testing and adjusting, "Testing
mounting bolts in the same order as the cover and adjusting of work equipment, swing, and
blocks of the control valve. travel circuit pressure".
Variable back pressure valve mounting bolt: Width Main relief valve assembly: Width across flats 30 mm
across flats 8 mm 3 Main relief valve assembly:
3 Variable back pressure valve mounting 49 to 58.8 Nm {5 to 6 kgm}
bolt:
58.8 to 73.6 Nm {6 to 7.5 kgm}
q Boom hydraulic drift prevention valve
a Tighten the boom hydraulic drift prevention valve

mounting bolts in the same order as the cover
blocks of the control valve.
50-204 HB215LC-2
Hydraulic system
HB215LC-2 50-205
Hydraulic system
Disassembly and assembly of work equipment PPC valve (ALL-PL28-926-K-00-A)
Disassembly (ALL-PL28-530-K-00-A)
C This section contains only the precautions for

disassembling the work equipment PPC valve
assembly.
C Each of springs (6) and (7), consists of two
springs having different load at installed length.
Note their installed positions (hydraulic ports)
and identify them with tags to ensure correct
installation.
Assembly (ALL-PL28-710-K-00-A)
C Only precautions for assembling the work C When installing plug (3) to valve body (1), check
equipment PPC valve assembly are described the insertion depth so that the tip of the plug
below. does not protrude into the H20 hole in the valve
body.
C Before assembly, thoroughly clean the parts and
check them for any dirt, rust or damage to 3 Plug (3):
prevent failures. 4 to 9 Nm {0.4 to 0.9 kgm}
C The head of plug (2) must not be projected from C Install spring (5) with its small diameter end
the surface of valve body (1). facing shim (4).
3 Plug (2): • Diameter of spring end tum (inside diameter)
6 to 11 Nm {0.6 to 1.1 kgm} Small diameter end: H 4.9 mm
Large diameter end: H 5.55 mm
50-206 HB215LC-2
Hydraulic system
a When installing springs (6) and (7), note that their a Apply grease (G2-LI) to the rocking parts of joint (12)
installed positions are determined by the hydraulic and to the contact surfaces on disc (13) and piston (8).
ports. 2 Grease (G2-LI)
q Installed height is 31.9 mm for all springs. q Rocking parts of joint: 2 to 4 cc/entire periphery
q Load at installed length q Contact surfaces on disc and piston: 0.3 to 0.8 cc/part
Spring (6) (P1, P2): 35.3 N {3.6 kg}
a Install disc (13), refering to Testing and adjusting,
Spring (7) (P1, P2): 21.6 N {2.2 kg}
"Adjusting play of work equipment and swing PPC
a Before installing piston (8), apply grease (G2-LI) to the valves".
periphery of the piston and the bore in the valve body.
a Lever play:
Bolt (11): Width across flats 10 mm
0.5 to 3 mm (at 200 mm from lever pivot point)
3 3 Bolt (11):
Nut (14): Width across flats 22 mm
3
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
Nut (14):
a When installing joint (12) to valve body (1), apply 69 to 88 Nm {7 to 9 kgm}
Loctite according to the following procedure.
1. When installing the joint, apply a drop (approx. 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
Joint (12): Width across flats 17 mm
3 Joint (12):
39 to 49 Nm {4 to 5 kgm}
HB215LC-2 50-207
Hydraulic system
Disassembly and assembly of travel PPC valve assembly (HB205-C6V0-926-K-00-A)
Disassembly (HB205-C6V0-530-K-00-A)
1. Remove screws (22), and remove damper

assembly (21).
2. Remove mounting bolt (19), and remove case
(18), shaft (16), and lever (13) together as a unit.
3. Remove mounting bolts (11), and remove plate
(10).
C Check and record the thickness and
installing position of washer (12).
C Pull out pin (24) from body (1).
4. Remove seal (9) and collar (8).
5. Pull out piston (7), and remove retainer (6),
springs (5) and (4), and shim (3).
C Check the thickness and quantity of shims
(3) at each installing position, and store
them.
6. Pull out valve (2) from body (1).
Assembly (HB205-C6V0-710-K-00-A)
Only precautions for assembly are described. C When assembling piston (7), apply grease (G2-
LI) to the piston periphery and inner periphery of
C Carefully clean and inspect the parts to prevent
the body hole.
failure due to dust, rust, scratch, etc., and then
take extreme care when assembling them. C When installing spring (4), install the end surface
of the smaller end turn diameter to shim (3) side.
• End turn diameter of spring (inside diameter)
50-208 HB215LC-2
Hydraulic system
Small diameter side: φ4.9 mm

Large diameter side: φ5.55 mm
a Apply grease (G2-LI) to the contact surfaces of lever

(13) and piston (7) and to the contact surfaces of
damper (21) and pin (20).
2 Amount of grease (G2-LI)
Connection point of lever (13) and piston (7):
0.3 to 0.8 cc/1 place
Connection point of damper (21) and pin (20):
0.3 to 0.8 cc/location
a If difference between right and left at lever full stroke

is larger than 0.7 deg. when installing washer (12) (t =
1.6), change the washer thickness to reduce the
difference to 0.7 deg. or less. (By reducing washer
thickness by 0.3 mm, full stroke angle increases by
0.39 deg.)
a
q Number of washer (12) t = 1.0, 1.3, 1.6, 1.9, 2.2
a Tightening torque of each part is as following.

Screw (22): Width across flats 3.5 mm
3 Screw (22):
0.441 to 0.588 Nm {0.045 to 0.06 kgm}
3 Bolt (19):
25 to 30 Nm {2.5 to 3.2 kgm}
3 Bolt (11):
27 to 34 Nm {2.8 to 3.5 kgm}
HB215LC-2 50-209
Work equipment
Work equipment
Workequipment (ALL-L000-001-K-50-A)
Removalandinstallationofworkequipmentassembly
C Special tools C Bind the piston rod with wires and lower it on
a support so that the piston rod doesn't come
Necessity
off, or place a batten on the bottom side so
Sym-
Q'ty
Part No. Part name that the cylinder doesn't lower. Remove the
bol
grease nipple on the bottom side to place a
batten.
796-900-1200 Remover V 1
796-900-1210 • Sleeve 1 C Remove the boom cylinder on the opposite
792-900-1520 • Plate 1 side in the same way.
• Screw 1 C If the lifting tool interferes the working lamp
796-900-1240 • Adapter 1 during slinging the work equipment, remove
V 01643-33080 • Washer 1 the working lamp.
01803-13034 • Nut 1 6. Release the remaining pressure in the piping
Puller (490 kN {50 after stopping the engine. See Testing and
790-101-4000 ton} long) V 1 adjusting, "Releasing remaining pressure from
Pump (294 kN {30 hydraulic system".
790-101-1102 ton}) V 1 7. Disconnect bucket cylinder hoses (6) (2 pieces)
and arm cylinder hoses (7) (2 pieces).
k Extend the arm and bucket fully, and lower
C Plug the hoses to prevent oil leakage, and fix
the work equipment to the ground.
them to the valve side with ropes.
8. Disconnect intermediate connector A13 (8) for
the working lamp.
Removal (PC200_10-L410-520-K-01-A)
1. Disconnect grease hose (1).

2. Set slings to boom cylinder assembly (2).
3. Remove lock bolt (3).
4. Remove plate (4), and remove the boom
cylinder head pin. [*1]
C Check the quantity and installing positions of
installed shims in advance.
4 Boom cylinder head pin: 9. Open tool case (9), remove rubber caps (10),
30 kg and remove the mounting bolts.
10.Remove mounting bolt (11), and remove cover

5. Start the engine, and retract the piston rod. (12).
50-210 HB215LC-2
Work equipment
11.Sling the work equipment assembly, remove Installation (PC220-L410-720-K-00-A)

plate (13), and remove boom foot pin (14). [*2]
[*1]
2 Inner surface of bushing when installing
pin:
Molybdenum disulphide lubricant (LM-P)
2 Pin after installed in position:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
C Adjust clearance (b) between cylinder rod (16)

• When using tool V for removal and plate (4) to 1.5 mm or less by using shims.
Remove plate (13), and remove boom foot C Install one shim or more on each end face.
pin (14) by using tool V.
C Shim thickness (resin shim)
C Check the quantity and installing positions of
• Shim (17): adjust by combining 1.0 mm and
installed shims in advance.
2.0 mm shims
4 Boom foot pin: • Shim (18): 1.0 mm
• Shim (19): 1.0 mm
55 kg • Shim (20): 1.0 mm
12.Remove work equipment assembly (15).

[*2]
4 Work equipment assembly:
2 Inner surface of bushing when installing
4,500 kg pin:
Molybdenum disulphide lubricant (LM-P)
2 Pin after installed in position:
Grease (LM-G)
HB215LC-2 50-211
Work equipment
C Adjust clearance (c) between the foot end face

of boom (21) and bracket (22) to 1 mm or less by
using shims.
C Install one shim or more on each end face.
C Shim thickness (resin shim)
• Shim (23): 2.0 mm
• Shim (24): adjust by combining 2.0 mm, 2.5
mm, 3.0 mm, or 3.5 mm shims
• 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.
• Bleeding air
Bleed the air. See Testing and adjusting
"Bleeding air from hydraulic circuit".
50-212 HB215LC-2
Work equipment
Disassembly and assembly of work equipment cylinder assembly (HB205-

PPZ0-926-K-00-A)
C Special tools
N-
e-
c-
Sym- e-
Part No. Part name
bol s- Q'ty
si-
ty
790–502–1003 Cylinder repair stand S 1
1
790–101–1102 Pump S 1
790–102–4300 Wrench assembly V 1
2
790–102–4310 Pin V 2
3 790–720–1000 Expander S 1
Rubber band (for Disassembly of piston rod assembly
796–720–1670 boom and arm) S 1
1. Set piston rod assembly (2) to tool U1.
07281 – 01279 Clamp S 1
4
Rubber band (for
796–720–1660 arm) S 1
07281 – 01159 Clamp S 1
790–201–1702 Push tool kit V 1
U • Push tool (for
790-201–1940 boom) 1
• Push tool (for
790–201–1930 arm) 1
5
• Push tool (for
790–201–1831 bucket) 1
790–101–5021 • Grip 1
01010 – 50816 • Bolt 2
790–201–1980 Plate (for boom) V 1 2. Remove lock screw (3) from the top end of
790–201–1990 Plate (for arm) V 1 piston assembly (4) by using a hexagonal
6 790–201–1640 Plate (for bucket) V 1 wrench (6 mm).
790–101–5021 Grip V 1 C This step is common in work of the boom,
01010 – 50816 Bolt V 1 arm, and bucket cylinder.
• Screw size: M12 x 1.75 mm (Length: 16 mm)
Disassembly (HB205-PPZ0-530-K-00-A)
Disconnecting cylinder assembly from piston
rod assembly
1. Remove the piping from the cylinder assembly.
2. Remove the mounting bolts (12 pieces), and
disconnect cylinder head assembly (1).
3. Pull out piston rod assembly (2).
C Place a container under the cylinder to
collect oil from the cylinder.
C If screw (3) is too firm to remove, tighten the

screw further in and tap on the screw with tap
(T), and remove it.
HB215LC-2 50-213
Work equipment
3. Remove piston assembly (4) by using tool U2.

Disassembly of piston assembly
C When not using tool U2, use drilled holes (H) 1. Remove rings (11) (2 pieces).
(H10 mm, 2 places) to loosen the piston 2. Remove wear rings (12) (2 pieces).
assembly. 3. Remove piston ring (13).
4. Remove the O-ring and backup rings (14) (2
pieces).
4. Remove plunger (5) and collar (6).

C Only for boom cylinder and arm cylinder Disassembly of cylinder head assembly
5. Remove cylinder head assembly (7). 1. Remove the O-ring and backup ring (15).
2. Remove snap ring (16), and remove dust seal
(17).
3. Remove rod packing (18) and buffer ring (19).
4. Remove snap ring (30).
5. Remove bushing (20).
6. Remove cap (8), pull out balls (9) (12 pieces),

and remove plunger (10).
C Only for arm cylinder
Disassembly of cylinder assembly (arm cylinder

only)
1. Remove plug (21).
2. Remove spring (22) and valve (23).
50-214 HB215LC-2
Work equipment
HB215LC-2 50-215
Work equipment
Assembly (HB205-PPZ0-710-K-00-A)
a Be careful not to damage the packings, dust seals,
O-rings, etc.
a Clean each parts. After installing them, cover the

piping ports and pin holes to keep dirt from entering.
a When installing the backup ring, do not install it

forcibly. Warm it in hot water at approximately 50 to
60°C, and install it.
Assembly of cylinder assembly (arm cylinder only)

1. Install valve (23) and spring (22).
2. Install plug (21) together with O-ring (24).
a Clean, degrease, and dry the threaded part of the
plug, and apply liquid gasket on the entire
threaded part.
3 Plug (21):
83.4 to 102.9 Nm {8.5 to 10.5 kgm}
2 Plug (21):
Liquid gasket (LG–5)
Assembly of piston assembly

1. Set piston ring (13) to tool U3 and rotate the handle 8
to 10 turns to expand piston ring (13).
2. Remove piston ring (13) from tool U3 and install to the
piston.
3. Compress piston ring (13) by using tool U4.
Assembly of cylinder head assembly

1. Press-fit bushing (20) by using tool U5.
2. Install snap ring (30).
3. Install buffer ring (19) and rod packing (18).
4. Install dust seal (17) by using tool U6 and secure it
with snap ring (16).
5. Install backup ring (15) and the O-ring.
4. Install backup rings (14) (2 pieces) and the O-ring.
a Install the backup ring and O-ring in the directions

shown in the figure.
5. Install wear rings (12) (2 pieces).
6. Install rings (11) (2 pieces).
a Take care not to expand the ring mating part

excessively.
50-216 HB215LC-2
Work equipment
6. When reusing both of piston rod assembly (2)

Assembly of piston rod assembly. and piston assembly (4), assemble them
1. Set piston rod assembly (2) on tool U1. according to the following procedure. (When
replacing either or both of them with new ones,
see step 7.)
1) By using tool U2, install piston assembly (4)
to piston rod assembly (2).
C Any burrs or sharp edges on threaded
parts must be removed using files before
installation.
2. Install cylinder head assembly (7).

3. Install the O-ring and the backup ring to collar (6)
and install the collar to the piston rod.
C Install the backup rings (2 pieces) before and
after the O-ring.
C Only for boom cylinder and arm cylinder
4. Install plunger (5).
C Only for boom cylinder and arm cylinder C Fully screw on piston assembly (4) until it
comes into contact with the rod end face
(b). Then, screw out the assembly until
the screw holes (H) in the piston and the
rod end face become aligned with each
other.
C For a cylinder with head cushion, check
that plunger (5) has a certain play after
installing piston assembly (4).
• Only for boom cylinder and arm
cylinder
5. Set plunger (10) to piston rod assembly (2),

install balls (9) (12 pieces), and install cap (8).
C After installing the plunger, check that it has a
little play at its end.
C Only for arm cylinder
HB215LC-2 50-217
Work equipment
2) Install screw (3) to lock piston assembly (4) and 2) Drill a screw hole in the threaded parts of piston
piston rod assembly (2). rod assembly (2) and piston assembly (4).
2 Threaded part of screw (3): a With a drill aligned with V groove in piston
Adhesive (Loctite #262) assembly (4) and piston rod assembly (2), drill
Screw (3): Width across flats 6 mm a hole horizontally.
3 Screw (3): a The cylinder with the bottom cushion must not
58.9 to 73.6 Nm {6 to 7.5 kgm} be machined in the cap machining hole
a After installing screw (3), crimp the screw at 4 position.
peripheral places (a). q Drilling dimensions (mm):
Tap drill hole diameter 10.3

Depth for drilling tap hole 27
Screw hole size 12 × 1.75
Screw hole depth 20
a After tapping the screw hole, remove chips and

other dirt and thoroughly clean the area.
7. When replacing either or both of piston rod assembly

(2) and piston assembly (4) with new ones, assemble
the new ones according to the following procedure.
1) By using tool U2, tighten piston assembly (4) until
it touches end face (b) of the rod.
a If the cylinder has the bottom cushion, put a

mark to indicate the tightening position of the
ball cap on the rod end.
3 Piston assembly (4):
294 ± 29.4 Nm {30 ± 3.0 kgm} 3) Install screw (3) to lock piston assembly (4) and
piston rod assembly (2).
a For a cylinder with head cushion, check that
plunger (5) has a certain play after installing a After installing screw (3), crimp the screw (3) at
piston assembly (4). 4 peripheral places (a).
q Only for boom cylinder and arm cylinder
50-218 HB215LC-2
Work equipment
2 Threaded part of screw (3): 3 Cylinder head assembly (1) mounting bolt:
Liquid adhesive (Loctite #262) Boom cylinder: 270 ± 39 Nm {27.5 ±
Screw (3): Width across flats 6 mm 4.0 kgm}
3 Screw (3): Arm cylinder: 373 ± 54 Nm {38.0 ± 5.5 kgm}
58.9 to 73.6 Nm {6 to 7.5 kgm} Bucket cylinder: 270 ± 39 Nm {27.5 ±
4.0 kgm}
Bucket cylinder (demolition specification):
373 ± 54 Nm {38.0 ± 5.5 kgm}
Connecting cylinder assembly to the piston rod

assembly
1. Set piston rod assembly (2) to tool U1.
4. Install the piping.
Mounting bolts of piping fixing bands
Boom cylinder: Width across flats 14 mm
Arm and bucket cylinder: Width across flats 17 mm
3 Mounting bolts of piping fixing bands
Boom cylinder:
27.4 ± 6.9 Nm {2.8 ± 0.7 kgm}
Arm and bucket cylinder:
98 to 122.5 Nm {10 to 12.5 kgm}
2. Install the cylinder assembly to piston rod assembly

(2).
a Align it with the axis of the cylinder tube when

inserting.
a Check the ring for damage or falling off, and push

it in fully.
3. Tighten the mounting bolts for cylinder head assembly

(1).
HB215LC-2 50-219

Removal and installation of operator's cab assembly (PC220-K000-924-K-00-A)
k Park the machine on a level ground, swing

the upper structure by 90 deg., lower the
work equipment to the ground stably, and
stop the engine.


C Positions of the controllers are shown below.
5. Remove box (9) (5 bolts).
• A: Pump controller assembly
• B: Air conditioner controller assembly C Disconnect the hose at the bottom of box (9).
• C: KOMTRAX terminal 6. Remove box (10) (3 bolts).
C Be careful about connectors (11) and (12)
located behind box (10). (Machines equipped
with 12 V power socket)
• Connector (11): 12 V power socket
intermediate harness (M13A)
intermediate harness (M13B)
7. Remove cover (13) (3 bolts).
Removal (HB205-K000-520-K-00-A)
1. Remove the machine monitor assembly. For

details, see "Removal and installation of
machine monitor assembly (50-234 page)".
2. Remove the floor mat.
3. Remove cover (1) first, and remove cover (2).
4. Remove cover and duct assembly (3).
C Remove wiring harness (4) through the
space between cover (5) and duct (6).

C Disconnect connector (15) on the back of
cover (14).
• Connector (15): Cigarette lighter (M04)
50-220 HB215LC-2
9. Remove duct (16). 13.Remove ducts (23) and (24).

10.Remove cover (17). 14.Disconnect connector (25).
C Disconnect connectors (18), (19) and (19a) • Connector (25): Room lamp (L03)
on the back of cover (17). C Cut the cable ties that are fixing the ducts
• Connector (18): R.H. console and connectors.
intermediate harness (H14)
• Connector (19): R.H. console
intermediate harness (H15)
15.Disconnect connectors (26) to (29) from

KOMTRAX terminal (C).
• Connector (26):Communication antenna
(GPS)
• Connector (27): Machine main wiring
harness (CK01)
harness (CK02)
C Move the removed connectors away from the
operator's cab and gather them on the floor.
11.Remove plate (20).

12.Pull up lock pin (21) to unlock the lock, and
remove duct (22).
16.Pull out connector (30) from the clip on the

operator's cab side.
HB215LC-2 50-221
• Connector (30): L.H. console intermediate 21.Disconnect connectors (38) to (40) from air
harness (H16) conditioner controller assembly (B).
C Move the disconnected connectors away • Connector (38): Air conditioner compressor
from the operator's cab and gather them on solenoid clutch relay (R21)
the floor. • Connector (39): Machine main wiring
17.Pull out connectors (31) to (35) from the clip on harness (AC02)
the operator's cab side and disconnect them. • Connector (40): Machine main wiring
harness (AC01)
• Connector (31):12 V power supply
intermediate harness (M10) (Machines C If you disconnect the above connectors, you
equipped with 12 V power supply) can remove air conditioner controller
• Connector (32): Handsfree microphone assembly (B) easily.
intermediate harness (M46) (Machine
C Move the disconnected connectors away
equipped with handsfree microphone)
from the operator's cab and gather them on
• Connector (33): AUX intermediate connector
the floor.
(M01B)
22.Remove bolts (41) (2 pieces), move air
• Connector (34): Operator's cab roof
conditioner controller assembly (B) away from
intermediate connector (H09)
the operator's cab, and gather it on the floor.
• Connector (35): Speaker intermediate
connector (H08)
C Move the removed connectors away from the
operator's cab and gather them on the floor.
18.Disconnect ground cable (35a).
19.Disconnect radio antenna (36).
C Cut the cable tie that is fixing the antenna.
C Move the removed radio antenna away from
the operator's cab and gather it on the floor.
23.Remove ducts (42) and (43).

C Cut the cable tie fixing the duct.
• Connector (44): Front window wiper motor
(M05)
20.Remove bolts (37) (4 pieces), move pump

controller assembly (A) away from the operator's
cab, and gather it on the floor.
25.Remove ducts (45) to (47).
50-222 HB215LC-2
26.Remove clamp (49). 31.Remove operator's cab mounting bolt (56) and
nut (57). [*3]
C Bolt (56): 6 places
C Nut (57): 4 places
27.Disconnect window washer hose (50).

28.Cut cable tie (52) that is fixing window washer
hose (50) and wiring harness (51).
C Move window washer hose (50) and wiring
32.Sling operator's cab assembly (58), and remove
harness (51) on the floor.
it.
C Check that all the hoses, connectors, and
clamps are disconnected, and sling it
gradually.
4 Operator's cab assembly (58):

430 kg
29.Remove bolt (53) from underside of the

operator's cab, and remove lock plate (54). [*1]
30.Remove operator's cab tipping stopper (55)
(Width across flats: 46 mm). [*2]
HB215LC-2 50-223
Installation (PC220-K000-720-K-00-A)
[*1]
Lock plate mounting bolt (53): Width across flats 19 mm
3 Lock plate mounting bolt (53):
98 to 123 Nm {10.0 to 12.5 kgm}
[*2]
Cab tipping stopper (55): Width across flats 46 mm
3 Cab tipping stopper (55):
245 to 309 Nm {25.0 to 31.5 kgm}
[*3]
Operator's cab mounting bolt (56): Width across flats
19 mm
3 Operator's cab mounting bolt (56):
98.1 to 122.6 Nm {10 to 12.5 kgm}
50-224 HB215LC-2
Removal and installation of operator cab glass (adhered glass) (PC220-K183-924-

K-00-A)
C Special tools
Necessity
Sym-
Q'ty
Part No. Part Name
bol
2 793-498-1210 Lifter (suction cup) V 2

X
3 20Y-54-13180 Stopper rubber V 2
C Although some of the figures depict another

model, the replacement procedure is basically
the same.
C Among the glass panels on the four sides of the
operator's cab, five panes (1) to (4) and (18) are
adhered.
C In this section, the procedures for replacing the
adhered glass are explained.
C When replacing front window glass (4), remove
front window assembly (5). (It is impossible to
replace only the front window glass while the
front window assembly is installed to the
operator's cab.)
C For the procedure for replacing the front window
assembly, see "Removal and installation of front
window assembly".
HB215LC-2 50-225
(1): Right side window glass

(2): Left side rear window glass
(3): Door lower window glass
(4): Front window glass
(5): Front window assembly (front window glass and front frame)
(6): Dam rubber
(17): Center trim seal
(18): Rear window glass
50-226 HB215LC-2
Removal (PC220-K183-520-K-00-A)
C Remove the window glass to be replaced

1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab
(metal sheet) (8).
C If the window glass is broken into small

pieces, they may be removed with knife [4]
and a flat-head screwdriver.
C Widening the cut with a flat-head screwdriver,
cut the adhesive and dam rubber with knife
[4].
2. Remove the window glass.
HB215LC-2 50-227
1. Using a knife and scraper [5], remove the C Use the primer within two hours after opening
remaining adhesive and dam rubber from the container.
sheet metal (adhesion surfaces) of the
C Even if the container of the primer is capped
operator's cab.
again just after it is opened, use it out within
C Remove the adhesive and dam rubber to a 24 hours after it is opened for the first time.
degree that they will not affect adhesion of (Discard the primer which is left unused 24
the new adhesive. Take care not to scratch hours after it is opened.)
the painted surfaces. (If the painted surfaces 1) Stir the primers for painted surface and glass
are damaged, adhesion will be lowered.) sufficiently before using them.
(The figure shows the operator's cab of a wheel
loader.) C If the primer is stored in a refrigerator,
leave it at the room temperature for at
least half a day before stirring it. (If the
primer is opened just after taken 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.
C After washing the brush, check it again
for dirt and contaminants.
C Prepare respective brushes for the
painted surface primer and glass primer.
2. Remove oil, dust, dirt, etc. from the adhesion
surfaces on cab (8) and window glass (9) with
white gasoline.
C If the adhesion surfaces are not cleaned well,
the window glass may not be bonded
perfectly.
C Clean all the black part on the back of the
window glass.
C After cleaning the adhesion surfaces, leave
them for at least 5 minutes to dry.
(The figure shows the operator's cab of a wheel
loader.) 3) Evenly apply the painted surface primer to
the surfaces on operator's cab (8); the
surface where dam rubber (6) is bonded on
and its outside surfaces where the adhesive
is applied to.
2 Primer for painted surface:
Sunstar Primer 580 Super for
painted surfaces
C Do not apply the primer more than two
times. (Applying primer more than twice
will degrade the performance.)
3. Apply primer (10).

C The primer is good for four months after the
date of manufacture. Do not use the primer
after the expiration date.
50-228 HB215LC-2
C Places to apply: Apply over the entire C Never apply wrong primer. If the paint
circumference with dimension (a). primer is applied by mistake, wipe it off
• Primer applying dimension (a): 30 mm with white gasoline. If glass primer, etc. is
applied by mistake, wipe it off with white
gasoline.
4) Evenly apply the glass primer to the
adhesion surfaces of glass (9).
2 Primer for glass:
Sunstar Primer 453-41 for glass
C Do not apply the primer more than two
times. (Applying primer more than twice
will degrade the performance.)
C In addition to the above places, apply

primer to right side window glass (1) and
lower door glass (3).
• Area to apply additional primer for right
side window glass (1): (b)
• Area to apply additional primer for lower
door window glass (3): (c)
C After applying the primer, leave it in air for
at least five minutes (maximum eight
hours) to dry. C Places to apply: Apply the primer to
adhesion surface (d) on window glass (9)
along its circumference, which is
determined by the installed position of
dam rubber (6) and operator's cab (8).
• Primer applying dimension (d): 30 mm
C Do not apply the primer to the boarder
area of about 5 mm wide between the
black portion and transparent portion of
the glass.
C After applying the primer, leave it in air for
at least 5 minutes (maximum 8 hours) to
dry.
C Never apply wrong primer. If painted
surface primer is applied by mistake,
wipe it off with white gasoline.
HB215LC-2 50-229
C Stick additional dam rubber (6a) for right

side window glass (1).
• Positions to stick additional dam rubber
for right side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm
4. Stick dam rubber (double-sided tape) (6) to the

operator's cab as follows.
C Do not remove the release tape of dam
rubber on the glass sticking side before
sticking the window glass.
C When sticking the dam rubber, do not touch
the cleaned surface. 2) Stick dam rubber (6) for left side rear window
C Care should be taken not to slacken the dam glass (2) to the position as shown in the
rubber of each sticking corner. figure.
3) Stick dam rubber (6) for door lower window

C When sticking dam rubber (6) all around, do glass (3) to the position as shown in the
not overlap the ends. Or, provide a clearance figure.
of approximately 5 mm between ends (e).
1) Stick dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
C Stick additional dam rubber (6b) for door

lower window glass (3).
• Positions to stick additional dam rubber
for door lower window glass:
(j): 110 mm
50-230 HB215LC-2
(k): 90 mm C For accurate positioning, stick tape [6]

(m): 200 mm across the left, right, and bottom edges of
the right side window glass, left side rear
window glass, and door lower window
glass.
3) Cut the tape between window glass (9) and
operator's cab (8) with a knife, etc. and then
remove the window glass.
C Do not remove the tapes left on the
window glass and operator's cab (8)
before installing the window glass.
4) Stick dam rubber (6) for front window glass

(4) to the position shown in the figure.
C Stick lower dam rubber (6c) for the front

window glass along the outside edge of
the lower frame, differently from other
dam rubbers (6). (If it is stuck along the
inside, it will be seen through the
transparent portion of the glass.)
C When positioning front glass (4),

• set right and left installing positions to
the frame width.
• 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 operator's cab on the right, left,
upper, and lower sides, and then position the
window glass so that it is centered.
2) Stick tapes [6] between window glass (9) and
operator's cab (8). Draw a positioning line (n)
on each tape.
HB215LC-2 50-231
6. Apply adhesive.
C Use either of the two types of adhesives
according to the season.
2 Adhesive (summer):
Sunstar penguine seal 580 super "S"
or equivalent
2 Adhesive (winter):
Sunstar penguine seal 580 super "W"
or equivalent
C The using limit of the adhesive is four months
after the date of manufacture. Do not use the 4) Remove the release tape from dam rubber
adhesive after the period. (6) on the glass sticking side.
5) Apply adhesive (15) to the outside of dam
C Keep the adhesive in a dark place where the
rubber (6) on the operator's cab.
temperature is below 25°C.
C Never heat the adhesive higher than 30°C.
C When reusing the adhesive, remove all the
hardened part from the nozzle tip.
1) Remove aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
C Adjacent to dam rubber (6) on operator's cab

(8), apply adhesive (15) in dimensions (s)
and (t) as shown in the figure.
• Dimension (s): 10 mm
• Dimension (t): 15 mm
C Apply adhesive (15) thicker than dam rubber
2) Cut the tip of the adhesive nozzle (14) so that (6).
dimensions (q) and (r) are as follows. C Apply the adhesive evenly in height.
• Dimension (q): 10 mm
• Dimension (r): 15 mm
C Apply adhesive (15) adjacent to additional

3) Set adhesive cartridge (12) to caulking gun dam rubber (6a) for right side window glass
[7]. and additional dam rubber (6b) for lower door
window glass.
C An electric caulking gun is more efficient.
50-232 HB215LC-2
C After installing front window glass (4) fill

the clearances between the window glass
and center trim seal (16) with caulking
material in range (s) with dimensions (t)
and (u).
C After applying the primer to the part of
window glass (4) shown in section A-A,
apply the adhesive as caulking material.
• Caulking dimension (t): 2 mm
• Caulking dimension (u): 5 mm
C When caulking, apply masking to the
7. Install the window glass. window glass and form the adhesive with
1) Install window glass (9) while aligning the a rubber spatula as shown in the figure.
lines drawn on the positioning tapes in step C Wipe off the squeezed adhesive.
5.
2 Primer for glass:
C Since the window glass cannot be
Sunstar Primer 580 Super for
removed and installed again, install it with
glass
utmost caution.
2 Adhesive:
C Install the window glass within 5 minutes
after applying the adhesive. Sikaflex 250-2
2) After installing window glass (9), press entire
circumferential area until it adheres firmly to
the dam rubber.
C Press the corners of the window glass
firmly.
C You can perform this work efficiently by

pulling window glass (9) from inside of the
operator's cab using suction cup X2.
HB215LC-2 50-233
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass to the dam
rubber to bond them completely.
9. After installing the window glass, remove any

excess of the primer and adhesive on the
operator's cab and window glass.
C Use white gasoline to wipe off the remaining
adhesive before it dries up.
C When cleaning the glass, do not give an
impact to it.
10.Cure the stuck window glass.
1) Keep the stopper rubbers, styrene foam
8. Fix the glass. blocks, and rubber bands installed for ten
hours as a curing period. (at temperature of
1) After installing right side window glass (1) to 20℃ and humidity of 60%)
the operator's cab, install stopper rubbers X3 2) After removing the stopper rubbers, styrene
to 2 places (v) at the bottom of the window foam blocks, and rubber bands, wait at least
glass to fix it. fourteen hours, at least twenty four hours in
total, before operating the machine actually.
50-234 HB215LC-2
Removal and installation of front window assembly (PC220-K181-924-K-00-A)

the engine.
k Removal and installation must be done by a

pair of two workers.
C To replace the front window glass, the front

window assembly must be removed from the
operator's cab.
Removal (PC220-K181-520-K-00-A)
1. Pull up front window assembly (1) to the ceiling

and lock it. 4. Release the lock of front window asembly (1).
C Make sure that the assembly is certainly

locked.
2. Remove front lower window (2).
3. Remove bracket (3) at the left corner (two

screws) and bracket (4) at the right corner (two
screws). [*1]
C Leave mounting screws (5) and washers (6)
for bracket (3) at the left corner in position.
They are used to hook the pull-up assist
cable in Step 6.
5. Carefully slide front window assembly (1) down

until the lower part of front window assembly (1)
is detached from the operator's cab through the
ends from which the corner brackets are
removed in Step 2 (rail missing ends) and
support the lower part of the front window
assembly.
C Right and left rollers (8) and (7) are insertion-
fitted, so they easily become detached.
Handle them carefully.
HB215LC-2 50-235
7. Lower front window assembly (1) completely.

C Take care not to let front window assembly
(1) touch machine monitor (12).
6. Remove pin (9). [*2]

C Removal of pin (9) allows plate (11) at the
end of pull-up assist cable (10) to come off.
C Hook plate (11) on screw (5) of left corner 8. Carefully slide front window assembly (1) down
bracket (3) to hold the plate (used washer (6) to detach the top of the front window assembly
as well). from the operator's cab through the ends from
which the left and right corner brackets are
removed in Step 2 (rail missing ends).
k Pull-up assist cable (10) is under a return
load of 58.8 N {6 kg} that is working C Right and left rollers (14) and (13) are
toward the rear of the operator's cab. So insertion-fitted, so they easily become
be fully careful when removing pin (9) detached. Handle them carefully.
during the disconnection of the cable.
50-236 HB215LC-2
[*1]
q Adjust opening and closing of front window assembly
1. Open and close front window assembly (1) 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 or closing of front
window assembly (1), loosen mounting bolts (16) of
roller adjustment bracket (15) and adjust the condition
of the front window, and then tighten the mounting
bolts again.
a Make sure that bracket (15) is not slanted when

mounted.
Mounting bolt (16) of bracket (15): Width across flats
5 mm
3 Mounting bolt (16) of bracket (15):
19.6 to 25.0 Nm {2.0 to 2.5 kgm}
5. Install left corner bracket (3).
a Tighten lightly for the meantime. Bolts are

tightened to the specified torque after adjusting
the locks for the front window assembly (1) in its
"closed" position in the following step 6.
a Install left corner bracket (3) so that clearance (b)

between rail (18) and left corner bracket (3)
becomes 0 to 2.0 mm.
a There must be no level difference on rolling

3. Pull up front window assembly (1) to the ceiling and
surface (R) for the roller (same as the right corner
lock it. bracket).
a Make sure that the assembly is certainly locked.
4. Install right corner bracket (4).
a Tighten lightly for the meantime. Bolts are

tightened to the specified torque after adjusting
the locks for the front window assembly (1) in its
"closed" position in the following step 6.
a Install right corner bracket (4) so that clearance (a)

between rail (17) and right corner bracket (4)
becomes 0 to 2.0 mm.
a There must be no level difference on rolling

surface (R) for the roller.
6. Adjust the locks for the front window assembly (1) in
its "closed" position according to the following
procedure.
1) Install right and left corner brackets (4) and (3) in
roughly right positions so that front
HB215LC-2 50-237
window glass (19) is closely attached to cab-

side trim seal (20).
7. After the adjustment, splash water heavily over

the front window glass and check that the water
does not leak into the cab.
2) Check the working condition of right and left
8. Adjust the locks for front window assembly (1) in
locks (22) and (21) when opening and
its "open" position.
closing front window assembly (1).
1) After adjusting the locks for the front window
C If right and left locks (22) and (21) rattle; assembly (1) in its "closed" position in steps
1] Loosen lock fixing bolt (23) inside the 6 and 7, pull up front window assembly (1) to
cover, move lock (21) forward, and then the ceiling.
tighten the bolt again. (The same applies 2) Check the locks at the rear right and left of
to the right side.) the operator's cab on the following items with
2] After moving the lock, check the contact front window assembly (1) in its "open"
between front window glass (19) and cab- position.
side trim seal (20) which was checked in • Check the working condition of right and
step 1). left locks (22) and (21) (as explained
3] Repeat the work in 1] and 2] until the above).
contact of front window glass (19) and the • Front window assembly (1) must be in
working condition of right and left locks contact with the right and left rubber
(22) and (21) are both acceptable, and stoppers (24), and furthermore, must be
then tighten the mounting bolts of the pushing them backward by 1.5 to 3.0
right and left corner brackets (tighten to mm.
the specified torque). • Check that limit switch (25) is pushed
back 4 to 7 mm by front window assembly
(1).
C Since the position of limit switch (25)
cannot be adjusted, the "open" position of
front window assembly (1) is decided
within the functioning range of this switch.
C Limit switch (25) prohibits wiper operation
if the wiper switch is turned ON by
mistake while the front window assembly
is "open".
C The wiper falls into the operator's cab and
breaks if operated when front window
assembly (1) is open.
C To check whether limit switch (25) is
working, turn the starting switch to ON
position and see that, even if the wiper
switch is turned on, the wiper does not
operate when front window assembly (1)
is in the "open" position.
50-238 HB215LC-2
• When adjustment is needed after 6) Adjustment of right and left rubber stoppers
performing check in step 8; (24)
3) Close front window assembly (1). • Bring right and left rubber stoppers (24)
4) Loosen locknuts (26) of right and left rubber into contact with front window assembly
stoppers (24) and move the stoppers (1) (locked in "open" position).
backward so that front window assembly (1)
does not touch the stoppers when it is locked
in its "open" position.
• Close front window assembly (1).

• Turn right and left rubber stoppers (24) to
the left one and a half rotation.
5) Loosen lock nut (27) at both sides, and
adjust the position of striker bolt (28). C One turn of rubber stopper (24) to the left
is equivalent to squashing the rubber by
• Striker bolt (28): M10
approximately 1.5 mm.
• Diameter of hole in plate (29): 14.5 mm
C When front window assembly (1) is
locked in "open" position, front window
assembly (1) must be pushing right and
left rubber stoppers (24) by 1.5 to 3.0
mm.
• Front window assembly (1) (locked in

"open" position) must be pushing the limit
switch (25) backward by 4 to 7 mm.
• Working condition of lock (31).
• Tighten lock nuts (26) of right and left

rubber stoppers (24).
HB215LC-2 50-239
9. Adjust anti-vibration stoppers (30) of front window

a Also check the latching efforts of right and left
assembly (1). locks (33) and (34) for the front window assembly
1) Adjust and lock anti-vibration stopper (30) at both in its "closed" position (at front side of the
sides so that surface (d) of stopper (D) is in operator's cab).
contact with surface (c) of anti-vibration stopper
(30) when front window assembly (1) is pulled up.
[*2]
Pin (9): Width across flats 19 mm
3 Pin (9):
27 to 34 Nm {2.8 to 3.5 kgm}
2 Thread portion of pin (9):
Adhesive (LT-2)
10. Check the latching efforts of front window assembly

(1).
a After finishing the adjustment of steps 6 to 9,

check that latching efforts of both right and left
locks (32) and (31) are even.
50-240 HB215LC-2
Removal and installation of floor frame assembly (PC220-H1H0-924-K-01-A)
Removal (HB205-H1H0-520-K-00-A)
1. Remove operator's cab assembly (1). For details,

see "Removal and installation of operator's cab
assembly".
6. Disconnect ground cable (5).
2. Collect the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit. [*1]
C Quantity of refrigerant to be collected:
930 ± 50 g
7. Disconnect connectors (7) to (10) from travel

PPC valve (6).
• Connector (7): L.H. reverse oil pressure
sensor (P10)
• Connector (8): L.H. forward oil pressure
sensor (P09)
• Connector (9): R.H. forward oil pressure
sensor (P11)
• Connector (10): R.H. reverse oil pressure
sensor (P12)
4. Loosen drain valve (3) to drain the coolant.
8. Disconnect hoses (11) to (14) from travel PPC
(Inside diameter of drain hose: H7 mm)
valve (6).
6 Radiator: C The band color of the hoses are as shown
23 N below.
• Hose (11): Red (L.H. forward port (P2))
• Hose (12): No band (L.H. reverse port
(P1))
• Hose (13): Blue (R.H. reverse port (P3))
• Hose (14): Green (R.H. forward port (P4))
HB215LC-2 50-241
• Connector (25): Attachment flow adjustment

EPC valve (V30)
• Connector (26): Attachment oil pressure
switch intermediate connector (P13)
C Cut all the cable ties that are fixing the wiring
harness and floor frame.
9. Disconnect connectors (16) and (17) from 2nd-

line attachment PPC valve (15). (Machines
equipped with attachment)
• Connector (16): Pedal forward tilt oil
pressure switch (P16)
• Connector (17): Pedal backward tilt oil
10.Disconnect hoses (18) and (19) from 2nd-line 14.Disconnect clamp (27) (2 bolts).
attachment PPC valve (15). (Machines equipped
with attachment)
C The band color of the hoses are as shown
below.
• Hose (18): Black (Port (P1))
• Hose (19): Brown (Port (P2))
15.Disconnect ground cable (28).

C The ground cables are named as (T04),
(T05), (T06), (T07), (T09), and (T10) from the
left.
16.Disconnect clamps (29) and (30).
11.Disconnect connectors (21) and (22) from 1st-

line attachment PPC valve (20). (Machines
• Connector (21): Pedal backward tilt oil
• Connector (22): Pedal forward tilt oil
12.Disconnect hoses (23) and (24) from 1st-line
attachment PPC valve (20). (Machines equipped
with attachment)
below. 17.Pull out connectors (31) to (33) from the clips.
• Hose (23): Yellow (Port (P1)) • Connector (31): Intermediate connector
• Hose (24): No band (Port (P2)) (A41) (Machine equipped with camera 2)
13.Disconnect connectors (25) and (26). (Machines • Connector (32): Intermediate connector
equipped with attachment) (A42) (Machine equipped with camera 3)
50-242 HB215LC-2
• Connector (33): Intermediate connector

(A08) (Machines equipped with attachment)
18.Disconnect hose (34).　
• Hose (34): Port (P) (Circuit from PPC oil
pressure lock solenoid valve)
C Disconnect hoses (P) of the work equipment
PPC valve from the junction block. (See Step
34.)
28.Disconnect connector (46) and remove air

conditioner controller (B) from the main wiring
harness.
harness (AC04)
19.Disconnect hose (35).

• Hose (35): Port (T) (Drain circuit to hydraulic
tank)
• Connector (36): Dual pressure switch (P17)
of air conditioner
C Cut all the cable ties that are fixing the wiring
harness and floor frame.
21.Remove bolt (37) and then disconnect air 29.Disconnect connectors (47) to (49).
conditioner tube (38). [*2] • Connector (47): R.H. console intermediate
22.Remove clamp (39) (1 bolt) that is fixing tube harness (H14)
(38). • Connector (48): R.H. console intermediate
23.Disconnect heater core hoses (40) (2 pieces). harness (H15A)
[*3] • Connector (48a): R.H. console intermediate
24.Remove clamp (with spacers) (41) (1 bolt) that is harness (H15B)
fixing hoses (40). • Connector (49): L.H. console intermediate
harness (H16)
25.Remove clamps (42) and (43) (2 bolts each).

26.Cut cable tie (44).
27.Remove clamp (45) (1 bolt). (Machines
HB215LC-2 50-243
30.Disconnect ground cable (T01) (50). 34.Disconnect work equipment PPC valve hoses
31.Disconnect all clamps that fasten main wiring (57) to (64) from junction block (56).
harness (51) to the floor frame.
C Be sure to prepare an oil pan to catch the
C Separate the pump controller assembly and leaking hydraulic oil before disconnecting the
main harness from the floor frame and move hoses.
them toward the boom.
below.
• Hose (57): White (Bucket CURL circuit)
• Hose (58): Brown (Boom LOWER circuit)
• Hose (59): No band (Swing RIGHT
circuit)
• Hose (60): Blue (Arm IN circuit)
• Hose (61): Black (Bucket DUMP circuit)
• Hose (62): Green (Boom RAISE circuit)
• Hose (63): Red (Swing LEFT circuit)
• Hose (64): Yellow (Arm OUT circuit)
32.Open the engine hood and remove cover (52) (4

bolts).
35.Pull out hose assembly (65).
33.Remove clamps (53) and (54) that are fixing

hoses.
C Move the hoses toward the control valve so
that you can disconnect the work equipment
PPC valve hoses from the junction block.
C Cut the cable ties that are binding up the
hoses.
36.Sling floor frame assembly (66), and remove it.
50-244 HB215LC-2
a Check that all the hoses, connectors, and clamps Installation (HB205-H1H0-720-K-00-A)
are disconnected, and sling it gradually. q Perform installation in the reverse order to removal.
4 Floor frame assembly (66): [*1]
250 kg q Filling of refrigerant (air conditioner gas: R134a) Refill
the air conditioner circuit with refrigerant (air
a Refill amount:
930 ± 50 g
q Refilling of air conditioner compressor oil
See Air conditioner, "Refilling with compressor oil".
q Refilling with coolant (radiator)
Refill with coolant to the specified level through the
coolant filler port. Run the engine to circulate the
coolant through the system. Then check the coolant
level again.
5
Reference: Precautions for removing work equipment Radiator:
control lever 23 ℓ
Push lock (69) of plastic frame (68) in boot (67) with a
[*2]
flat-head screwdriver, etc., and remove boot (67) from
console plastic cover (70). a When installing the hose for the air conditioner circuit,
a If you pull a portion other than lock (69) of plastic be careful not to let dirt, dusts and water going into the
frame (68) forcibly, you may break plastic frame (68). hose.
a Check that the O-rings are fitted to the joints when

connecting the air conditioner piping.
a Once an O-ring is used, it is deformed and

deteriorated. Accordingly, do not reuse it.
a When removing the O-rings, use a soft tool so that the

piping is not damaged.
a Check that the O-ring is not damaged or deteriorated.
a Apply compressor oil (DENSO: ND-OIL8) for

refrigerant (R134a) to O-ring.
Hose clamp (M6 bolt): Width across flats 10 mm

3 Hose clamp (M6 bolt):
8 to 12 Nm {0.8 to 1.2 kgm}
[*3]
HB215LC-2 50-245
C When installing the heater core hose, install it so

that the white line (mark) on the heater hose
becomes a straight line to avoid any twist of the
heater hose.
Reference: Precautions for installation cab
mount
C Since different dampers are installed to different
locations, record their identification seals when
removing them. (See Structure and function,
"Cab mount and cab tipping stopper")
C Install the cab mount so that mount rubber
groove (1) is as shown in the figure below. (The
left figure shows the front side seen from above
the machine.)
50-246 HB215LC-2
Removal and installation of air conditioner unit assembly (PC220-K500-924-K-01-A)
Removal (HB205-K500-520-K-00-A)

930 ± 50 g
2. Drain the coolant. (inside diameter of drain hose:
H 7 mm)
6 Coolant:
23 N
3. Pull up front window assembly (1) to the ceiling
and lock it.
C Be sure that the assembly is certainly locked.
5. Remove floor mat (3).

C Disconnect connector (14) on the back of
cover (13).
C Disconnect the hose at the bottom of box (8).
C Be careful about connectors (10) and (11)
located behind box (9). (Machines equipped
with 12 V power socket)
intermediate harness (M13A)
intermediate harness (M13B)
8. Pull cover (12) (3 bolts) upward to remove it.
C Be careful not to catch the connectors and 10.Remove duct (15) (2 bolt).
harnesses on the back. 11.Remove cover (16) (3 bolts) and bracket (41) (2
bolts).
C Disconnect connectors (17), (18) and (18a)
on the back of cover (16).
• Connector (17): R.H. console intermediate
harness (H14)
• Connector (18): R.H. console intermediate
harness (H15A)
• Connector (18a): R.H. console intermediate
harness (H15B)
HB215LC-2 50-247
15.Remove cable tie (39) of the left console

harness.
16.Remove cable tie (40) of the floor harness.
12.Remove plate (19) (2 bolts).

13.Pull up lock pin (20) to unlock the lock, and
remove duct (21).
17.Remove bolts (29) (4 pieces), move pump
controller assembly (A) away from the operator's
cab, and gather it on the floor.
14.Remove ducts (24) to (28). [*2]

C Cut the cable tie fixing the duct.
18.Disconnect connectors (30) to (32) from air

conditioner controller assembly (B).
harness (AC01)
harness (AC02)
• Connector (32): Air conditioner unit harness
(AC04)
50-248 HB215LC-2
19.Disconnect connectors (42) to (45). 24.Remove mounting bolts (37) (6 pieces) to

• Connector (42):Communication antenna remove air conditioner unit assembly (38).
(GPS)
harness (CK01)
harness (CK02)
20.Remove KOMTRAX terminal (C) (4 bolts).
Installation (HB205-K500-720-K-00-A)

removal.
[*1]
• Filling of refrigerant (air conditioner gas: R134a)
Refill the air conditioner circuit with refrigerant
21.Remove cover (33). (air conditioner gas: R134a).
C Refill amount:
930 ± 50 g
• Refilling with air conditioner compressor oil
See Air conditioner, "Refilling with compressor
oil".
• Refilling with coolant (radiator)
Refill with coolant to the specified level through
the coolant filler port. Run the engine to circulate
the coolant through the system. Then check the
coolant level again.
5 Radiator:
22.Remove bolt (34) and then disconnect air 23 N
conditioner tube (35). [*3] [*2]
23.Disconnect heater core hose (36). [*4] When installing ducts (24) and (26), remove cover
(48), then the work is easier.
C The mounting bolt of cover (48) is behind cover
(47). Remove cover (47) first.
HB215LC-2 50-249
[*3]
a When installing the hose for the air conditioner circuit,
be careful not to let dirt, dusts and water going into the
hose.
a When removing the O-rings, use a soft tool so that the
piping is not damaged.
Hose clamp (M6 bolt): Width across flats 10 mm

3 Hose clamp (M6 bolt):
8 to 12 Nm {0.8 to 1.2 kgm}
[*4]
a When installing the heater core hose, install it so that

the white line (mark) on the heater hose becomes a
straight line to avoid any twist of the heater hose.
50-250 HB215LC-2
Removal and installation of operator's seat (PC220-K2Q0-924-K-00-A)

the work equipment to the ground stably, and
stop the engine.

k Removal and installation work must be done

by a pair of two workers.
C Note the connector numbers and installed

positions before disconnecting wiring and hoses.
3. Pull lever (1) again and move operator's seat (2)

Removal (PC220-K2Q0-520-K-00-A) forward and fold the backrest forward.
1. Pull lever (1) and move operator's seat (2) 4. Remove two bolts (5) (with hexagonal socket)
backward. and two reinforcing plates (7), on the seat rail at
the rear side of operator's seat. [*1]
5. Disconnect connector (6) of the operator's seat.
• Connector (6): Seat belt caution switch (S19)
2. Remove two bolts (3) (with hexagonal socket)

and two reinforcing plates (4), on the seat rail at
the front side of operator's seat. [*1]
C For the heated seat

Remove wiring harness fixing band (8) and
disconnect connector (9).
(Connector (9) is located under the seat rail
mounting frame.)
• Connector (9): Heated sheet (M35)
HB215LC-2 50-251
4. Slide adjusters (11) and (12) backward and forward

approximately three times to make sure that they slide
smoothly.
5. Make sure that they are locked at the midpoint of the
sliding move, then tighten four bolts (13).
49 Nm {5.0 kgm}
6. Slide the seat assembly backward and forward

approximately three times. After making sure that they
are locked in the rearmost position, tighten two bolts
6. Remove the operator's seat.
(15) of the front side.
4 Operator's seat:
Mounting bolt (15) (front side): Width across flats 6
21 kg
mm
Installation (PC220-K2Q0-720-K-00-A) 3 Mounting bolt (15) (front side):
q Perform installation in the reverse order to removal. 49 Nm {5.0 kgm}
[*1]
7. Slide the seat assembly backward and forward
Mounting bolts (3) and (5) of operator's seat (hexagonal
approximately three times again. After making sure
socket head): Width across flats 6 mm
that they are locked in the rearmost position, tighten
3 Mounting bolts (3) and (5) of operator's seat
two bolts (15) of the rear side.
(hexagonal socket head):
Mounting bolt (15) (rear side): Width across flats 6 mm
25.5 Nm {2.6 kgm}
3 Mounting bolt (15) (rear side):
Reference: Assembly and adjustment procedure for 49 Nm {5.0 kgm}
operator’s seat adjuster
8. If a large operating effort is required (target is max.15
1. Using four bolts (13), install adjusters (11) and (12) kg), repeat adjustment and make sure right and left
loosely to frame (10). At the same time, install two locks work properly at respective positions.
wires (14) for releasing slide lock.
a Check that right and left locks work properly.
2. Slide adjusters (11) and (12) backward and install

them loosely to base (16) using two bolts (15).
a Place washer (17) between adjusters (11), (12)

and base (16).
3. Slide adjusters (11) and (12) forward and install them
loosely to base (16) using two bolts (15).
49 Nm {5.0 kgm}
50-252 HB215LC-2
Removal and installation of seat belt (PC220-K2Q3-924-K-00-A)

k Park the machine on a level ground, lower the
engine.
k Turn the battery disconnect switch to the OFF

k Removal and installation work must be done by a

pair of two workers.
a Note the connector numbers and installed positions

6. Remove operator seat (2).
4 Operator's seat (2):
Removal (PC220-K2Q3-520-K-00-A) 21 kg
1. Pull lever (1) and move operator's seat (2) backward. 7. Remove mounting bolt (6) of seat belt (7) (one on
each side) to remove seat belt (7). [*2]
2. Remove two hexagonal socket head bolts (3) from the

seat rails. [*1]
Installation (PC220-K2Q3-720-K-00-A)
3. Pull lever (1) again and move operator's seat (2)
forward and fold the backrest forward. [*1]
4. Remove two hexagonal socket head bolts (4) from the
Mounting bolts (hexagonal socket head) (3) and (4) of
seat rails. [*1] operator's seat (2): Width across flats 6 mm
5. Disconnect connector (5). 3 Mounting bolts (hexagonal socket head) (3)
q Connector (5): Seat belt caution switch (S19) and (4) of operator's seat (2):
25.5 Nm {2.6 kgm}
[*2]
HB215LC-2 50-253
Mounting bolt (6) of seat belt (7): Width across flats 15.9
mm
3 Mounting bolt (6) of seat belt (7):
19.6 – 29.4 Nm {2.0 to 3.0 kgm}
50-254 HB215LC-2
Removal and installation of work equipment control lever assembly

When you make the machine stable, obey the items that follow.
k Stop the machine on a level ground, and fully lower the work equipment to the ground in a stable
attitude.
k Set the parking brake switch to the LOCK position.
k Set the work equipment lock switch to the LOCK position.
When you stop the engine, obey the items that follow.
k Turn the starting switch to the OFF position to stop the engine.
k Make sure that the system operating lamp is off, and set the battery disconnect switch to the OFF
position.
REMARK
For details, see Testing and adjusting, “Battery disconnect switch”.
Before you start the work, obey the items that follow.
k Immediately after the engine stops, the temperature of the coolant, oil, and parts around the engine
are very hot and they can cause burn injury. Wait until the temperature decreases, and then start
the work.
REMARK
Special caution is necessary as the temperature of the aftertreatment devices and area around
them are 400°C or above.
k The remaining pressure in the hydraulic tank can cause an accident. Release the remaining pres-
sure carefully.
REMARK
For details, see Testing and adjusting, “Release remaining pressure from hydraulic tank”.
k Examine for flammable materials such as dry leaves and twigs stuck to the aftertreatment devices.
If dirt or flammable materials are found, remove them.
k The aftertreatment devices can be damaged by the shock if they fall. Handle them carefully. Do not
use the damaged parts again.
When you handle the wirings and hoses, obey the items that follow.
k Before you disconnect the wirings, hoses, and clamps, and write them down, examine the connec-
tor numbers and installation positions.
k If the wirings and hoses can be deformed or damaged, remove the clips and clamps before the
work.
k Before you disconnect the hoses, prepare a container to receive oil.
k Install a plug or flange to the parts where a hydraulic hose is disconnected not to let oil flow out.
k Replace the O-ring, seal washer, and gasket with new ones.
HB215LC-2 50-254-1
Removal
REMARK
Shape is different by machine models in some cases.
Right hand lever
1. Remove the 2 bolts (1), and pull up the armrest (2).
2. Remove the boot (45).

REMARK
q When you remove the boot from the cover, push the lock
of the frame with a flat-head screwdriver or such.
q If you pull parts other than the lock of the frame by force,
it can cause damage to the frame. Be careful.
q A seat is inserted between the boot and cover. Be careful
not to lose it.
q The seat is not installed on some machines which were
made earlier.
3. Remove the fuel dial (46).
4. Remove the 3 bolts (47), and slide up the cover (48).
50-254-2 HB215LC-2
5. Remove the 3 bolts (49), and slide the bracket (50) sideway.
6. Remove the work equipment control lever assembly as

follows.
q Threaded type
1) Disconnect the connector (51).
2) Cut the band (52).
3) Loosen the nut (53), and remove the work equipment

control lever assembly (54).
q Split boss type

1) Disconnect the connector (51a).
HB215LC-2 50-254-3
2) Remove the clip (52b).
3) Cut the band (52a).
4) Remove the bolt (53a), and remove the work equipment

Left hand lever

7. Remove the 2 bolts (3), and pull up the armrest (4).
8. Remove the boot (60).

REMARK
q When you remove the boot from the cover, push the lock
of the frame with a flat-head screwdriver or such.
q If you pull parts other than the lock of the frame by force,
it can cause damage to the frame. Be careful.
q A seat is inserted between the boot and cover. Be careful
not to lose it.
made earlier.
50-254-4 HB215LC-2
9. Remove the ashtray (60a).
10. Remove the 4 bolts (61), and slide up the cover (62).
11. Remove the work equipment control lever assembly as follows.

q Threaded type
1) Disconnect the connector (63).
2) Cut the band (64).
HB215LC-2 50-254-5
3) Loosen the nut (65), and remove the work equipment

q Split boss type

1) Disconnect the connector (63a).
2) Cut the band (64a).
3) Remove the bolt (65a), and remove the work equipment

50-254-6 HB215LC-2
Installation
REMARK
Shape is different by machine models in some cases.
Left hand lever
1. Install the seat (66a) to the work equipment control lever
assembly (66).
REMARK
q Use a new work equipment control lever assembly.
q When you install the seat, put it onto the latches of the
boot.
made earlier.
2. Install the work equipment control lever assembly as follows.

q Threaded type
1) Install the work equipment control lever assembly (66)
with the nut (65).
REMARK
q Screw in the lever to the bottom of the valve.
q After you tighten it, turn it back by 3 and a half turns.
Adjust the lever height and direction, and tighten and
fix it.
3 Nut (65): 34.3 to 58.8Nm {3.5 to 6.0kgfm}
2) Install the band (64).

REMARK
q Use a new band.
q If you fix it tightly, the disconnection can occur.
q Put the wirings through the cut-out part of the bracket.
q After you fix it, operate the lever and make sure that the
wirings move freely.
q Band mounting angle: 45°
HB215LC-2 50-254-7
3) Connect the connector (63).
q Split boss type

with the bolt (65a).
3 Bolt (65a): 59 to 74Nm {6 to 7.5kgfm}
2) Install the band (64a).

REMARK
q Use a new band.
3) Connect the connector (63a).
50-254-8 HB215LC-2
3. Install the cover (62) with the 4 bolts (61).

3 Bolt (61): 9.8Nm {1.0kgfm}
4. Install the ashtray (60a).
5. Install the boot (60).
6. Install the armrest (4) with the 2 bolts (3).
HB215LC-2 50-254-9
Right hand lever

7. Install the seat (54a) to the work equipment control lever
assembly (54).
REMARK
q Use a new work equipment control lever assembly.
q When you install the seat, put it onto the latches of the
boot.
made earlier.
8. Install the work equipment control lever assembly as follows.

q Threaded type
with the nut (53).
REMARK
q Screw in the lever to the bottom of the valve.
q After you tighten it, turn it back by 3 and a half turns.
Adjust the lever height and direction, and tighten and
fix it.
3 Nut (53): 34.3 to 58.8Nm {3.5 to 6.0kgfm}
2) Fix it with the band (52).

REMARK
q Use a new band.
3) Connect the connector (51).
50-254-10 HB215LC-2
q Split boss type

with the bolt (53a).
3 Bolt (53a): 59 to 74Nm {6 to 7.5kgfm}
2) Install the band (52a).

REMARK
q Use a new band.
3) Install the clip (52b).
4) Connect the connector (51a).
HB215LC-2 50-254-11

3 Bolt (47): 9.8Nm {1.0kgfm}
11. Install the fuel dial (46).
12. Install the boot (45).
50-254-12 HB215LC-2
13. Install the armrest (2) with the 2 bolts (1).
HB215LC-2 50-254-13
50-254-14 HB215LC-2
Removal and installation of front wiper assembly (PC220-K710-924-K-00-A)

the engine.
k Set the work equipment lock lever in the

LOCK position.

Removal (PC220-K710-520-K-00-A)
1. CheckthatwiperDUP(1)isatstowedposition
(to the R.H. stay).
2. Pull lever (3) to release the lock while holding

handle (2) at right and left of upper part of front
window.
3. Hold lower handle (4) with left hand and upper

handle (5) with right hand, and pull up the front
window, and push it against lock cap (6) at the
rear of cab to lock.
4. Check lever (3) is securely locked.

C Check that the position of arrows on lock
case (7) and lever (3) match.
HB215LC-2 50-255
8. Disconnect connector P31 (14) inside cover

5. Remove lower window (9) by pulling up at knobs
(12).
(8).
9. Remove covers (15) and (16).

6. Remove cover (10) and floor mat (11).
10.Remove cover (17).

C Insert a flat-head screwdriver in slit (18) at
C One of four mounting screws is covered with left bottom, and pull it upward to remove
cap (13). cover (17) while releasing lug (19).
50-256 HB215LC-2
13.Move wiring harness (23) and remove connector

M05 (24).
14.Open cap (25), remove nut (26) and remove

wiper arm (27).
15.Remove cap (28), nut (29), washer (30) and
packing (31).
11.Remove duct (20).
16.Remove six mounting bolts (32) and remove

wiper motor assembly (33).
12.Remove the mounting bolts of bracket (21) and

keep the bracket with machine monitor (22) at
rear side.
C Ii is not necessary to disconnect the
connectors of machine monitor.
1. Install wiper motor assembly (33).

Adhesive (LT-2)
HB215LC-2 50-257
2. Install packing (31), washer (30) and tighten nut (29)

to the specified torque.
a Install washer (30) with its chamfered face toward

cab front.
3 Nut (29):
10.8 to 12.7 Nm {1.10 to 1.30 kgm}
3. Install cap (28) and wiper arm (27).
a Install the wiper arm (27) so that the dimension of

the clearance (a) between the washer nozzle (34)
and the wiper blade (35), and the overlap (d)
between the end face (c) of the stopper (41) and
the end face (b) of the slider (43) are as listed a Details on the part P
below: q Install the wiper arm with the stopper and the
q Dimension of (a): 22 mm slider overlapping one another.
q Dimension of (d): 8 mm
4. Tighten nut (26) and close cap (25).
3 Nut (26):
11.8 to 15.7 Nm {1.20 to 1.60 kgm}
50-258 HB215LC-2
C 6XSSOHPHQWDU\H[SODQDWLRQ 2) Install lower window (9) by holding knobs (8).

• .HHSWKHIROORZLQJVWDWHZKHQVWRULQJ
WKHZLSHUDUPZKHQWKHZLSHUVZLWFKLV
2))
3) Pull lever (3) down to release the lock while

holding handle (2) at right and left of front
window stowed in the ceiling.
5. Check the operation of the wiper arm according
1) Connect connector M05 (24) and P31 (14).
4) Hold lower handle (4) with left hand and

upper handle (5) with right hand securely,
and push down the window forward slowly.
C &KHFNWKDWWKHORZHUSDUWRIWKHIURQW
ZLQGRZGRHVQRWFRPHLQWRFRQWDFWZLWK
WKHZLSHUDUP
HB215LC-2 50-259
TurnthebatterydisconnectswitchtotheON
position.
Checkthattheworkequipmentlockleveris
intheLOCKposition,andthenstartthe
engine.
Checktheoperationofwiperarmwhilethe
frontwindowisdry.
@ Pushwiperswitch(37)3times
consecutively,checkthatwiperarm(27)
makesoneroundtripandthenbestowed
totheR.H.stayH.
5) When the bottom of front window touches the

top of lower window, push the upper portion
of front window against lock catcher (36) at
the front of the cab to lock.
2] Repeat Step 1] again.

C Rotating direction of motor crank
defers between Step 1] and Step 2].
Accordingly, check twice.
3] Push wiper switch (37), and check
clearance "b" with trim seal (38) becomes
following dimension when the tip of wiper
blade (35) reaches to the highest point.
6) Check lever (3) is securely locked. • Dimension "b": 130 mm or less
C Check that the position of arrows on lock
case (7) and lever (3) match.
50-260 HB215LC-2
10)Check the operation of wiper arm while the

front window is wet with washing fluid.
1] Keep pushing window washer switch (39)
for few seconds to wet the front window
throughout, then hand off the switch.
2] Check that wiper arm (27) makes two
round trips and then be stowed to the R.H.
stay
3] Repeat Step 1] again.
4] Check that wiper arm (27) makes round
trips in odd number and then be stowed
to the R.H. stay
5] Keep pushing window washer switch (39)
to operate the wiper, and check following. 11)If any abnormality is found in the above
• No interference between wiper slider checks, perform the installation adjustment
(40) and stopper (41) when the tip of of wiper arm in Step 3.
wiper blade (35) reaches to the 6. Performthesubsequentinstallationinthe
highest point. (If interferes, click reverse order to removal.
sound is heard.)
• No interference between wiper blade
(35) and front window seal (42) when
the tip of wiper blade (35) reaches to
the lowest point.
HB215LC-2 50-261
Electrical system
Electrical system
Removal and installation of air conditioner compressor assembly (HB205-

K590-924-K-00-A)



C Never release the refrigerant (air conditioner

C Ask a qualified person for collecting, adding and
Removal (HB205-K590-520-K-00-A)

Refrigerant to be collected:
930 ± 50 g

guard (3). 6. Disconnect air conditioner hoses (8) and (9). [*2]
4. Remove bolts (4) (2 pieces), and remove fan 7. Loosen belt adjustment bolts (10) (2 pieces),
guard (5). and remove air conditioner compressor drive
5. Remove bolts (6) (3 pieces), and remove fan belt (11). [*3]
guard (7). 8. Open clip (12), disconnect air conditioner
compressor connector AC03 (13).
9. Remove air conditioner compressor mounting
bolt (14). [*4]
10.Remove bracket (15).
50-262 HB215LC-2
Electrical system
Air conditioner compressor assembly mounting bolts:

3 Air conditioner compressor assembly
mounting bolts:
24.5 to 29.4 Nm {2.5 to 3.0 kgm}
[*1]
a Filling of refrigerant (air conditioner gas: R134a) Refill

the air conditioner circuit with refrigerant (air
Refill amount:
930 ± 50 g
a Refilling of air conditioner compressor oil

[*2]

hose.



Hose clamp: Width across flats 10 mm
3 Hose clamp:
8 to 12 Nm {0.8 to 1.2 kgm}
[*3]
a See Testing and adjusting, "Testing and adjusting air

conditioner compressor belt tension".
a Seat the nut, and then install the bolt.

3 Mounting bolt:
102.9 Nm {10.5 kgm}
[*4]
HB215LC-2 50-263
Electrical system
Removal and installation of air conditioner condenser assembly (HB205-K580-

924-K-00-A)


k If refrigerant gas (air conditioner gas: R134a)

gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.
C Never release the refrigerant (air conditioner

C Ask a qualified person for collecting, adding and
Removal (HB205-K580-520-K-00-A)
1. Open engine hood (1). 5. Remove mounting bolts (5) (4 pieces), and
2. Collect the refrigerant (air conditioner gas: remove air conditioner condenser assembly (6).
R134a) from the air conditioner circuit. [*1] [*3]
930 ± 50 g
3. Open side door (2) on the left side of the
machine body.

removal.
[*1]
4. Disconnect air conditioner hoses (3) and (4). [*2]
C Filling of refrigerant (air conditioner gas: R134a)
Refill the air conditioner circuit with refrigerant
(air conditioner gas: R134a).
• Refill amount:
930 ± 50 g
50-264 HB215LC-2
Electrical system
a Refilling of air conditioner compressor oil

[*2]

hose.



Hose clamp: Width across flats 10 mm
3 Hose clamp:
8 to 12 Nm {0.8 to 1.2 kgm}
[*3]
2 Threaded portion of air conditioner condenser
assembly mounting bolts:
Liquid gasket (LT-2)
12.5 ± 2.5 Nm {1.2 to 0.25 kgm}
HB215LC-2 50-265
Electrical system
Removal and installation of engine controller assembly (HB205-AP70-924-K-00-A)


Removal (HB205-AP70-520-K-00-A)
1. Swing the upper structure by 90 deg.

3. Disconnect connector E24 (2) from the engine 4. Disconnect connectors ECM (7) and CE03 (8)
controller according to the following procedure. from the engine controller. [*1]
C Clean the connector carefully so that mud, C Clean the connector carefully so that mud,
etc. sticking around it does not enter into the etc. sticking around it does not enter into the
connector. connector.
1) Roll up rubber cover (3), slide down lever C The connector is locked with hexagonal
(red) (4) , and unlock it. socket head bolt (9) (4mm).
remove engine controller (11). [*2]
C Ground cable (12) is tightened together.
2) Hold connector (2) with your fingers, press

lock stopper (6), pull it out, and disconnect it.
C Lock stopper (6) is located in the back of
connector (2).
50-266 HB215LC-2
Electrical system
Installation (HB205-AP70-720-K-00-A)
[*1]
Hexagonal socket head bolt (9): Width across flats 4 mm
3 Hexagonal socket head bolt (9):
3 ± 1 Nm {0.31 ± 0.1 kgm}
[*2]
Tighten mounting bolt (10) together with ground cable
(12).
Engine controller mounting bolt: Width across flats 12 mm
3 Engine controller mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
HB215LC-2 50-267
Electrical system
Removal and installation of pump controller assembly (PC220-C3V1-924-K-00-A)

the engine.


C The position of the pump controller is shown in
the figure.
• A: Pump controller
3. Disconnect connectors (4) and (5) according to
C While pressing lock (L1), move lock (L2) to
the other side.
C Slider (B) comes out and the lock is
released.
• Connector (4): Pump controller (CP01)
• Connector (5): Pump controller (CP02)
4. Remove four bolts (6) to remove pump controller
(A).
Removal (PC220-C3V1-520-K-00-A)
1. Pull up cover (1) (three bolts) to remove.

C The connectors and harnesses at the rear
must not be caught.
2. Remove bolts (2) to remove plate (3).
Installation (PC220-C3V1-720-K-00-A)

removal.
Reference: Procedure for removing connector
cover (1)
1. Cut and remove cable tie (2).
50-268 HB215LC-2
Electrical system
2. Move lever (3) upward.
C Right and left sliders (4) are pushed in as far

3. Lightly press part (A) on both sides of connector as they go. (See the left figure shown below.)
cover (1) to release tabs (B). 2. Move lever (3) on connector cover (1) from the
4. Arc connector cover (1) around tab (C) to top position to the left position (locked position)
remove the cover. as shown in the following figure.
C (B) and (C): Tab
C If the sliders and lever are not set as shown
in the following figure, the connector is not
disconnected or locked securely with the
lever. Accordingly, check their positions
again.
C The figure below shows the connector

without connector cover (1).
3. Set tab (C) to the connector and place connector

cover (1).
C Take care that wiring harness (5) be not
caught.
Reference: Procedure for installing connector

cover (1)
1. Push in right and left sliders (4) as far as they
go.
4. Put tabs (B) in to install connector cover (1).
HB215LC-2 50-269
Electrical system
5. Using a new cable tie (2), bind connector cover

(1) and harness (6).
50-270 HB215LC-2
Electrical system
Removal and installation of machine monitor assembly (PC220-Q170-924-K-00-A)

the engine.


Removal (PC220-Q170-520-K-00-A)
1. Pull up front window assembly (1) to the ceiling 5. Remove connector (6) and then remove cover
and lock it. (4).
• Connector (6): Sunlight sensor (P31)
C Check that the front window is securely
locked.
6. Remove duct (10) (one bolt).
3. Remove rubber panel (3) (two bolts).
7. Insert a flat-head screwdriver in slit (7) and pull it

upward to remove cover (9) while releasing lug
(8).
4. Remove three mounting screws of cover (4).
C One of the three screws is covered with cap
(5).
HB215LC-2 50-271
Electrical system
10.Disconnect connectors (13) to (16).

C Hook (17) beneath cover (9) unites cover (9).
C Disconnecting connector (15) first makes
easier to disconnect the other connectors.
• Connector (13): Machine monitor (CM01)
• Connector (14): Machine monitor (CM02)
• Connector (15): Machine monitor (not used)
(CM03)
• Connector (16): Machine monitor (for camera
connection) (CM04)
8. Loosen mounting bolts (19) of cover and duct

assembly (18).
C Loosening mounting bolts (19) first makes
easier to remove machine monitor mounting
bolts.
9. Remove four mounting bolts (11) of machine

monitor (12).
Installation (PC220-Q170-720-K-00-A)

removal.
50-272 HB215LC-2
Electrical system
Removal and installation of pump swash plate sensor (PC220-C3WG-924-K-00-A)

k Park the machine on a level ground, lower the
engine.
k Turn the battery disconnect switch to the OFF

a Note connector numbers and installed positions

Removal (PC220-C3WG-520-K-00-A)
1. Open the right side cover and remove rubber-lined
cover (1) (4 bolts). Installation (PC220-C3WG-720-K-00-A)
Pump swash plate sensor mounting bolt: Width across
flats 5 mm
3 Pump swash plate sensor mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
a Adjust the pump swash plate sensor. For details, see
Testing and adjusting, "Special function of machine
monitor", "Adjustment (Cal F pump swash plate
sensor)" and "Adjustment (Cal R pump swash plate
sensor)".
2. Remove harness (2) from clip (3).

3. Disconnect connectors (4) and (5).
q Connector (4): Front pump swash plate sensor
(P27)
q Connector (5): Rear pump swash plate sensor
(P28)
4. Remove clamp (6) (one bolt) holding the swash plate

sensor harness.
5. Remove two swash plate sensor mounting bolts (7),
then remove front pump swash plate sensor (8) and
rear pump swash plate sensor (9).
HB215LC-2 50-273
Electrical system
Removal and installation of mass air flow and temperature sensor

(PC220-A96H-924-K-00-A)
k Turn the battery disconnect switch to the OFF [*1]

position and remove the key. Screw (5) for air intake flow/temperature sensor: Width
across flats 3 mm
Removal (PC200_10-A96H-520-K-00-A) 3 Screw (5) for air intake flow/temperature
1. Open side door (1) on the left side of the machine. sensor:
0.98 to 1.27 Nm {0.1 to 0.13 kgm}
2. Remove connector cover (2).
3. Disconnect connector (3).

Connector No.(3): P55
4. Remove intake air flow/temperature sensor (4).[*1]
a Be careful about dust from entering into air
cleaner.
Installation (PC220-A96H-720-K-00-A)
50-274 HB215LC-2
Electrical system
Removal and installation of KOMTRAX terminal assembly (PC220-Q210-924-K-00-A)

the engine.


C The position of the KOMTRAX terminal is shown
below.
• C: KOMTRAX terminal
4. Remove cover (6) (seven bolts).
C Be careful about connector (7) located
behind cover (6).
Removal (PC220-Q210-520-K-00-A)
1. Remove box (1) (five bolts).

C Disconnect the hose located under box (1).
5. Disconnect connectors (8) to (11).
2. Remove box (2) (three bolts).
• Connector (8): Communication antenna
C Be careful about connectors (3) and (4) (GPS)
located behind box (2) (for machines • Connector (9): Machine main harness
equipped with 12 V power socket). (CK01).
• Connector (3): 12 V power socket • Connector (10): Machine main harness
intermediate harness (M13A) (CK02).
• Connector (4): 12 V power socket • Connector (11): Communication antenna
intermediate harness (M13B) 6. Remove KOMTRAX terminal (C) (four bolts).
3. Remove cover (5) (three bolts).
HB215LC-2 50-275
Electrical system
Installation (PC220-Q210-720-K-00-A)

removal.
50-276 HB215LC-2
SHOP MANUAL
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
60 Maintenance standard
8 60 Maintenance standard
HB215LC-2 60-1
Table of contents

60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Power train system ..................................................................................................................... 60-5
Swing circle ......................................................................................................................... 60-5
Swing machinery with swing brake ........................................................................................ 60-6
Final drive ........................................................................................................................... 60-8
Sprocket............................................................................................................................ 60-10
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-16
Carrier roller ...................................................................................................................... 60-17
Track shoe ........................................................................................................................ 60-18
Hydraulic tank.................................................................................................................... 60-24
Main pump ........................................................................................................................ 60-25
Control valve ..................................................................................................................... 60-26
Travel motor ...................................................................................................................... 60-36
PPC valve ......................................................................................................................... 60-39
Solenoid valve ................................................................................................................... 60-49
Attachment circuit selector valve (for high-pressure circuit) .................................................... 60-50
Attachment circuit selector valve (for low-pressure circuit) ..................................................... 60-51
Center swivel joint .............................................................................................................. 60-52
Work equipment ....................................................................................................................... 60-53
Work equipment................................................................................................................. 60-53
Work equipment cylinder .................................................................................................... 60-62
60-2 HB215LC-2
Engine mount
Engine mount (HB205-H320-034-K-00-A)
HB215LC-2 60-3
Cooling system
Cooling system (HB205-B000-034-K-00-A)
60-4 HB215LC-2
Swing circle
Power train system (ALL-C100-001-K-60-A)
Swing circle (HB205-J110-034-K-01-A)
Unit: mm
Axial clearance of Standard clearance Allowable clearance
bearing
1 Replace
(when mounted on 0.5 to 1.6 3.2
machine)
HB215LC-2 60-5
Swing machinery with swing brake (HB205-J130-034-K-00-A)
60-6 HB215LC-2
Unit: mm
Standard clearance Allowable clearance
Backlash between
1 swing motor shaft and 0.07 to 0.18 -
No. 1 sun gear
Backlash between No.
2 1 sun gear and No. 1 0.09 to 0.27 0.80
planetary gear
3 1 planetary gear and 0.14 to 0.43 0.90
ring gear
4 1 planetary carrier and 0.07 to 0.21 -
No. 2 sun gear
5 2 sun gear and No. 2 0.16 to 0.50 1.00
planetary gear
6 2 planetary gear and 0.18 to 0.59 1.10 Replace
No. 2 ring gear
7 2 planetary carrier and 0.39 to 0.71 1.20
No. 3 sun gear
No. 2 ring gear
9 3 sun gear and No. 3 0.16 to 0.50 0.90
planetary gear
Backlash between
10 swing pinion and No. 3 0.07 to 0.23 -
planetary carrier
Backlash between
11 swing pinion and swing 0.22 to 1.32 2.00
circle
Standard Repair limit
Tolerance
dimension
Repair by
Outside diameter of oil 0 hard chrome
12 seal contact surface of 125 -
–0.100 plating or
swing pinion
replace
Standard clearance Allowable clearance
Clearance between No.
13 1.66 to 2.94 -
3 sun gear and plate
Clearance between Replace
14 plate and No. 3 0.66 to 1.14 -
planetary carrier
HB215LC-2 60-7
Final drive
Final drive (HB205-DF10-034-K-00-A)
60-8 HB215LC-2
Final drive
Unit: mm
Backlash between Standard clearance Allowable clearance
1 travel motor and No. 2
planetary carrier 0.06 to 0.25 1.00
ring gear
3 2 planetary gear and 0.15 to 0.49 -
No. 2 sun gear
Replace
ring gear
No. 1 sun gear shaft
6 1 planetary carrier and 0.38 to 0.66 1.00
No. 2 sun gear
HB215LC-2 60-9
Sprocket
Sprocket (PC228-DT60-034-K-00-A)
Unit: mm
Standard dimension Repair limit
1 Wear of tooth tip
294.5 282.5
Thickness of tooth Rebuild by
2 17 11 build-up
bottom
welding or
3 Width of tooth 71 65
replace
Repair limit: 6
4 Wear of tooth profile
(Use "Full-scale drawing of sprocket profile" for judgment)
60-10 HB215LC-2
Sprocket
Full-scale drawing of sprocket tooth profile

a Duplicate the full-scale drawing onto an OHP sheet.
HB215LC-2 60-11
Track frame and idler cushion (HB205-DT20-034-K-01-A)
60-12 HB215LC-2
Unit: mm
Standard dimension Tolerance Repair limit
Track +3
Vertical width 107 111
1 of idler guide frame -1
Rebuild by
Idler
105 ±0.5 103 build-up
support
welding or
Track +4 replace
250 255
Lateral width frame -1
2 of idler guide
Idler
247.4 ‐ 245.4
support
Free height Installed Load at Load at
x outside installed Free height installed
3 Recoil spring height Replace
diameter height height
126.5 kN 101kN
561 x 237 433 535
{12,900 kg} {10,300 kg}
HB215LC-2 60-13
Idler
Idler (PC220-DT90-034-K-00-A)
60-14 HB215LC-2
Idler
Unit: mm
Outside diameter of Standard dimension Repair limit
1 protrusion 538 -
Outside diameter of Rebuild by
2 500 488
tread build-up
3 Thickness of tread 26 20 welding or
4 Depth of tread 19 25 replace
5 Overall width 159 -
6 Width of tread 37.5 -
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
7 shaft and bushing -0.250 +0.164 0.176 to
65 -
-0.350 -0.074 0.514
Tolerance Standard Allowable
Standard
interfer- interfer- Replace
Interference between dimension Shaft Hole
8 ence ence bushing
idler and bushing
+0.108 -0.032 0.040 to
72 -
+0.008 -0.062 0.170
Clearance between Standard dimension Repair limit
9 bushing and support
0.5 to 1.0 -
(Total on both sides)
HB215LC-2 60-15
Track roller
Track roller (PC200_10-DTD0-034-K-00-A)
Unit:mm
1 flange 188 -
Outside diameter of Build-up
2 156 144
tread welding for
3 Thickness of tread 44.5 38.5 rebuilding or
4 Ovevall width 225 - replace
5 Width of tread 44.5 -
6 Width of flange 25.5 -
Clearance between dimension Shaft Hole clearance clearance
7 shaft and bushing –0.215 +0.195 0.215 to
60 -
–0.315 0 0.510 Replace
Tolerance Standard Allowable bushing
Standard
interfer- interfer-
8 ence ence
roller and bushing
+0.153 +0.030 0.023 to
67 -
+0.053 0 0.153
Clearance between Standard dimension Repair limit
9 bushing and collar Replace
0.5 to 1.0 -
(Total of both sides)
60-16 HB215LC-2
Carrier roller
Carrier roller (PC200_10-DTJ0-034-K-00-A)
Unit: mm
1 flange 143 -
Outside diameter of
2 120 106
tread
3 Width of tread 43 -
4 Thickness of tread 23 16
5 Width of flange 14 -
Clearance between dimension Shaft Hole clearance clearance Replace
6 shaft and bushing –0.170 +0.301 0.338 to
40 -
–0.190 +0.168 0.491
Tolerance Standard Allowable
Standard
interfer- interfer-
7 ence ence
roller and bushing
+0.061 0 0.016 to
47 -
+0.016 –0.040 0.101
End play of roller (play Standard clearance Allowable clearance
8 in axial direction) 0.44 to 0.76 -
HB215LC-2 60-17
Track shoe
Track shoe (PC200_10-DTL0-034-K-00-A)
a Portion P shows the link on the side where the bushing is press-fitted.
*1: Triple grouser shoe
*2: Road liner
*3: Swamp shoe
*4: Flat shoe
60-18 HB215LC-2
Track shoe
Unit:mm
1 Link pitch
190.3 193.3 Turn 180
Outside diameter of Standard dimension Repair limit deg. or
2 bushing replace
59.4 54.4
3 Thickness of bushing 10.4 5.4
4 Link height
105 97 Repair or
Thickness of link replace
5 (bushing press fit part) 28.5 20.5
6 160.4
7 Shoe bolt pitch 124.4
8 62
Inside
9 84.8
width
Overall
10 Link 45.4
width
Tread
11 39.6
width
Adjust or
Protrusion of Regular 2.5
12 pin replace
Master 2.5
Protrusion of Regular 4.85
13 bushing
Master 0.0
Overall length Regular 212
14 of pin
Master 212
Overall length Regular 138.5
15 of bushing
Master 128.7
16 Thickness of spacer -
17 Bushing 88.2 to 245 kN {9 to 25 ton}
Regular
18 Press-fitting 127.4 to 274.4 kN {13 to 28 ton}
pin -
force
(*1) Master
78.4 to 147 kN {8 to 15 ton}
19 pin
Tightening torque Retightening angle
(Nm {kgm}) (deg.)
Regular Triple grouser 490 ± 49
120 ± 10
link shoe {50 ± 5}
20 Shoe bolt 549 ± 59 Retighten
Road liner -
{56 ± 6}
Tightening torque Retightening angle Lower limit torque
Master (Nm {kgm}) (deg.) (Nm {kgm})
link -
- -
HB215LC-2 60-19
Track shoe
Unit:mm
Standard Tolerance Standard
Interference between dimension Shaft Hole interference
21 bushing and link +0.434 +0.074
59 0.320 to 0.434
+0.394 0
Interference between +0.222 –0.138
22 regular pin and link 38 0.300 to 0.422
+0.162 –0.200
Clearance between dimension Shaft Hole clearance
23 regular pin and bushing +0.222 +0.902 Adjust or
38 0.180 to 0.740 replace
+0.162 +0.402
(*1) Interference between dimension Shaft Hole interference
24 master pin and link +0.280 +0.062
37.8 0.188 to 0.280
+0.250 0
(*1) Clearance between dimension Shaft Hole clearance
25 master pin and bushing –0.150 +0.902
38 0.552 to 1.252
–0.350 +0.402
*1: For the dry type track
60-20 HB215LC-2
Track shoe
Triple grouser shoe (PC200_10-DTL8-034-K-00-A)
Unit:mm
1 Grouser overall height
26 16
Shoe overall 36 26
2 height (*) 34.5 26
10 Build-up
Plate
3 welding for
thickness (*) 8.5 rebuilding or
4 26 replace
Grouser base length
5 19
6 20
7 Grouser tip length 14
8 19
*: 600 mm width shoe.
HB215LC-2 60-21
Track shoe
Swamp shoe (PC-DTLA-034-K-00-A)
Unit: mm
Standard dimension Repair limit Build-up
1 Shoe height welding for
102.5 90.5
rebuilding or
2 Shoe thickness 17 5 replace
60-22 HB215LC-2
Track shoe
Road liner (PC-DTLK-034-K-00-A)
Unit: mm
1 Height 70 Replace
HB215LC-2 60-23
Hydraulic tank
Hydraulic tank (PC200_10-PM30-034-K-00-A)
60-24 HB215LC-2
Main pump
Main pump (PC-C200-034-K-00-A)
HB215LC-2 60-25
Control valve
Control valve (HB205-C030-034-K-01-A)

General view
60-26 HB215LC-2
Control valve
Sectional view
(1/5)
HB215LC-2 60-27
Control valve
Unit: mm
x Outside installed Free height installed
1 Spool return spring height
407 N 326 N
55.2 x 34.4 51.2 - Replace
{41.5 kg} {33.2 kg}
spring if
393 N 315 N damaged or
2 Spool return spring 54.5 x 34.8 51.2 -
{40.1 kg} {32.1 kg} deformed
375 N 300 N
{38.2 kg} {30.6 kg}
421 N 336 N
{42.9 kg} {34.3 kg}
60-28 HB215LC-2
Control valve
(2/5)
HB215LC-2 60-29
Control valve
Unit: mm
1 Suction valve spring height Replace
spring if
5.5 N 4.4 N damaged or
46.8 x 7.5 40.6 -
1.5 N 1.2 N
2 Check valve spring 11.5 x 4.6 8.5 -
{0.15 kg} {0.12 kg}
60-30 HB215LC-2
Control valve
(3/5)
HB215LC-2 60-31
Control valve
Unit: mm
Check valve return x Outside installed Free height installed
1 height
spring diameter height height
14.7 N 11.8 N
59.3 x 14.4 43 -
{1.5 kg} {1.2 kg}
13.7 N 11 N
2 Check valve spring 33.8 x 6 29 - Replace
{1.4 kg} {1.12 kg}
spring if
170 N 135 N damaged or
3 Piston return spring 60.2 x 20 36 -
5.9 N 4.71 N
{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}
60-32 HB215LC-2
Control valve
(4/5)
HB215LC-2 60-33
Control valve
Unit: mm
Spring of merge-divider x Outside installed Free height installed
1 height
valve (for LS) diameter height height
121 N 96.5 N
36.4 x 21.8 33.0 -
{12.3 kg} {9.84 kg}
250 N 200 N
2 Sequence valve spring 70.9 x 18.0 56.0 -
{25.5 kg} {20.4 kg}
Spring of merge-divider 178 N 142 N Replace
3 64.5 x 32.3 63.0 - spring if
valve (Main) {18.1 kg} {14.5 kg}
damaged or
Check valve spring of 35.3 N 28.2 N deformed
4 hydraulic drift 33.0 x 12.0 26.0 -
prevention valve {3.6 kg} {2.88 kg}
13.7 N 11.0 N
{1.4 kg} {1.12 kg}
Check valve spring for 5.9 N 4.71 N
6 31.5 x 10.3 19.5 -
regeneration circuit {0.6 kg} {0.48 kg}
Travel junction valve 50.0 N 40.0 N
7 30.7 x 20.5 23 -
spring {5.1 kg} {4.08 kg}
60-34 HB215LC-2
Control valve
(5/5)
HB215LC-2 60-35
Travel motor
Travel motor (HB205-C400-034-K-01-A)
60-36 HB215LC-2
Travel motor
HB215LC-2 60-37
Travel motor
Unit: mm
Criteria
No. Item Free Load at Load at Remedy
height x Installed installed Free
installed
outside height height
height height
diameter
46.9 x 223 N 178 N
1 Regulator piston spring 37.1 -
20.3 {22.8 kg} {18.2 kg}
51.1 x 69.6 N 55.7 N
2 Regulator piston spring 39.1 -
13.5 {7.1 kg} {5.7 kg}
21.5 x 54.9 N 43.9 N Replace
3 Regulator valve spring 17.1 - spring if
11.1 {5.6 kg} {4.48 kg}
damaged
2.55 N 2.04 N
4 Check valve spring 13.0 x 6.5 8.5 - or
7.16 N 5.72 N
5 Suction safety valve spring 32.5 x 6.5 24.2 -
{0.73 kg} {0.58 kg}
58.4 x 410 N 328 N
6 Counterbalance valve spring 42.6 -
30.0 {41.9 kg} {33.5 kg}
60-38 HB215LC-2
PPC valve
PPC valve (ALL-CW10-001-P-00-A)

Work equipment and swing PPC valve (PC200_10-PL28-034-K-00-A)
HB215LC-2 60-39
PPC valve
60-40 HB215LC-2
PPC valve
Unit:mm
Centering spring x Outside installed Free height installed
1 height
(for ports P3 and P4) diameter length length
17.7 N 14.1 N Replace ring
42.5 x 15.5 34.0 - if damaged
{1.80 kg} {1.44 kg}
or deformed
Centering spring 29.4 N 23.5 N
2 44.5 x 15.5 34.0 -
(for ports P1 and P2) {3.0 kg} {2.40 kg}
16.7 N 13.3 N
3 Metering spring 26.5 x 8.15 24.9 -
{1.70 kg} {1.36 kg}
HB215LC-2 60-41
PPC valve
Travel PPC valve (PC-C6V0-034-K-00-A)
60-42 HB215LC-2
PPC valve
Unit:mm
x Outside installed Free height installed If damaged
1 Centering spring height
diameter length length or deformed,
48.57 x 108 N 86.3 N replace
32.5 ‐
15.5 {11 kg} {8.8 kg} spring
26.53 x 16.7 N 13.3 N
2 Metering spring 24.9 ‐
8.15 {1.7 kg} {1.36 kg}
HB215LC-2 60-43
PPC valve
1st-line attachment PPC valve (with EPC valve) (PC200_10-PL29-034-K-00-A)

60-44 HB215LC-2
PPC valve
Unit:mm
x Outside installed Free height installed If damaged
diameter length length or deformed,
125 N 100 N replace
33.9 x 15.3 28.4 ‐
{12.7 kg} {10.2 kg} spring
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0 ‐
{1.70 kg} {1.36 kg}
HB215LC-2 60-45
PPC valve
EPC valve (PC200_10-PL2B-034-K-00-A)

Unit: mm
Free height Installed Load at Load at Replace
x Outside installed Free height installed PPC valve
1 Metering spring height assembly if
diameter length length
damaged or
3.1 N 2.5 N
9.5x 11.4 8.4 ‐ deformed
{0.32 kg} {0.26 kg}
60-46 HB215LC-2
PPC valve
2nd-line attachment PPC valve (PC-PL2A-034-K-00-A)

HB215LC-2 60-47
PPC valve
Unit:mm
diameter length length Replace ring
125 N 100 N if damaged
33.9 x 15.3 28.4 ‐ or deformed
{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}
60-48 HB215LC-2
Solenoid valve
Solenoid valve (PC228-PQPT-034-K-00-A)
For the PPC Lock, travel junction, travel speed, swing brake and 2-Stage relief.
HB215LC-2 60-49
Attachment circuit selector valve (for high-pressure
circuit)
Attachment circuit selector valve (for high-pressure circuit) (PC-PQJ5-034-K-00-A)
Unit: mm
Free length Installed Load at Load at
x Outside installed Free length installed Replace ring
1 Spool return spring length if damaged
or deformed
28.7 N 22.9 N
33.4 x 11.2 27.3 -
{2.93 kg} {2.34 kg}
60-50 HB215LC-2
Attachment circuit selector valve (for low-pressure
circuit)
Attachment circuit selector valve (for low-pressure circuit) (PC-PQJ3-034-K-00-A)
Unit: mm
Free length Installed Load at Load at
x Outside installed Free length installed Replace ring
1 Spool return spring length if damaged
or deformed
834 N 667 N
132 x 29 114.5 -
{85.0 kg} {68.0 kg}
HB215LC-2 60-51
Center swivel joint
Center swivel joint (PC228-J8E0-034-K-00-A)
Unit: mm
Allowable
Clearance between Standard dimension Standard clearance
1 clearance Replace
rotor and shaft
80 0.056 to 0.105 0.111
60-52 HB215LC-2
Work equipment
Work equipment (ALL-L000-001-K-60-A)
Work equipment
HB215LC-2 60-53
Work equipment
60-54 HB215LC-2
Work equipment
Unit: mm
Criteria
No. Item Standard Tolerance Allowable Remedy
Clearance clearance
dimension Shaft Hole
Clearance between
mounting pin and -0.036 (+0.135) (0.110 to Replace pin
1 90 1.0
bushing of revolving -0.071 (+0.074) 0.206) and bushing
frame and boom
Inside diameter of hole
to insert bushing on (+0.035) Build up by
2 boom side at joint of 105 - - - welding, then
revolving frame and (0) work
boom
Clearance between
3 90 1.0
bushing of boom and -0.071 (+0.077) 0.208) and bushing
arm
(+0.054) Build up by
to insert bushing on arm - - -
4 105 welding, then
side at joint of boom and (0) work
arm
Clearance between (+0.158)
-0.030 (0.108 to Replace pin
5 mounting pin and 70 1.0
bushing of arm and link -0.076 (+0.078) 0.232) and bushing
6 85 welding, then
side at joint of arm and (0) work
link
Clearance between
7 80 1.0
bushing of arm and -0.076 (+0.074) 0.213) and bushing
bucket
8 110 welding, then
side at joint of arm and 0) work
bucket
Clearance between
mounting pin and -0.030 (+0.166) (0.116 to
9 80 1.0
bushing of link and -0.076 (+0.086) 0.242)
Replace pin
bucket
and bushing
Clearance between
-0.030 (+0.166) (0.116 to
10 mounting pin and 80 1.0
bushing of links -0.076 (+0.086) 0.242)
( ): Reference dimension
HB215LC-2 60-55
Work equipment
Unit: mm
Criteria
Greasing Width of boss Width of hinge Remedy
No. Item Standard
interval Standard Standard
Tolerance Tolerance clearance
dimension dimension
0 +1 Adjust
Joint of 625.5 632 4.5 to 8.0
-0.5 -2 clearance to
revolving L11: Adjust by combining shims 2.0 mm thick (2), 2.5 mm thick
11 1.0 mm or
frame and (*2) (1), 3.0 mm thick (1), and 3.5 mm thick (1) less by using
boom 500 hours R11: Insert shim 2.0 mm thick (1) shims
(*1) +1.5
96 ±1.2 99.3 2.1 to 6.0 Adjust
Joint of 0 clearance to
revolving L12: Adjust by combining shims 1.0 mm thick (1) and 2.0 mm 1.5 mm or
12
frame and (*2) thick (2) less by using
boom 500 hours shims
cylinder R12: Insert shim 1.0 mm thick (1)
+3
695 ±2.4 701 2.6 to 11.4
–1 Adjust
Joint of L13-1: Adjust by combining shims 1.0 mm thick (1) and 2.0 mm
boom and clearance to
13 boom thick (2) 1.5 mm or
(*2) L13-2: Insert shim 1.0 mm thick (1)
cylinder less by using
500 hours R13-1: Insert shim 1.0 mm thick (1) shims
R13-2: Insert shim 1.0 mm thick (1)
+1.5
96 ±1.2 99.3 2.1 to 6.0 Adjust
Joint of 0
clearance to
L14: Insert shim 1.0 mm thick (1)
14 boom and 1.5 mm or
arm cylinder (*2) R14: Adjust by combining shims 1.0 mm thick (1) and 2.0 mm less by using
500 hours thick (2) shims
60-56 HB215LC-2
Work equipment
Unit: mm
Criteria
Greasing Width of boss Width of hinge Remedy
No. Item Standard
interval Standard Standard
Tolerance Tolerance clearance
dimension dimension
0 +0.5 Adjust
305.5 310 4.5 to 5.5
Joint of –0.5 0 clearance to
15 boom and L15: Insert shim 2.0 mm thick (1) 1.0 mm or
(*2)
arm R15: Adjust by using shim 2.0 mm thick (1), 2.5 mm thick (1), less by using
500 hours or 3.0 mm thick (1) shims
+1.5
Joint of arm 106 ±1.2 109.3 2.1 to 6.0
0
16 cylinder and Replace shim
(*2) L16: Insert shim 1.0 mm thick (1)
arm
500 hours R16: Insert shim 1.0 mm thick (1)
+1.5 Adjust
96 ±1.2 99.3 2.1 to 6.0
Joint of arm 0 clearance to
17 and bucket L17: Insert shim 1.0 mm thick (1) 1.5 mm or
cylinder (*2)
R17: Adjust by combining shims 1.0 mm thick (1) and 2.0 mm less by using
325 ±0.5 326.5 ±1 0 to 3.0
Joint of link -
18 (*2) L18: -
and bucket
500 hours R18: -
Joint of 96 ±1.2 100.2 +0.5 2.5 to 5.9
bucket (*2) L19a: Insert shim 1.0 mm thick (1) -
19a
cylinder and
link 500 hours R19a: Insert shim 1.0 mm thick (1)
0 Adjust
280 - - -
–0.5 clearance to
Joint of L19b: Insert shim 1.0 mm thick (1)
19b 1.5 mm or
links (*2)
R19b: Adjust by combining shims 1.0 mm thick (1) and 2.0 mm less by using
500 hours thick (1). shims
0 Adjust
280 - - -
–0.5 clearance to
Joint of arm L20: Adjust by combining shims 1.0 mm thick (1) and 2.0 mm
20 1.5 mm or
and link (*2) thick (1) less by using
500 hours R20: Insert shim 1.0 mm thick (1) shims
0 +2.2 Adjust
325 327.5 2.3 to 5.2
–0.5 –0.2 clearance to
Joint of arm L21: -
21 0.5 to 1.0 mm
and bucket (*3)
R21: Adjust by combining shims 0.5 mm thick (4) and 1.0 mm by using
*1: The criteria are for the L.H. boom cylinder. The shim adjustment position of the R.H. boom cylinder is
reverse to L.H.
*2: Use plastic (flanged) shims.
*3: Use split-type iron shims.
a The number in ( ) after each shim thickness indicates the quantity of shim to be prepared.
HB215LC-2 60-57
Work equipment
Dimensions of arm (PC200_10-L412-034-K-00-A)
60-58 HB215LC-2
Work equipment
Unit: mm
Tolerance
No. Measurement point Standard dimension
Shaft Hole
-0.030 +0.100
1 - 80
-0.076 0
+1.5
Arm side 109.3
2 0
Cylinder head side 106 ±1.2
+0.5
Boom side 310
0
3
0
Arm side 305.5
-0.5
-0.036 +0.054
4 - 90
-0.071 0
5 - 402.1 ±1.0
6 - 187.2 ±0.5
7 - 829.1 ±1.0
8 - 2,919 -
9 - 2,630.5 ±1.0
10 - 410 ±1.0
11 - 640 ±0.2
12 - 600 ±0.5
13 - 458.1 -
14 - 1,486 -
-0.030 +0.100
15 - 80
-0.076 0
Link side 325 ±0.5
16
Bucket side 326.5 ±1.0
-0.030 +0.100
17 - 80
-0.076 0
0
without bushing 311
18 -0.5
with bushing press- -
325
fitted
Min. 1,680 -
19
Max. 2,800 -
HB215LC-2 60-59
Work equipment
Dimensions of bucket (PC200_10-LBK0-034-K-00-A)
60-60 HB215LC-2
Work equipment
Unit: mm
No. Measurement point Standard dimension Tolerance
1 - 457.6 ±0.5
2 - 22 ±0.5
3 - 92°45′ -
4 - 458.1 -
5 - 1,477.3 -
6 - 158.6 -
7 - - -
8 - 15°54′ -
+0.1
9 - 80
0
10 - 326.5 ±1.0
11 - 56 -
12 - 106 -
13 - 470 -
14 - 23.5 -
15 - 140 -
16 - 190 -
17 - 133.2 -
18 - 131.6 -
19 - 107 -
20 - 85 -
+2.0
21 - 348.5
0
22 - 38 -
HB215LC-2 60-61
Work equipment cylinder
Work equipment cylinder (ALL-PPZ0-001-K-00-A)
Boom cylinder (large diameter piston)
Unit: mm
1 piston rod and bushing bushing
-0.036 +0.257 0.084 to
90 0.437
-0.090 +0.048 0.347
piston rod support shaft
-0.030 (0.100 to
2 80 1.0
and bushing -0.060 (+0.070) 0.250)
Replace pin
Clearance between and bushing
-0.030 (+0.165) (0.075 to
3 cylinder bottom support 70 1.0
shaft and bushing -0.060 (+0.045) 0.225)
Tightening torque of
4 373 ± 54.0 Nm {38.0 ± 5.5 kgm}
cylinder head
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
6 cylinder piston fixing 58.9 to 73.6 Nm {6.0 to 7.5 kgm}
screw
60-62 HB215LC-2
Arm cylinder
Unit: mm
-0.036 +0.222 0.083 to
95 0.412
-0.090 +0.047 0.312
-0.030 (0.100 to
2 80 1.0
and bushing -0.076 (+0.070) 0.266)
Replace pin
Clearance between or bushing
-0.030 (+0.190) (0.100 to
4 373 ± 54.0 Nm {38.0 ± 5.5 kgm}
cylinder head
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
6 cylinder piston lock 58.9 to 73.6 Nm {6.0 to 7.5 kgm}
screw
HB215LC-2 60-63
Bucket cylinder
Unit: mm
-0.030 +0.258 0.078 to
80 0.434
-0.076 +0.048 0.334
-0.030 (0.100 to
2 70 1.0
and bushing -0.060 (+0.070) 0.230)
Replace pin
Clearance between or bushing
-0.030 (+0.165) (0.075 to
4 270 ± 39 Nm {27.5 ± 4.0 kgm}
cylinder head
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
6 cylinder piston lock 58.9 to 73.6 Nm {6.0 to 7.5 kgm}
screw
60-64 HB215LC-2
SHOP MANUAL
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
80 Appendix
9 80 Appendix
HB215LC-2 80-1
80 Appendix
Table of contents

80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-17
Air conditioner controller ..................................................................................................... 80-18
Compressor....................................................................................................................... 80-19
Air conditioner condenser ................................................................................................... 80-20
Sunlight sensor .................................................................................................................. 80-22
Outer temperature sensor (outside air temperature sensor) ................................................... 80-23
Procedure for testing and troubleshooting ............................................................................ 80-24
Circuit diagram and arrangement of connector pins............................................................... 80-26
System diagram................................................................................................................. 80-28
Parts and connectors layout................................................................................................ 80-31
Testing air leakage (duct) .................................................................................................... 80-35
Testing with self-diagnosis function ...................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-41
Testing FRESH/RECIRC air changeover.............................................................................. 80-43
Testing sunlight sensor ....................................................................................................... 80-44
Testing (dual) pressure switch for refrigerant......................................................................... 80-45
Testing relays .................................................................................................................... 80-46
Failure code list related to air conditioner.............................................................................. 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-54
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-55
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-57
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-59
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-60
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-61
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-63
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-64
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-65
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-66
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-68
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-71
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-73
Troubleshooting with gauge pressure................................................................................... 80-75
Connection of service tool................................................................................................... 80-78
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-80
Handling of compressor oil.................................................................................................. 80-82
Desiccant replacement ....................................................................................................... 80-84
80-2 HB215LC-2
80 Appendix
Precautions for refrigerant
Air conditioner components (ALL-K500-001-K-02-A)
Precautions for refrigerant (ALL-K512-012-K-00-A)
k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses to replace the air conditioner unit or condenser, the air
conditioner compressor, receiver drier, etc.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
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. Put on protective eyeglasses, gloves and working clothes with long
sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
HB215LC-2 80-3
80 Appendix
Air conditioner component
Air conditioner component (HB205-K500-04D-K-00-A)
80-4 HB215LC-2
80 Appendix
1. Compressor
2. Condenser
3. Modulator (with desiccating agent)
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
9. Air conditioner controller
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
A. Front vent
B. Rear vent
C. Foot area vent
D. Defroster vent
E: Recirculation air inlet
HB215LC-2 80-5
80 Appendix
F: Fresh air inlet

Specification (ALL-K500-030-K-00-A)
Refrigerant R134a
Refrigerant refilling level (g) 930 ± 50
80-6 HB215LC-2
80 Appendix
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle (ALL-K500-042-K-00-A)
Cycle Compression Condensation Expansion Evaporation

(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator's cab In operator's cab
Engine
Location compartment Front of radiator (Built in air conditioner (Built into air
unit) conditioner unit)
Circulates Lowers temperature
By evaporating
refrigerant gas and Condenses and pressure of
refrigerant, absorb
increases its refrigerant to refrigerant liquid and
heat from the air
temperature and discharge heat gas for easy
around the evaporator,
Function pressure so that it absorbed in evaporation with
and cools the
can be liquefied evaporator. throttle. Controls flow
surrounding air.
easily in condenser. (condensation of rate, too.
(Evaporation of
(Compression of refrigerant) (Throttle action of
refrigerant)
refrigerant) refrigerant)
Gas o gas Gas o liquid Liquid, gas o gas
State of Liquid o liquid, gas
refrigerant Adiabatic Constant pressure Constant pressure
Adiabatic expansion
compression change change
HB215LC-2 80-7
80 Appendix
Outline of refrigeration cycle
Outline of refrigeration cycle (ALL-K500-04A-K-00-A)
• The refrigerating cycle performs the following four processes. The refrigerant is liquefied and gasified
repeatedly while it is circulated in the cycle.
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 temperature and
pressure at which it can be easily liquefied when cooled to the ambient temperature.
Condensation (Condenser)
• The condenser cools and liquefies the high pressure 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 dehydrated in the modulator and cooled further in the sub-cool
section to increase the cooling efficiency.
• In the compression cycle, the gaseous refrigerant 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.
(The condensation pressure varies depending on the condensation temperature of the refrigerant)
Expansion (Expansion valve)

• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be
easily evaporated by the throttle action (*1).
• The action of reducing the liquid refrigerant pressure 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 refrigerant 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 temperature (evaporation pressure).
• 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 consequently, its pressure and temperature are reduced.
• No heat is transferred from or to the outside during the throttle action.
Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
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 refrigerant 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

• The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat
from inside the cab.
80-8 HB215LC-2
80 Appendix
Outline of refrigeration cycle
• 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 defective air conditioning.
• 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.
• 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 defective air conditioning.
HB215LC-2 80-9
80 Appendix
Air conditioner unit
Air conditioner unit (ALL-K540-041-K-00-A)
a This air conditioner unit is auto temperature control type.
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
80-10 HB215LC-2
80 Appendix
C: Hot water inlet

D: Hot water outlet
E: Recirculation air hole
F: Fresh air hole
G: Front air vents
H: Rear air vents
J: Foot level air vents
K: Defroster vents
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan, blower motor
5. Air mix servomotor
6. Air mix door
7. Vent (mode) changeover servomotor
Vent (mode) changeover door
8. Rear door
9. Foot door
10. Defroster door
11. FRESH/RECIRC air changeover servomotor
12. FRESH/RECIRC air changeover door
13. Power transistor
14. Evaporator temperature sensor
15. Insidel air temperature sensor
a The door is the same as the damper.
Function (ALL-K540-042-K-00-A)
• The air conditioner unit consists of evaporator (1) and heater core (2), and is used to cool down or warm
up the air in the cab.
Temperature control
• When the temperature control switch on the machine monitor is operated, the set temperature data is sent
to the air conditioner controller that is located at the rear of the operator's seat.
• The air conditioner controller controls air mix servomotor (5) to change the angle of air mix door (6) so that
the set temperature is reached
Over-cooling (Freezing) prevention

• Evaporator temperature sensor (14) varies the resistance of its resistor according to temperature.
• The air conditioner controller converts the change in resistance of evaporator temperature sensor (14) into
the change in voltage to determine the temperature of evaporator (1).
• The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the
compressor clutch relay (*) to stop the compressor.
*: For details of compressor clutch relay, see "Parts and connectors layout".
Air flow adjustment

• When the air flow adjusting switch on the machine monitor is operated, the set air flow data is sent to the
air conditioner controller. The air conditioner controller controls blower motor (4) by using power transistor
(13) in order to adjust the air flow.
Vent (mode) changeover

• When a vent switch on the machine monitor is operated, mode data is sent to the air conditioner controller.
The air conditioner controller controls mode changeover servomotor (7) to adjust the opening and closing
angles of mode changeover doors (8) to (10) so that the selected vents are available.
HB215LC-2 80-11
80 Appendix
FRESH/RECIRC air changeover

• When the FRESH/RECIRC air selector switch on the machine monitor is operated, the set data of
FRESH/RECIRC air changeover is sent to the air conditioner controller. The air conditioner controller
controls FRESH/RECIRC air changeover servomotor (11) to open or close FRESH/RECIRC air
changeover door (12).
Automatic mode of air conditioner

• Inside air temperature sensor (15) detects the temperature inside operator's cab based on changes in
resistance. The air conditioner controller converts the change in resistance of inside air temperature
sensor (15) into the change in voltage to determine the room temperature.
The air conditioner controller checks the voltage of inside air temperature sensor (15) and controls the
room temperature so that it matches the setting made on the machine monitor.
The air conditioner controller also takes into consideration data from the sunlight sensor and the outer
sensor (outside air temperature sensor) when adjusting the room temperature.
Changeover pattern of the vent (mode) changeover door
Rear door (8) Foot door (9) Defroster door (10)
Opening Opening Opening
and closing Angle and closing Angle and closing Angle
door door door
Front Close 0 Close 0 Close 0
Front and rear Open 25 Close 0 Close 0
Front, rear and Open Open
25 35 Close 0
Air vent foot
mode Foot Open 25 Open 53 Close 0
Foot and Open Open Open
25 23 38
defroster
Defroster Open 25 Open 0 Open 38
Selection pattern of air mix door (6)
Set temperature Opening and closing door Angle (deg.)
Max. Cool Close 0
Max. Hot Open 80
80-12 HB215LC-2
80 Appendix
Functions of major components (ALL-K540-001-K-00-A)
a For details of the numbers in the following sentence, see “Air conditioner unit”.
Evaporator (ALL-K549-042-K-00-A)
• Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion
valve (3).
• Air from blower motor (4) is cooled and dehumidified when passing through the evaporator fins.
Heater core (ALL-K547-042-K-00-A)

• Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from blower
motor (4) is warmed when passing through fins of the heater core (2).
Evaporator temperature sensor (ALL-K5FF-042-K-00-A)

• Evaporator temperature sensor (14) is installed to evaporator (1) with the holder. Its resistance changes in
accordance with the temperature change of the evaporator. The air conditioner controller determines the
temperature of evaporator (1) from voltage changes of evaporator temperature sensor (14) to prevent
freeze of the evaporator.
HB215LC-2 80-13
80 Appendix
Servomotor (ALL-K5D2-042-K-00-A)
a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover.
• When a switch on the machine monitor is operated, the air conditioner controller applies 24V power
between servomotor terminal B (6) and servomotor terminal A (7). (Rotation direction switches according
to the polarity of supply voltage.) )
• The servomotor contains a variable resistor, and its resistance value changes as the motor rotates.
• The air conditioner controller applies a voltage of 5 V to the variable resistor and determines the motor
rotation angle from the potential difference.
• When the door (damper) reaches the position specified by each switch, the air conditioner controller stops
the supply of current to the servomotor, then the corresponding door stops.
• When the air conditioner controller cannot recognize the potential difference that corresponds to the
command to the servomotor, it generates a air conditioner failure code to inform the machine monitor of
failure in air conditioner system. Failure code [879EMC] or [879FMC] is displayed on the electrical system
failure record screen of the machine monitor.
a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore,
does not have a self-diagnosis function.
a Do not try to drive a servomotor by supplying power directly between servomotor terminals (6) and (7)
during inspection.
80-14 HB215LC-2
80 Appendix
Expansion valve (ALL-K548-041-K-00-A)
A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From capacitor (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
Structure
• Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc.
• Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of
needle valve (1a).
• The expansion valve (1) converts high-pressure and high-temperature liquid refrigerant from the receiver
drier to low-pressure, low-temperature misty refrigerant through the throttle action.
• It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in
the cab.
• The temperature of the air blown out of the air vent is adjusted depending on the flow rate of refrigerant
circulating in the evaporator (3).
Operation (ALL-K548-044-K-00-A)
• Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3).
HB215LC-2 80-15
80 Appendix
• After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2)
in the diaphragm chamber (hatched area) through the thermoprobe (1a-2).
• The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in
response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg)
pushing the needle valve (1a).
• The opening level of the needle valve (1a) is determined based on the balance between the reaction force
exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the
needle valve (1a) through the diaphragm (1a-1) in a leftward direction.
• The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the
opening level of needle valve (1a).
When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve
(1a) moves leftward.
• As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the
evaporator (3) is increased to improve cooling capacity. (Condition (A) in previous figure)
When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased.
• 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 reaction force of spring (1b).
• The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is
reduced to lower the cooling capacity. (Condition (B) in previous figure)
80-16 HB215LC-2
80 Appendix
Dual pressure switch
Dual pressure switch (ALL-K5FG-044-K-00-A)
a The dual pressure switch is mounted on the air conditioner hose under the floor.
• The dual pressure switch turns "OFF" when the refrigerant circuit pressure becomes abnormally low or
abnormally high.
• When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch
relay "OFF". As a result, the compressor's magnet clutch is released and air conditioner components are
protected.
Function (ALL-K5FG-042-K-00-A)
a LA or lower: Abnormally low pressure

a HA or higher: Abnormally high pressure
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}
HB215LC-2 80-17
80 Appendix
Air conditioner controller
Air conditioner controller (ALL-K5G4-041-K-00-A)
a See "System Diagrams" for details regarding input/output signals.
80-18 HB215LC-2
80 Appendix
Compressor
Compressor (ALL-K590-041-K-00-A)
A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
Number of cylinders - Bore x Stroke (mm) 10 - 32 x 20.8

Piston capacity (cc/rev) 157.3
Max. allowable speed (rpm) 6,000
Compressor oil DENSO: ND-OIL8 (For R134a)
Compressor oil refill capacity (cc) 180
• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator
into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated
(liquefied) at the normal temperature.
• Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller
activates magnetic clutch (2) built in the compressor.
• When magnetic clutch (2) is engaged, the power of the engine rotates the compressor shaft along with
pulley (1) to drive the compressor.
HB215LC-2 80-19
80 Appendix
Air conditioner condenser
Air conditioner condenser (ALL-K580-041-K-00-A)
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to air conditioner unit)
1. Condenser
2. Modulator
3. Desiccating agent
4. Filter
5. Seal cap
6. O-ring
7. Snap ring
Fin pitch (mm) 4.0

Total heat dissipation surface (m2) 3.58
Max. working pressure (MPa{kg/cm2}) 3.53{36}
Weight of desiccating agent (g) 290
• The condensation section of condenser (1) cools and liquefies the high-pressure and high-temperature
misty refrigerant sent from the compressor.
• The sub-cooling section of condenser (1) further cools the liquid refrigerant that came through modulator
(2) to enhance the cooling efficiency.
• Modulator (2) stores high-pressure and high-temperature liquid refrigerant sent from the condenser. If
bubbles are mixed in the liquid refrigerant depending on heat radiation condition of the condenser, the
refrigerant is liquefied completely.
• Filter (4) and desiccating agent (3) built in modulator (2) eliminate foreign substances in the circulation
circuit and water in the refrigerant.
80-20 HB215LC-2
80 Appendix
Air conditioner condenser
a If its cooling fins are crushed or clogged with dirt and dust, heat exchange efficiency lowers. Accordingly,
the condenser cannot liquefy the refrigerant entirely. The circuit pressure in the refrigerant cycle increases
resulting in unnecessary load on the engine and poor cooling effect. Take care not to crush the fins in
handling and daily maintenance of the condenser.
a Refer to "Desiccant replacement procedure" when replacing desiccating agent (3) in modulator (2).
HB215LC-2 80-21
80 Appendix
Sunlight sensor
Sunlight sensor (ALL-K5FH-041-K-00-A)
1. Connector
2. Sensor
Function (ALL-K5FH-042-K-00-A)
• The sunlight sensor is mounted on top of the machine monitor.

• It detects the strength of incident sunlight and sends signals to the air conditioner controller.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the sunlight sensor in order to adjust the temperature and air flow.
80-22 HB215LC-2
80 Appendix
Outer temperature sensor (outside air temperature
sensor)
Outer temperature sensor (outside air temperature sensor) (ALL-K55C-041-K-00-A)
1. Connector
2. Sensor
Function (HB205-K55C-042-K-00-A)
• The outside air temperature sensor is installed to inverter bracket.

• The outside air temperature sensor has feature of change in resistance by temperature change, therefore,
can detect the ambient temperature.
• The air conditioner controller determines the ambient temperature by converting the changes in the
resistance of the outer sensor resistor into voltage changes.
• Only when the air conditioner is on AUTO mode, the air conditioner controller controls the blower motor
and the air mix servomotor with the data of the outer sensor in order to adjust the temperature and air flow.
HB215LC-2 80-23
80 Appendix
Procedure for testing and troubleshooting
Procedure for testing and troubleshooting (ALL-K500-422-K-00-A)
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
conditioner 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
conditioner 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
*1: By error display or abnormal display on "Electrical Systems" screen on the 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.
80-24 HB215LC-2
80 Appendix
Procedure for testing and troubleshooting
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
disconnecting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
HB215LC-2 80-25
80 Appendix
Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins (HB205-K500-051-K-00-A)
80-26 HB215LC-2
80 Appendix
Circuit diagram and arrangement of connector pins
a Diffuser servomotor means vent (mode) changeover servomotor.

a SERVOMOTOR OF INSIDE/OUTSIDE AIR means FRESH/RECIRC air changeover servomotor.
a Frost sensor means evaporator temperature sensor.
HB215LC-2 80-27
80 Appendix
System diagram
System diagram (HB205-K5F0-051-K-00-A)
Input and output signals of the air conditioner controller (ALL-K5G4-03C-K-00-A)
Controller connector: AMP 025 - 32PM
80-28 HB215LC-2
80 Appendix
System diagram
Wiring harness connector: ACECU
AMP025 - 32PF
Input/Output
Pin No. Symbol Signal name
signal
1 +Bback Backup power supply Input
2 – (*1) –
3 SS Sunlight sensor Input
4 THOUT Outside air temperature sensor Input
5 THF Evaporator temperature sensor Input
6 THI Inside air temperature sensor Input
7 POT5 V Servomotor potentiometer power supply (5 V) Output
8 BWFB Blower feedback signal Input
9 PTRB Power transistor control signal Output
10 CAN_H CAN communication signal (H) Input/output
11 CAN_L CAN communication signal (L) Input/output
12 – (*1) –
13 MRFA Fresh/recirculated air servomotor terminal A Output
14 MRFB Fresh/recirculated air servomotor terminal B Output
15 MAMA Air mix servomotor terminal A Output
16 MAMB Air mix servomotor terminal B Output
17 +24 V 24 V power supply Input
18 – (*1) –
19 SAM Air mix servomotor potentiometer signal Input
20 SVI Vent (mode) changeover servomotor potentiometer signal Input
21 PRESS SW Dual pressure switch Input
22 – (*1) –
23 – (*1) –
24 – (*1) –
25 GNDS Sensor GND Input
26 GND GND Input
27 – (*1) –
28 – (*1) –
29 RLCC Compressor clutch relay Output
30 – (*1) –
31 MV1A Vent (mode) changeover servomotor terminal A Output
32 MV1B Vent (mode) changeover servomotor terminal B Output
Function (ALL-K5G4-042-K-00-A)
• Operation of air conditioner controller

1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air
conditioner unit by inputting switches associated with air conditioning.
2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to
adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air
changeover.
3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch
for activating the compressor).
4. The air conditioner controller controls the air flow volume using the power transistor.
a The power transistor has an overcurrent prevention fuse in it.
5. The air conditioner controller detects the evaporator temperature using the evaporator temperature
sensor.
6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by
turning the compressor clutch relay ON and OFF.
HB215LC-2 80-29
80 Appendix
System diagram
a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner
controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating.
7. When performing automatic air conditioning, the air conditioner controller controls the inside (air)
temperature to the set temperature and adjust the air flow according to the data from the sunlight sensor,
the outside air temperature sensor, and the inside air temperature sensor.
8. The air conditioner controller has the self-diagnosis function. If any abnormality is detected, the controller
notifies it to the machine monitor by the CAN communication. Then, failure code [879***] is displayed on
the "Electrical Systems" screen of the electrical system on the machine monitor.
80-30 HB215LC-2
80 Appendix
Parts and connectors layout
Parts and connectors layout (HB205-K500-055-K-00-A)
• Three fuses related to the air conditioner are located in the fuse box at the right rear of the operator's seat.
• The air conditioner unit is installed behind the rear cover at the rear of the operator's seat.
k Park the machine on a level ground, swing the upper structure by 90 ° , lower the work equipment
to the ground stably, and stop the engine.
k Turn the battery disconnect switch to the "OFF" position and pull out the key.
a Note connector numbers and installed positions before disconnecting wiring and hoses.
Item No. to be
Connector No. Remarks Location
referred to
AC01 Intermediate connector Rear right of cab 2.
AC02 Intermediate connector Rear right of cab 2.
AC03 Air conditioner compressor Engine 7.
ACECU Engine controller Rear of cab 2.
CM01* Machine monitor Front of cab 5.
CM02 Machine monitor Front of cab 5.
F01 Fuse box Rear right of cab 1.
Dual pressure switch
P17 Under cab 6.
a Turn the upper structure by 90 °.
P18 Outside air temperature sensor Cooling unit 8.
P31 Sunlight sensor Machine monitor 4.
R21 Relay Rear of cab 2.
[2] Power transistor Air conditioner unit 3.
[5]* FRESH/RECIRC air changeover
Air conditioner unit 3.
servomotor
[6]* Inside air temperature sensor Air conditioner unit 3.
Evaporator temperature sensor (frost
[7]* Air conditioner unit 3.
sensor)
*: Connectors that are not involved in the troubleshooting
Details (HB205-K500-04D-K-01-A)
1. Fuses in fuse box F01

Open the cover of fuse box at the rear right of the operator's seat.
• No. 10 (20 A): Fuse for power supply to blower (fan) and air conditioner compressor
• No. 13 (5 A): Fuse for air conditioner unit, air conditioner controller and primary side power supply of
electromagnetic clutch relay of air conditioner compressor
• No. 19 (5 A): Fuse for power supply (backup power supply) to air conditioner controller
HB215LC-2 80-31
80 Appendix
2. Air conditioner controller: *1

• AC01: Intermediate connector
• AC02: Intermediate connector
• ACECU: Air conditioner controller connector
• R21: Air conditioner compressor solenoid clutch relay connector

a [2], [5], [6], and [7] are unlabeled connectors.
a Rear side of air conditioner unit (Connectors cannot be disconnected while the unit is mounted on the
machine except connector [2])
[2]: Power transistor (*2) connector
[5]: FRESH/RECIRC air changeover servomotor connector
[6]: Inside air temperature sensor connector
[7]: Evaporator temperature sensor connector
*2: Power transistor
80-32 HB215LC-2
80 Appendix
4. Sunlight sensor
P31: Sunlight sensor connector
5. Machine monitor
• CM01 to CM04: Machine monitor connector
a Connector CM03: (Unused)
a Connector CM04: (for camera connection)
6. Dual pressure switch

a Remove the cab undercover by turning it 90 deg.
• P17: Dual pressure switch connector
HB215LC-2 80-33
80 Appendix
7. Air conditioner compressor

a Open the engine hood.
• AC03: Air conditioner compressor connector
8. Outside air temperature sensor

P18: Outside air temperature sensor connector
80-34 HB215LC-2
80 Appendix
Testing air leakage (duct)
Testing air leakage (duct) (ALL-K5D0-001-K-00-A)
k Place the machine on a level ground, lower the work equipment to the ground and stop the engine.
k Turn the battery disconnect switch to the OFF position and remove the key.
a Note the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
Check (ALL-K5D0-360-K-00-A)
1. Lift front window assembly (1) to the ceiling and lock it.
a Check that the front window is securely locked.
3. Remove floor mat (3).
4. Remove cover (4) first, and then remove cover (5).
6. Remove cap (7-1).

a Disconnect the sunlight sensor connector from the rear of cover (7).
8. Remove drink box (8) (five bolts).

a Disconnect the hose under drink box (8).
9. Remove magazine box (9) (three bolts).
a Be careful about connectors (10) and (11) behind magazine box (9). (for machines equipped with 12 V
power socket)
• Connector (10): 12 V power socket intermediate harness (M13A)
• Connector (11): 12 V power socket intermediate harness (M13B)
10.Pull up cover (12) (three bolts) to remove.
a The connectors and wiring harnesses at the rear must not be caught.
HB215LC-2 80-35
80 Appendix
11.Remove cover (13) (seven bolts).

a Be careful about connector (14) behind cover (13).
12.Check the following ducts and pins for disconnection.

• Front duct (15)
• Defroster duct (16)
• Rear duct (17)
• Fresh air inlet duct (18) and pin (19)
80-36 HB215LC-2
80 Appendix
HB215LC-2 80-37
80 Appendix
Testing with self-diagnosis function
Testing with self-diagnosis function (ALL-Q19Y-001-K-00-A)
Testing outline (HB205-Q19Y-360-K-00-A)
The air conditioner controller self-checks the the refrigerant pressure by using the outside air temperature
sensor, inside air temperature sensor, evaporator temperature sensor, temperature control switch, vent
selector mode, sunlight sensor, and dual pressure switch. If abnormally related to the temperature control,
vent (mode) selection, or refrigerant among them occurs, the machine monitor changes to the warning screen
momentarily, and then continues displaying "Air conditioner system state monitor".
a The machine monitor displays the system state monitor "!" when an error occurs in the communication
between the machine monitor and the air conditioner controller.
a The system performs self-diagnosis of various sensors. If any failure is detected, a failure code is
displayed on the "Electrical Systems Abnormality Record" screen in the service mode of the machine
monitor.
a Once a failure is detected in the self-diagnosis, the error condition is not canceled even if the failed part
returns to normal.
Turning the starting switch "OFF" clears a failure.
a FRESH/RECIRC air changeover servomotor is not checked in the self-diagnosis.
How to open the electrical system abnormality record screen in service mode
of the machine monitor (HB380-Q19Y-100-K-00-A)
• Overview of machine monitor operating procedure
1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order.
2. Press [F3] 2 times on the Service Menu screen, and press [F6].
3. Press [F3] 1 time on the Abnormality Record screen, and press [F6].
• Detailed description of machine monitor operating procedure
1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order.
2. Press [F3] twice on the Service Menu screen to select "03 Abnormality Record".
3. Validate the selection by pressing [F6].
80-38 HB215LC-2
80 Appendix
4. Press [F3] once on the Failure Record screen to select "02 Electrical System Abnormality Record".
5. Validate the selection by pressing [F6].
a For details, see the failure code list related to air conditioner.
Failure code Failure (Displayed on screen) Remarks
Air Conditioner Inner Sensor Open
879AKA
Circuit
*
Air Conditioner Inner Sensor Short
879AKB
Circuit
Air Conditioner Outer Sensor Open
879BKA
Circuit
Air Conditioner Outer Sensor Short
879BKB
Circuit
879CKA Ventilating Sensor Open Circuit
*
879CKB Ventilating Sensor Short Circuit
Sunlight Sensor Open or Short
879DKZ
Circuit
879EMC Ventilation Damper Abnormality *
879FMC Air Mix Damper Abnormality *
879GKX Refrigerant Abnormality
DAZ9KQ Inconsistency of Model Selection
See Chapter 40, "Troubleshooting
CAN2 Disconnection (Air by failure code"
DAZQKR Conditioner ECU)
*: Troubleshooting cannot be performed while the controller is mounted on the machine since the connector
cannot be checked.
**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
HB215LC-2 80-39
80 Appendix
a The air mix damper means the temperature adjustment (air mix) damper (door).
80-40 HB215LC-2
80 Appendix
Testing vent (mode) changeover
Testing vent (mode) changeover (ALL-K5FR-001-K-00-A)
Testing (ALL-K5FR-360-K-00-A)
1. Remove drink box (1) (five bolts).

a Disconnect the hose under drink box (1).
2. Remove magazine box (2) (three bolts).
a Be careful about connectors (3) and (4) behind magazine box (2). (for machines equipped with 12 V
power socket).
• Connector (3): 12 V power socket intermediate harness (M13A)
• Connector (4): 12 V power socket intermediate harness (M13B)
3. Remove cover (5) (three bolts).
4. Remove cover (6) (seven bolts).

a Be careful about connector (7) behind cover (6).
HB215LC-2 80-41
80 Appendix
Testing vent (mode) changeover
5. Remove ducts (8) and (9).
6. Turn the battery disconnect switch to the "ON" position.

7. Start the engine and turn the air conditioner power "ON".
8. Operate the vent changeover switch on the machine monitor.
9. Check the opening/closing operation of rear door (11) and defroster door (12) of air conditioner unit (10).
10.After finishing the inspection, turn the starting switch to the OFF position.
80-42 HB215LC-2
80 Appendix
Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air changeover (ALL-K5D2-001-K-00-A)
Testing (ALL-K5D2-360-K-00-A)
1. Open outside air filter cover (1) and remove outside air filter (2).
2. Start the engine and turn the air conditioner power "ON".
3. Operate the FRESH/RECIRC air selector switch on the machine monitor.
4. Check the opening/closing operation of FRESH/RECIRC air changeover rear door (3) through the fresh
air inlet on the left side of the cab.
5. After finishing the inspection, turn the starting switch to the OFF position.
HB215LC-2 80-43
80 Appendix
Testing sunlight sensor
Testing sunlight sensor (PC220-K5FH-001-K-00-A)
Testing (PC220-K5FH-360-K-01-A)
1. Remove the machine monitor cover. For details, see "Testing air leakage (duct)", Steps 6 and 7.
2. Check connector P31 at the rear of the sunlight sensor. (Check whether the connector is coming off.)
3. Disconnect connector P31, remove the sunlight sensor, and measure the voltage between the terminals
on the sensor side using a circuit tester in voltage range.
• Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
80-44 HB215LC-2
80 Appendix
Testing (dual) pressure switch for refrigerant
Testing (dual) pressure switch for refrigerant (PC220-K5FG-001-K-00-A)
Testing (PC220-K5FG-360-K-01-A)
1. Swing by 90 ° .
2. Remove the cab undercover.
3. Disconnect the dual pressure switch connector P17.
4. 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 dual 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 service tool" and
"Troubleshooting with gauge pressure."
a If the refrigerant pressure is normal, the dual pressure switch is defective.
• (Dual) pressure switch
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}
k When replacing the dual pressure switch, refrigerant must be collected in advance.
a If resistance between the switch-side terminals from connector P17 is shorted (ON), perform
"Troubleshooting for compressor and refrigerant system".
HB215LC-2 80-45
80 Appendix
Testing relays
Testing relays (PC220-K5FE-001-K-00-A)
Testing (PC220-K5FE-360-K-03-A)
1. Check contact R21 of connector (for disconnection).

2. Turn the starting switch ON (do not start the engine), turn the main power of the air conditioner ON, and
turn the air conditioner switch. If the compressor relay is normal, it is turned ON. Check whether it clicks.
a The air conditioner controller will not turn on the compressor clutch relay 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 abnormality (it is turned OFF).
• 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.
Compressor clutch relay (CCRL), connector (AC04)
1. The coil resistance between terminals (1) and (2) is approximately 370 to 530 z.
2. While voltage (DC 20 to 30 V) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are
connected.
3. While voltage (DC 20 to 30 V) is applied between terminals (1) (+) and (2), terminals (3) and (5) are
connected.
80-46 HB215LC-2
80 Appendix
Troubleshooting chart 1
Troubleshooting chart 1 (PC220-3840-421-A-00-A)
Numbers in T represent the item numbers in the troubleshooting quick reference table.
1. Lowered cooling performance
2. Lowered heating performance
HB215LC-2 80-47
80 Appendix
Troubleshooting chart 2 (PC220-3840-421-A-01-A)
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Check the connector for disconnection. Repair broken parts
Wire breakage or defective and connect
connection See "Parts and connectors layout". correctly
Operate the fan switches in order and check the fan
Defective blower fan motor speed. Replace
See "Air conditioner unit".
Defective power transistor Operate the fan switches in order and check the fan
Replace
(PTR) speed.
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check duct joints.
Repair
joints See "Testing air leakage (duct)".
Obstruction at evaporator Check evaporator for stain and obstruction Remove obstruction
inlet and clean
Defective evaporator Evaporator is frozen.
temperature sensor, Sensor fixing clip inspection, sensor contaminated
defective contact of Repair or replace
evaporator temperature Inspect the air conditioner hose around the pressure
switch for frost.
sensor, 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.
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 Collect refrigerant,
connected. then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 to 0.2 MPa {1.3 to 2.0 kg/
cm2 }
Judgment by pressure at See Troubleshooting
inlet/outlet of compressor High pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2 with gauge pressure
}
Temperature in operator's cab: 30 to 35 °C , Engine
speed: Approx. 1,500 rpm
80-48 HB215LC-2
80 Appendix
4. During cooling, the compressor will not operate smoothly, or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled
part
Deflection of belt is large.
Compressor See "Checking and adjusting air
belt
Slack of belt conditioner compressor belt tension" in Adjust tension
the "Testing and adjusting" in Chapter
30.
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling
Heating of compressor
Seizing on compressor compressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 to 20 z) Replace
Magnet
Check ground cable and joints.
clutch Wire breakage or defective
connection of ground wire See "Troubleshooting for compressor Repair
and refrigerant system".
Defective compressor clutch
Relay See "Testing relays" Replace
relay
See
Refrigerant Low/high pressure (Operation See "Troubleshooting with gauge "Troubleshooting
pressure of pressure switch) pressure". with gauge
pressure".
See "Troubleshooting for compressor
Pressure and refrigerant system".
Defective pressure switch Replace
switch See "Testing refrigerant (dual) pressure
switch".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check the duct joints by referring to "Testing air leakage
Repair
joints (duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling
Low engine coolant Warm up engine, and then check engine coolant
temperature temperature Find out cause
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging.
engine coolant Bleed air and correct
(Hose, pipe and core)
The connection of IN and
OUT heater hoses is in Check the destination of heater hoses Correct
reverse.
7. Fan speed abnormalities during cooling
See "Replacing fan belt" in "Testing and adjusting" in
Fan speed is low Replace
Chapter 30.
HB215LC-2 80-49
80 Appendix
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be Select manual mode and change temperature setting.
controlled
Vent (mode) changeover is Common to cooling
See "Testing vent (mode) changeover".
not possible. and heating
FRESH/RECIRC air cannot
See "Testing FRESH/RECIRC air changeover".
be changed over
Excessive compressor oil See "Handling of compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
80-50 HB215LC-2
80 Appendix
Information in troubleshooting table
Information in troubleshooting table (ALL-5170-421-A-03-A)

Information in troubleshooting table
Failure Failure symptom that appears on machine
Related information Information on occurred failure or troubleshooting
[Information described]
• Procedure
• Measuring location
1
a "Between A and B" denotes measuring voltage or resistance, etc.
Probable cause of failure between A and B.
(Perform troubleshooting • Criteria to determine probable causes
according to these.) • Remarks for judgment of Good or No good
[Notes on troubleshooting]
2 (1) pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (-) tester leads
as shown below unless otherwise specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (-) lead to a pin or harness indicated in the
rear.
3 Defective — (2) Example of troubleshooting done by testing multiple items
a Normal in 1 but abnormal in 2
At this time, "Defective component" shown at left 3 is applied.
a If a wiring harness is burnt, replace it.

[Defective wiring harness]
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power (24V) circuit comes into contact with the power (24V) circuit
accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with another independent wire. (poor
insulation at connector and others)
Related circuit diagram

This is the extracted circuit diagram related to failure
• Indicates connector No., and pin No.
• See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for
connector location
• 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.
• N.C.: Normally closed (Normally ON)
• [1], [2], ... are numbers of unlabeled connectors.
• The arrow (io) indicates their rough installation position on the machine.
HB215LC-2 80-51
80 Appendix
Failure code list related to air conditioner
Failure code list related to air conditioner (ALL-K500-441-K-00-A)

Compo-
Failure Failure (Displayed on screen) nent in Action Category
Remarks
code charge level of record
A/C Inner Sensor Open Electrical Troubleshooting cannot be
879AKA MON –
Circuit system performed while the controller
is mounted on the machine
A/C Inner Sensor Short Electrical
879AKB MON – since the connector cannot
Circuit system
be checked.
A/C Outer Sensor Open Electrical
879BKA MON –
Circuit system
A/C Outer Sensor Short Electrical
879BKB MON –
Circuit system
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON –
Circuit system performed while the controller
Ventilating Sensor Short Electrical
879CKB MON – since the connector cannot
Circuit system
be checked.
Sunlight Sensor Open or Electrical
879DKZ MON –
Short Circuit system
Ventilation Dumper Electrical Troubleshooting cannot be
879EMC Abnormality MON L01 system performed while the controller
Electrical
879FMC Air Mix Dumper Abnormality MON L01 since the connector cannot
system
be checked.
Electrical
879GKX Refrigerant Abnormality MON L01 system
A/C Model Selection Electrical
DAZ9KQ Abnormality MON –
system See Chapter 40,
"Troubleshooting by failure
Electrical
DAZQKR CAN2 Discon (Aircon ECU) MON L01 code"
system
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The vent damper means the vent (mode) changeover damper (door).
a The Air Mix Damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes is explained after failure code
[879GKX].
• Troubleshooting for power supply system (Air conditioner does not operate)
• Troubleshooting for compressor and refrigerant system (Air is not cooled)
• Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
• Troubleshooting for FRESH/RECIRC air changeover
80-52 HB215LC-2
80 Appendix
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKA] A/C Inner Sensor Open Circuit (D155-879AKA-400-A-00-A)
Action level Failure code Open circuit in air conditioner inside air temperature sensor
Failure
- 879AKA (Machine monitor system)
Detail of • Air conditioner controller detected open circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of open circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
• Check whether this failure code is displayed on the "Electrical Systems" screen in service
Related mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
Defective air conditioner Air conditioner controller may be defective. (Since this is an internal
1 defect, troubleshooting cannot be performed.)
controller
Air conditioner unit may be defective. (Since this is an internal defect,
2 Defective air conditioner unit troubleshooting cannot be performed.)
HB215LC-2 80-53
80 Appendix
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit (D155-879AKB-400-A-00-A)
Action level Failure code Short circuit in air conditioner inside air temperature sensor
Failure
- 879AKB (Machine monitor system)
Detail of • Air conditioner controller detected short circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
• Check whether this failure code is displayed on the electrical system abnormality record
Related screen in service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
controller
80-54 HB215LC-2
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit
Failure code [879BKA] A/C Outer sensor Open Circuit (PC220_10-879BKA-400-A-00-A)
Action Air conditioner outside air temperature sensor disconnection

Failure code
level Failure
— (Machine monitor system)
879BKA
Details of • Air conditioner controller detected disconnection in outside (air) temperature sensor.
failure
• The air conditioner controller sends information about the outside (air) temperature
Action of sensor disconnection to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside (air)
temperature sensor.
• Since the air conditioner outside temperature sensor has a disconnection, outside
Problem on temperature is not counted in automatic mode.
machine (The air conditioner is not affected in manual mode)
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
electrical system in the service mode of the machine monitor.
• For connectors and other parts, see "Parts and connectors layout".
• Since connector ACECU of the air conditioner controller has small pins and does not
Related have a T-adapter, carry out troubleshooting by using the intermediate connector
information (Although the intermediate connector does not have a T-adapter either, it does have large
pins).
• If the air conditioner wiring harness between connector ACECU of the air conditioner
controller and the intermediate connector needs to be replaced, the air conditioner unit
must be replaced.
1. Turn starting switch to "OFF" position.
Defective outside
1 air temperature
sensor Between P18
Resistance 25°C Approx 1.7 kz
(male) (1) and (2)
Open circuit or 2. Disconnect connector AC01.
2 short circuit in a Same as above, if resistance is normal
wiring harness
Between AC01
a If cause 2 is not the cause for the failure, this check is not required.
Breaking of 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors P18 and AC01.
3 (Wire breakage or Between AC01 (female) (7) and P18
defective contact of (female) (1) Max. 1 z
connectors) Resistance
Between AC01 (female) (8) and P18
Defective air If no failures are found by the above checks, the air conditioner controller may be
4 conditioner defective.
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
5
conditioner unit
HB215LC-2 80-55
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit
Circuit diagram related to air conditioner outside air temperature sensor
80-56 HB215LC-2
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit
Failure code [879BKB] A/C Outer sensor Short Circuit (PC220_10-879BKB-400-A-00-A)
Action Air conditioner outside air temperature sensor short circuit

Failure code
level Failure
879BKB
Details of • Air conditioner controller detected short circuit in outside (air) temperature sensor.
failure
• The air conditioner controller sends information about the outside (air) temperature
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside (air)
temperature sensor.
• Since air conditioner outside temperature sensor has short circuit, outside temperature is
Problem on not counted in automatic mode.
pins).
must be replaced.
1. Turn starting switch to "OFF" position.
Defective outside
1 air temperature
sensor Between P18
(male) (1) and (2)
Open circuit or 2. Disconnect connector AC01.
2 short circuit in a Same as above, if resistance is normal
wiring harness
Between AC01
a If cause 2 is not the cause for the failure, this check is not required.
Short-circuiting of 1. Turn starting switch to OFF position.
3 2. Disconnect connectors P18 and AC01.
harness
Between AC01 (female) (7) and (8), or
Resistance between P18 (female) (1) and (2) Min. 1 Mz
harness 2. Disconnect connectors P18 and AC01.
4
(Contact with GND Between ground and AC01 (female) (8)
circuit) Resistance or P18 (female) (1) Min. 1 Mz
6
conditioner unit
HB215LC-2 80-57
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit
Circuit diagram related to air conditioner outside air temperature sensor
80-58 HB215LC-2
80 Appendix
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit (D155-879CKA-400-A-00-A)
Action level Failure code Open circuit in evaporator temperature (frost) sensor
Failure
- 879CKA (Machine monitor system)
Detail of • Air conditioner controller detected open circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor open circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to an open circuit in the evaporator temperature
machine (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
controller
HB215LC-2 80-59
80 Appendix
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit (D155-879CKB-400-A-00-A)
Action level Failure code Short circuit in evaporator temperature (frost) sensor
Failure
- 879CKB (Machine monitor system)
Detail of • Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a short circuit in the evaporator temperature
machine (frost) sensor.
• Method of reproducing failure code: Starting switch ON
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
controller
80-60 HB215LC-2
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit (PC220_10-879DKZ-

400-A-00-A)
Action Sunlight sensor disconnection or short circuit
Failure code
level Failure
879DKZ
Details of • Air conditioner controller detected disconnection or short circuit in sunlight sensor.
failure
• The air conditioner controller sends information about sunlight sensor disconnection or
Action of short circuit to the machine monitor via CAN communication.
controller • Continues control of the air conditioner in automatic mode, ignoring sunlight sensor data.
• Since the air conditioner sunlight sensor has a disconnection or short circuit, sunlight
Problem on strength is not counted in automatic mode.
pins).
must be replaced.
1. See "Testing sunlight sensor".
Defective sunlight Direct sunlight Approx. 0.55 V
1 Between sunlight
sensor Voltage Cloudy Approx. 0.45 V
sensor terminals
Indoor Approx. 0.4 V
Breaking of 2. Disconnect connector P31.
harness a See "Testing sunlight sensor".
2 (Wire breakage or Between P31 (female) (1) and AC01
defective contact of (female) (10) Max. 1 z
connectors) Resistance
Between P31 (female) (2) and AC01
4
conditioner unit
HB215LC-2 80-61
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Circuit diagram related to sunlight sensor
80-62 HB215LC-2
80 Appendix
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879EMC] Ventilation Damper Abnormality (D155-879EMC-400-A-00-A)
Action level Failure code Abnormality in vent (mode) changeover damper servomotor
Failure
L01 879EMC (Machine monitor system)
Detail of • Air conditioner controller judged from potentiometer voltage of servomotor that vent
failure (mode) changeover damper servomotor is not operating.
Action of • The air conditioner controller sends information about the abnormality in vent (mode)
controller changeover damper to the machine monitor via CAN communication.
Problem on • Vent (mode) cannot be changed but air conditioner can be operated.
machine
information • Troubleshooting cannot be performed since the connector portion of vent (mode)
changeover damper servomotor cannot be checked while the air conditioner unit is
installed on the machine.
controller
HB215LC-2 80-63
80 Appendix
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality (D155-879FMC-400-A-00-A)
Action level Failure code Abnormality in air mix (temperature control) damper
Failure servomotor
L01 879FMC
Detail of • The air conditioner controller judged from the potentiometer voltage of the servomotor that
failure the air mix (temperature regulation) damper servomotor is not operating.
Action of • The air conditioner controller sends information about the air mix damper abnormality to
controller the machine monitor via CAN communication.
Problem on • The air conditioner does not operate since temperature cannot be regulated.
machine
Related
screen in service mode of the machine monitor.
information
• Troubleshooting cannot be performed since the connector portion of the air mix damper
servomotor cannot be checked while the air conditioner unit is installed on the machine.
controller
80-64 HB215LC-2
80 Appendix
Failure code [879GKX] Refrigerant Abnormality
Failure code [879GKX] Refrigerant Abnormality (PC220_10-879GKX-400-A-00-A)
Action Refrigerant (dual) pressure switch abnormality

Failure code
level Failure
L01 879GKX
Details of • Air conditioner controller detected that dual pressure switch was OFF (abnormal).
failure
• The air conditioner controller sends information about the refrigerant pressure
abnormality to the machine monitor via CAN communication.
Action of • The air conditioner controller turns OFF compressor clutch relay, since refrigerant
controller pressure is abnormal.
(The air conditioner compressor stops)
Problem on • The air conditioner (cooling) does not operate.
machine
• For each connector and other parts, see "Parts and connectors layout".
pins).
must be replaced.
Defective 1. See "Testing (dual) pressure switch for refrigerant".
1 refrigerant (dual)
k When replacing the dual pressure switch, be sure to collect refrigerant in
pressure switch
advance. See "Precautions for refrigerant".
Breaking of
2. Disconnect connector AC01 and P17.
harness
Between P17 (female) (1) and AC01
2 (Wire breakage or (female) (6) Max. 1 z
defective contact of Resistance Between P17 (female) (2) and ground
connectors) Max. 1 z
a Looseness and rust of T06
4
conditioner unit
Circuit diagram related to (dual) pressure switch for refrigerant
HB215LC-2 80-65
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)
A-1 Troubleshooting for power supply system (Air conditioner does not
operate) (HB205-FJ0-400-A-00-A)
• Air conditioner does not operate due to power supply system failure.
Failure • [DAZQKR] is displayed on the operation screen of machine monitor.　
• No air blows out (Blower motor does not rotate).
• If failure code [DAZQKR] is displayed on the machine monitor, perform this
troubleshooting first.
a The machine monitor, engine controller, pump controller, inverter (hybrid controller), and
air conditioner controller are connected via CAN communication.
• [DAZQKR] is displayed on operation screen of machine monitor in any of the following
cases. 1) and 2) of these will be covered here.
1) The air conditioner controller is receiving no power.
2) The air conditioner controller is broken.
3) No communication is possible between the air conditioner controller and the machine
monitor.
a For 3), see failure code [DAZQKR].
• Turn the starting switch ON, and check whether failure code [DAZQKR] for an
Related abnormality in CAN communication is displayed. An abnormality in CAN communication
information refers to the state in which CAN communication between the air conditioner controller on
the air conditioner unit and the machine monitor is disabled.
• Referring to "Layout drawing of parts and connectors", check fuse No. 13 (5 A) in fuse
box F01 for breakage.
• Ground cable of air conditioner is connected in machine wiring harness together with
electrical equipment of machine.
• For each connector, see "Layout drawing of parts and connectors".
• In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for
compressor and refrigerant system."
• Since T-adapter is not provided for the connector ACECU of the air conditioner controller
and the pin size is small, use the intermediate connector for troubleshooting (T-adapter is
also not provided for the intermediate connector, however, the pin size is larger).
• When replacing the air conditioner wiring harness between connector ACECU of the air
conditioner controller and the intermediate connector, you must replace the entire air
conditioner unit.
Defective wiring 2. Turn the battery disconnect switch to OFF position.
1 harness (ground) 3. Disconnect connector AC02.
Between (1) (black) on harness side of
Resistance connector AC02 and chassis ground Max. 1 z

2 Blown fuse 2. Referring to "Layout drawing of parts and connectors", check fuse No. 13 (5 A)
in fuse box F01 for breakage.
a If fuse described in Related information is blown, replace it.
Defective wiring 3. Disconnect connector AC02.
3
harness 4. Turn the battery disconnect switch to ON position.
Between connector AC02 (female) (4)
Voltage 20 to 30 V
(green) and (1) (black)
Ground fault in a If a fuse is blown again in the above test, perform the following procedure.
machine wiring
4 2. Turn the battery disconnect switch to OFF position.
(Contact with 3. Disconnect connector AC02.
ground circuit) 4. Remove fuse No. 13 from fuse box F01.
80-66 HB215LC-2
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)

Between ground and connector AC02
Resistance (female) (4) (green) or F01-13 Min. 1 Mz

wiring harness 2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector AC02.
5 (Wire breakage or
4. Remove fuse No. 13 from fuse box F01.
Between connector AC02 (female) (4)
connector) Resistance (green) and F01-13 Max. 1 z
Defective air
6 conditioner Replace the air conditioner controller.
controller
Defective air If no failure is found by the above checks, the air conditioner unit may be defective.
7
conditioner unit (Since this is an internal defect, troubleshooting cannot be performed.)
Defective machine When test result for cause 1 through 7 is normal, machine monitor is defective.
8
monitor
Circuit diagram related to power supply system
HB215LC-2 80-67
80 Appendix
A-2 Troubleshooting for compressor and refrigerant
system (Air is not cooled)
A-2 Troubleshooting for compressor and refrigerant system (Air is not

cooled) (HB205-FKE-400-A-Z0-A)
Air is not cooled due to compressor or refrigerant system failure.
Failure
• When engine is started and A/C switch is pressed on air conditioner screen of machine
Problem on monitor, air is not cooled as displayed on screen.
machine • Air conditioner compressor does not operate.
• Referring to inspection by self-diagnosis function, display the "Electrical Systems" screen
on the machine monitor to check whether an inappropriate refrigerant is being used by
confirming that failure code [879GKX] is displayed. If an inappropriate refrigerant is being
used, the compressor is not turned on, and air is not cooled.
a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the
dual pressure switch is not grounded".
• In certain cases, the air conditioner will not turn on at 3°C or lower (normal).
Related • When air does not come out, see "Troubleshooting of blower motor system".
information • For each connector and fuse, see "Parts and connectors layout".
a A T-adapter is provided only for the connector AC03.
also not provided for the intermediate connector, however, the pin size is larger).
• When replacing the air conditioner wiring harness between connector ACECU of the air
conditioner unit.
a This troubleshooting is performed when failure code [879GKX] is
displayed on the "Electrical Systems" screen of the machine monitor.
See failure code [879GKX].
Defective dual pressure a In certain cases, the dual pressure switch may be operating normally and
1 switch system set to OFF position, therefore, if abnormality is indicated (i.e., switch OFF),
attach a pressure gauge to the air conditioner compressor and check the
refrigerant pressure. (See "Troubleshooting with gauge pressure.")
k Before replacing pressure switch, collect refrigerant.
2. Disconnect the connector AC03 from the air conditioner compressor and
connect a T-adapter to the male side.
Defective air conditioner a Ensure connection of air conditioner compressor ground cable (E).
2 compressor (See "Parts and connectors layout".)
Between connector AC03 (male) (1) and the Approx. 15
Resistance chassis ground (i.e., air conditioner compressor coil z
resistance)
80-68 HB215LC-2
80 Appendix

• Referring to "Testing relays", check sound when compressor clutch relay
is turned ON.
Clicking sound is heard. — A
a When A above is abnormal and B below is abnormal and C is normal (if
the relay is normal), go to cause 4.
2. Disconnect connector R21.
Defective compressor 3. Use a wire to short-circuit (3) (white) and (5) (red line on yellow base) of
3 clutch relay (does not connector R21 (wiring harness side). (This forces the compressor to
turn ON) operate without using the relay.)
Air is cooled. — B
Approx. 300
Between R21 (male) (1) and (2) (coil to
Resistance resistance) C
530 z
a Make sure that result of check of cause 2 is normal (air conditioner
compressor is normal).
Between connector R21 (female) (5) and F01-10
Open circuit in wiring Max. 1 z
4 (When dual pressure switch is ON.)
harness
Between connector R21 (female) (3) and chassis
Approx. 15
Resistance ground z
(Air conditioner compressor coil resistance)
Between F01-14 and AC01 (female) (4) 300 to 530
a Relay coil resistance z
Ground fault in wiring a If the fuse is not blown, skip troubleshooting.

5 2. Disconnect connectors AC03 and R21, and connect a T-adapter to the
circuit) female side of AC03.
Resistance Between AC03 (female) (1) and chassis ground Min. 1 Mz
2. Disconnect connectors AC01, AC02, and R21.
6 a Ensure that test result for cause 2 is normal.
harness
Between wiring harness side (2) of connector R21
Resistance and AC02 (female) (2), (3)*, and (4) Min. 1 Mz

Defective air conditioner 4. Display the air conditioner operation screen on the machine monitor and
7
controller press the A/C switch.
Voltage Between connector R21 (female) (2) and ground Max. 1 V
Defective machine 1. Turn starting switch to ON position.

8 monitor 2. Display the air conditioner operation screen on the machine monitor.
(Defective switch) Press A/C switch. "A/C ON" is displayed
Defective air conditioner If no failure is found by the above checks, the air conditioner unit may be
9
unit defective.
*: For details of pin 3 of AC02, see "A-1 Troubleshooting for power supply system (Air conditioner does not
operate)".
HB215LC-2 80-69
80 Appendix
Circuit diagram related to compressor and refrigerant system
80-70 HB215LC-2
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
A-3 Troubleshooting for blower motor system (No air comes out or air
flow is abnormal) (PC220_10-FK3-400-A-00-A)
Failure No air comes out or air flow is abnormal due to blower motor system failure.
• This failure is not checked with self-diagnosis function.
• 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 3 A from
"Troubleshooting for compressor and refrigerant system")
2. Detachment of the evaporator temperature sensor's mounting holder (Replace the air
conditioner unit)
3. Incorrect adjustment of expansion valve (Replace air conditioner unit)
• If air comes out, fuse and motor are normal, and also wiring harness is normal.
• For connectors and power transistor, see "Parts and connectors layout".
Related
information a The power transistor is on the rear side of the air conditioner unit.
• If air comes out but its flow is abnormal in heating mode, replace power transistor. (When
no air comes out, the power transistor may also be defective.)
a The blower motor cannot be replaced unless the air conditioner unit is removed once.
have a T-adapter, carry out troubleshooting by using the intermediate connector
(Although the intermediate connector does not have a T-adapter either, it does have large
pins).
must be replaced.
Defective fuse No. If fuse is blown, circuit probably has ground fault.
1
10 in fuse box F01
Defective power 2. Replace power transistor.
2
transistor a If air comes out and air flow can be adjusted, the original power transistor is
defective.
Breaking of 1. Turn starting switch to OFF position.
harness 2. Disconnect connector AC02.
3 (Wire breakage or 3. Remove fuse No. 10 of fuse box F01.
connectors) Resistance Between AC02 (female) (2) and F01-10 Max. 1 z

harness 2. Disconnect connectors AC02 and R21.
4 3. Remove fuse No. 10 of F01.
(Contact with GND
Between AC02 (female) (2) or F01-10
circuit) Resistance and ground Max. 1 z
5 conditioner defective. (Since this is an internal defect, troubleshooting cannot be performed.)
controller
6
conditioner unit
HB215LC-2 80-71
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
Circuit diagram related to blower motor system
80-72 HB215LC-2
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
A-4 Troubleshooting for FRESH/RECIRC air changeover (HB205-FKF-400-A-00-A)
Failure • FRESH/RECIRC air changeover does not work.

• FRESH/RECIRC air changeover is not checked with self-diagnosis function.
• Operate FRESH/RECIRC air selector switch and check operation of FRESH/RECIRC air
changeover door (damper). For details, see "Testing FRESH/RECIRC air changeover".
• For each connector, see "Parts and connectors layout".
a The T-adapter is not prepared for the connector.
Related also not provided for the intermediate connector, however, the pin size is larger).
information • When replacing the air conditioner wiring harness between connector ACECU of the air
conditioner unit.
screen in service mode of the machine monitor.
• Troubleshooting cannot be performed since the connector portion of the servomotor
cannot be checked while it is installed on machine.
Defective fuse No.19 in fuse If fuse is blown, circuit probably has ground fault.
1
box F01
a Connector [5] installed on machine cannot be disconnected since it
is on the rear side of the air conditioner unit.
2 (Wire breakage or defective 2. Disconnect connector AC02.
contact of connector) 3. Remove fuse No. 19 of fuse box F01.
Resis- Between F01-19 and AC02 (female) (3)
Max. 1 z
tance
Ground fault in wiring harness 2. Disconnect connector AC02.
3 3. Remove fuse No. 19 of fuse box F01.
Resis- Between F01-19 and ground, or between
AC02 (female) (3) and ground Min. 1 Mz
tance
If no failures are found by the above checks, the air conditioner
Defective air conditioner controller may be defective. (Since this is an internal defect,
4
controller troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit
5 Defective air conditioner unit may be defective. (Since this is an internal defect, troubleshooting
Defective machine monitor 2. Display the air conditioner operation screen on the machine
6 monitor.
(defective switch)
Display of Recirc/
Press FRESH/RECIRC air selector switch. Fresh changes.
HB215LC-2 80-73
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
Circuit diagram related to FRESH/RECIRC air changeover
80-74 HB215LC-2
80 Appendix
Troubleshooting with gauge pressure
Troubleshooting with gauge pressure (PC220-3840-362-A-00-A)
Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see
"Connection of service tool".
a The gauge pressure varies largely with the weather condition and operating condition of the machine.
Check the gauge pressure under the pressure measurement conditions.
• Pressure of high-pressure line is too high: Min. approx. 2.5 MPa {25 kg/cm 2}
• Pressure of high-pressure line is too low: Max. approx. 1 MPa {10 kg/cm 2}
• Pressure of low-pressure line is too high: Min. approx. 0.3 MPa {3 kg/cm 2}
• Pressure of low-pressure line is too low: Max. approx. 0.05 MPa {0.5 kg/cm 2}
a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure
or low-pressure line is abnormal.
[Measurement condition for pressure]
Item Condition value
Ambient temperature 25 to 50 °C
Engine speed 1,500 rpm
Air conditioner switch ON
Fan switch HI
Set temperature Cool-Max
• Dual pressure switch
a The switch is normally "ON", and becomes "OFF" when it detects abnormal pressure for compressor
operation.
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}
HB215LC-2 80-75
80 Appendix
Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If any problem (poor cooling) is recognized, the cause
is in other system.
Pressure is normal Pressure of high-pressure line: Approx. 1.5 to -1.7 ―
MPa {15 to 17 kg/cm2}
Pressure of low-pressure line: Approx. 0.13 to 0.2
MPa {1.3 to 2.0 kg/cm2}
Collect refrigerant, then fill
Bubbles can be seen
Insufficient refrigerant up with proper quantity of
through sight glass. *1, *3
refrigerant again. *2
Temperature difference is
recognized between inlet
Clogging of receiver drier and outlet pipes of Replace *2
receiver drier.
Tank is frosty.
Clogging of expansion Expansion valve is frosty. Clean or replace *2
valve
Gas leakage at
<Pressure of both high- Low-pressure line gauge Replace *2
thermoprobe of expansion
pressure and low- reads vacuum.
valve
pressure lines are too
Evaporator is frozen.
low>
Flow rate of refrigerant is Repair or replace
Low-pressure line gauge Defective evaporator
reduced due to freezing.
reads vacuum temperature sensor or Replace receiver drier.
defective contact of (If air conditioner is set to
sensor (coming off of Cool Max. and HI fan
up with proper quantity of
mounting clip) speed modes, later its
cooling performance
lowers.)
Piping between receiver
drier and compressor is
clogged or crushed.
Clogged or crushed piping Clean or replace *2
If clogged completely, low-
pressure line gauge reads
vacuum
Filling of too much
Connect gauge manifold. up with proper quantity of
refrigerant
Check condenser for dirt, Clean condenser, repair
Defective cooling of fins for clogging or fins, or repair or replace
condenser crushing, and cooling fan cooling fan *2
<Pressure of both high- for defective rotation.
pressure and low- Defective adjustment of
pressure lines are too expansion valve Bubbles can be seen
high> Replace *2
(Valve is excessively through sight glass. *3
opened.)
Evacuate air from air
Air sucked in cooling Bubbles can be seen conditioner and then fill up
cycle parts through sight glass. *3 with proper quantity of
80-76 HB215LC-2
80 Appendix
Indicated gauge pressure Cause Check method Remedy

<Pressure of high- Piping between Remarkable temperature Clean inside of cooling
pressure line is too high compressor and difference is recognized cycle parts or replace
and that of low-pressure condenser is Clogged or across clogged part. them.*2
line is too low> crushed.
Pressures of high-
pressure and low-
<Pressure of high- pressure lines are almost
Defective compressor
pressure line is too low the same while
(compression trouble of Replace *2
and that of low-pressure compressor is running.
compressor)
line is too high>
Compressor has seized
and is extremely 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 cooling cycle parts, be sure to collect refrigerant. For details, see "Precautions for
refrigerant". After replacing parts, fill the air conditioner circuit with refrigerant.
*3: Sight glass is on the air conditioner hose near the condenser.
HB215LC-2 80-77
80 Appendix
Connection of service tool
Connection of service tool (PC300-K500-061-K-00-A)
k Park the machine on a level surface, lower the work equipment to the ground so that it is stable,
k Turn the battery disconnect switch to OFF position, and remove the key.
a Following service tool kit is used for work with refrigerant R134a.
Symbol Part No. Part name
X 799-703-1200 Service tool kit
a Use the service tool kit for R134a.

Service tool kit X
(1): Gauge manifold
(2): Red high-pressure line charging hose
(3): Blue low-pressure line charging hose
(4): Large diameter quick joint (for high-pressure line)
(5): Small diameter quick joint (for low-pressure line)
(a): Note that the threads are coarse and the hoses are relatively easy to loosen.
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close high-pressure line valve (6) and low-pressure line valve (7) of gauge manifold (1).
2. Connect red high-pressure line charging hose (2) to the gauge manifold (HI side) and blue low-pressure
line charging hose (3) to the gauge manifold (LO side).
3. Connect quick joints (4) and (5) to each hose.
4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.
80-78 HB215LC-2
80 Appendix
Connection of service tool
A: From operator's cab

B: To condenser
HB215LC-2 80-79
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
Precautions for disconnecting and connecting air conditioner

piping (PC200_10-K5B0-924-K-00-A)
Precautions for connecting
k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses to replace the air conditioner unit or condenser, the air
conditioner compressor, receiver drier, etc.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
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. Put on protective eyeglasses, gloves and working clothes with long
sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
• When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2 wrenches.
Use one wrench to fix and use the other one to loosen the nuts.
• When disconnecting conditioner hoses and tubes, cover so that dust, dirt or water dose not enter them.
Precautions for connecting

• Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it.
• When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged.
• Check that there is no defect or deterioration on the O-ring.
• Apply compressor oil (ND-OIL8) for R134a to the O-rings. (See item 4 of "Handling compressor oil")
a Do not apply oil to the threads of a bolt, nut or union, however.
• Push in each pipe to the stopper and tighten the bolt or nut fully with your fingers.
• 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).
a Example of fitting of O-ring
• Every joint portion of the air conditioner piping has an O-ring/
80-80 HB215LC-2
80 Appendix
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
HB215LC-2 80-81
80 Appendix
Handling of compressor oil
Handling of compressor oil (PC200_10-K594-212-K-00-A)

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 oil Lubrication trouble and seizure of compressor
Cooling trouble (Excessive oil stick to parts and lower heat exchange
Excess of oil performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.
2. Filling compressor oil

k Refrigerant is potentially hazardous to health and to the environment. Before disconnecting air
conditioner hoses, therefore, refrigerant should be collected in accordance with "Precautions for
disconnecting and connecting air conditioner piping".
a If oil for CFC-12 (R-12) is used, lubrication trouble 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.
• When much refrigerant is discharged because of leakage.
• When the compressor is troubled and replaced.
(See 3 below)
• When a cycle parts such as air conditioner unit, condenser, modulator, refrigerant piping, etc. is replaced.
• Quantity of oil to be added when cycle part is replaced
Air conditioner part Quantity to be added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser (including modulator) Approx. 60
Modulator (desiccant) Approx. 20
Hose (between compressor and cab) Approx. 35
Hose (between condenser and compressor) Approx. 30
Hose (between condenser and cab) Approx. 10
3. Replacement of compressor
• In case of compressor seizure or breakage.
Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely.
80-82 HB215LC-2
80 Appendix
Handling of compressor oil
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 specified quantity (180 cc) filled in it.
• 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 quantity to be drained from the new
compressor would be 150 cc (i.e., 180 - 30 cc).
4. Applying compressor oil to O-rings

Whenever connecting piping or hoses, the compressor oil (ND-OIL8) must be applied to O-rings in order to
prevent the leakage of refrigerant.
HB215LC-2 80-83
80 Appendix
Desiccant replacement
Desiccant replacement (ALL-K523-923-K-00-A)
a Prepare desiccating agent replacement kit (20Y-810-1250).
k When replacing the desiccating agent, be sure to collect the refrigerant from the air conditioning
cycle. If the desiccating agent 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. Modulator
a The desiccanting agent is in modulator (2).
Taking out desiccanting agent (D)

1. Remove snap ring (SR) from modulator (2).
2. Hold boss (B) of cap (C) with pliers etc. to remove it from modulator (2).
a Cap (C) may be hard to remove. When removing it, exercise care not to damage or deform the seal or
modulator (2).
3. Remove filter (F) from modulator (2).
4. Remove desiccanting agent (D) from modulator (2).
a Replace snap ring (SR), cap (C), O-ring (OR), filter (F), and desiccanting agent (D) with the new parts
in the desiccanting agent replacement kit.
80-84 HB215LC-2
80 Appendix
Installing new desiccanting agent (D)

1. Apply compressor oil (ND-OIL8) to the periphery of O-ring (OR) of cap (C).
2. Install filter (F) to cap (C).
3. Insert desiccanting agent (D) in modulator (2).

4. Install cap (C) with filter (F) to modulator (2).
5. Fit snap ring (SR) to modulator (2) to fix cap (C).
a If snap ring (SR) is not fitted to the groove in modulator (2) securely, cap (C) may be come off.
HB215LC-2 80-85
80 Appendix
80-86 HB215LC-2
SHOP MANUAL
HYDRAULIC EXCAVATOR
HB215LC-2
Model Serial Number
90 Diagrams and drawings

10 90 Diagrams and drawings
HB215LC-2 90-1
Table of contents

90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram .............................................................................................................. 90-13
Symbols in electric circuit diagram ....................................................................................... 90-13
Electrical circuit diagram ..................................................................................................... 90-17
Electrical circuit diagram of air conditioner unit...................................................................... 90-47
90-2 HB215LC-2
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram (ALL-C000-001-K-90-A)
Symbols in hydraulic circuit diagram (PC220-0000-007-K-00-A)
(Rev. 2013/09)
Symbols Substances
Main piping line
Pilot or drain line
Flexible pipe (hose etc.)
Lines intersecting without jointing
Lines jointing (junction with a black dot)
Direction of flow
Throttle in passage
Variable
Electricity
Spring
Take-off port
Take-off port and pressure gauge
HB215LC-2 90-3
Symbols Substances
Check valve
Suction (with strainer)
Tank and return pipe
Filter
Oil cooler
Stop valve
Drive shaft (unidirectional)
Drive shaft (bidirectional)
Hydraulic pump
Note: Black triangle shows outlet port
Variable capacity hydraulic pump
Hydraulic motor
Note: Two black triangles in the figure show direction of oil entering
hydraulic motor depending on the oil entry port, the direction of rotation is
reversed.
Servo piston
PPC valve
90-4 HB215LC-2
Symbols Substances
Control valve
Single-acting solenoid valve
Single-acting proportional solenoid valve
Hydraulic pilot valve
Hydraulic two-stage pilot valve
Lock valve
Drain valve
Pressure regulator valve, Safety valve, Abnormal pressure prevention

valve
Pressure regulator valve, Safety valve, Abnormal pressure prevention

valve
(when the figure shows air pressure, being released to atmosphere)
Bypass valve
Accumulator
HB215LC-2 90-5
Symbols Substances
Cylinder
Component group
90-6 HB215LC-2
Hydraulic circuit diagram Hydraulic circuit diagram
HB215LC-2
HB215LC-2
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
HB215LC-2 90-7
Hydraulic circuit diagram (1/2) (EU specification) Hydraulic circuit diagram (1/2) (EU specification)
HB215LC-2
HB215LC-2
HB215LC-2 90-9
Hydraulic circuit diagram (2/2) (EU specification) Hydraulic circuit diagram (2/2) (EU specification)
HB215LC-2
HB215LC-2
HB215LC-2 90-11
Symbols in electric circuit diagram
Electric circuit diagram (ALL-0000-001-K-90-A)
Symbols in electric circuit diagram (PC220-0000-008-K-00-A)
(Rev. 2013/09)
Symbols Substances
Electric wire
Electric wire (wires intersecting without connecting)
Electric wire (wires intersecting and connecting (junction) with a black

dot)
Electric wire (bundled drawing style)
Terminal
Chassis ground
Chassis ground using terminal
Contact, Switch
Push-button type switch (N.O. type)

N.O.: Normally Open
Push-button type switch (N.C. type)

N.C.: Normally Close
Pull-button type switch (N.O. type)

N.O.: Normally Open
Pull-button type switch (N.C. type)

HB215LC-2 90-13
Symbols Substances
Variable
Resistor
Variable resistor
Diode
Light emitting diode (LED)
Photo diode
Constant voltage diode (zener diode)
Transistor (PNP type)
Transistor (NPN type)
Coil
Battery
Fuse
Connector
Note:
• Concave side of connecting portion (left in figure): female
• Convex side of connecting portion (right in figure): male
a Figure shows a line disconnection status
90-14 HB215LC-2
Symbols Substances
Plug and receptacle type connector (left: male, right: female)

a Figure shows a line connection status
Solenoid
Motor
Lamp
Pressure switch (N.O. type)

N.O.: Normally Open
Pressure switch (N.C. type)

Potentiometer, Fuel control dial
Temperature sensor
Starting switch
Back up alarm
Horn
Buzzer
Antenna
HB215LC-2 90-15
90-16 HB215LC-2
Electrical circuit diagram (1/7) Electrical circuit diagram (1/7)
HB215LC-2
HB215LC-2
HB215LC-2 90-17
HB215LC-2
HB215LC-2
HB215LC-2 90-19
HB215LC-2
HB215LC-2
HB215LC-2 90-21
HB215LC-2
HB215LC-2
HB215LC-2 90-23
HB215LC-2
HB215LC-2
HB215LC-2 90-25
HB215LC-2
HB215LC-2
HB215LC-2 90-27
HB215LC-2
HB215LC-2
HB215LC-2 90-29
Electrical circuit diagram (1/8) (EU specification) Electrical circuit diagram (1/8) (EU specification)
HB215LC-2
HB215LC-2
HB215LC-2 90-31
HB215LC-2
HB215LC-2
HB215LC-2 90-33
HB215LC-2
HB215LC-2
HB215LC-2 90-35
HB215LC-2
HB215LC-2
HB215LC-2 90-37
HB215LC-2
HB215LC-2
HB215LC-2 90-39
HB215LC-2
HB215LC-2
HB215LC-2 90-41
HB215LC-2
HB215LC-2
HB215LC-2 90-43
HB215LC-2
HB215LC-2
HB215LC-2 90-45
Electrical circuit diagram of air conditioner unit Electrical circuit diagram of air conditioner unit
HB215LC-2
HB215LC-2
a In the drawing, full line shows air conditioner wiring harness, and dashed line shows cab and chassis wiring harness. (For the detail of cab and chassis harness, see "Electrical circuit diagram")
a In the drawing, dot and dash line shows machine monitor wiring, and using twisted line (AVS 0.5 x 2, pitch 45 mm or less).
HB215LC-2 90-47
INDEX
INDEX
1st-line attachment PPC valve (with EPC Connection of service tool ............................. 80-78
valve)............................................. 10-170, 60-44 Connector contact identification ..................... 40-64
Connector list and layout ............................... 40-53
Control valve ...................................... 10-89, 60-26
A Conversion table .......................................... 00-67
A-1 Troubleshooting for power supply system Cooling system.....................................10-22, 60-4
(Air conditioner does not operate) ................. 80-66 Cooling system of hybrid component .............. 10-30
A-2 Troubleshooting for compressor and
refrigerant system (Air is not cooled) ............. 80-68 D
A-4 Troubleshooting for FRESH/RECIRC air Desiccant replacement.................................. 80-84
changeover ................................................ 80-73 Diagnostic procedure for wiring harness open
A-3 Troubleshooting for blower motor system curcuit of pressure sensor system ................ 40-51
(No air comes out or air flow is abnormal) ...... 80-71 Disassembly and assembly of carrier roller
Accumulator ............................................... 10-190 assembly....................................................... 50-176
Adjusting play of work equipment and swing Disassembly and assembly of control valve
PPC valves ................................................ 30-72 assembly........................................................ 50-200
Air conditioner component ............................... 80-4 Disassembly and assembly of final drive
Air conditioner condenser .............................. 80-20 assembly........................................................ 50-137
Air conditioner controller ................................ 80-18 Disassembly and assembly of idler................. 50-170
Air conditioner unit ........................................ 80-10 Disassembly and assembly of idler
Attachment circuit selector valve (for high cushion assembly ......................................... 50-172
pressure circuit) ........................................ 10-183 Disassembly and assembly of swing
Attachment circuit selector valve (for low machinery assembly ..................................... 50-150
pressure circuit) ........................................ 10-185 Disassembly and assembly of track roller
Attachment circuit selector valve (for high- assembly........................................................ 50-174
pressure circuit) .......................................... 60-50 Disassembly and assembly of travel PPC
Attachment circuit selector valve (for low- valve assembly ............................................. 50-208
pressure circuit) .......................................... 60-51 Disassembly and assembly of work equipment
cylinder assembly ......................................... 50-213
Disassembly and assembly of work equipment
B PPC valve ...................................................... 50-206
Bleeding air from fuel system ......................... 30-30 Draining coolant, refilling with coolant, and
Bleeding air from hydraulic circuit ................... 30-78 bleeding air for hybrid system........................ 50-102
Boom cylinder (large diameter piston)............. 60-62 Dual pressure switch..................................... 80-17
Bucket play adjustment shim ....................... 10-193
E
E-1 Engine does not start (Engine does not
C crank) ...................................................... 40-592
Cab mount and cab tipping stopper .............. 10-194 E-2 Manual preheating system does not work .....40-
Carrier roller ................................................. 60-17 598
Center swivel joint............................. 10-188, 60-52 E-3 Automatic preheating system does not
Checking and adjusting air conditioner work......................................................... 40-601
compressor belt tension............................... 30-35 E-4 While preheating is working, preheating
Checking cab tipping stopper......................... 30-80 monitor does not light up............................ 40-603
Checks before troubleshooting....................... 40-14 E-5 When starting switch is turned to ON
Classification and procedure for position, machine monitor displays nothing.. 40-605
troubleshooting ........................................... 40-43 E-6 When starting switch is turned to ON
Cleaning and replacing oil filter of electric position (before starting engine), engine oil
swing motor ................................................ 30-43 level monitor lights up in yellow .................. 40-609
CLSS........................................................... 10-54 E-7 When starting switch is turned to ON
Coating materials list....................................... 50-7 position (before starting engine), radiator
Compressor ................................................. 80-19 coolant level monitor lights up in yellow ....... 40-610
Configuration and function of refrigeration E-8 Engine coolant temperature monitor lights
cycle ............................................................ 80-7 up in white while engine is running.............. 40-611
Configuration of hybrid system ....................... 10-25
HB215LC-2 1
INDEX
E-9 Hydraulic oil temperature monitor lights up E-35 Travel speed does not change while
in white while engine is running .................. 40-612 travel speed selection is changed ............... 40-642
E-10 Charge level monitor lights up in red while E-36 Alarm buzzer does not stop sounding ... 40-643
engine is running....................................... 40-613 E-37 Service meter is not displayed, while
E-11 Fuel level monitor lights up in red while starting switch is in OFF position ................ 40-644
engine is running....................................... 40-614 E-38 Service mode cannot be selected......... 40-645
E-12 Air cleaner clogging monitor lights up in E-39 None of work equipment, swing or travel
yellow while engine is running .................... 40-615 works ....................................................... 40-646
E-13 Water separator monitor lights up in red E-40 Any of work equipment, swing and travel
while engine is running .............................. 40-616 cannot be locked....................................... 40-648
E-14 Engine coolant temperature monitor E-41 Upper structure does not swing while
lights up in red while engine is running ........ 40-617 swing parking brake cancel switch is set to
E-15 Hydraulic oil temperature monitor lights CANCEL position ...................................... 40-650
up in red while engine is running................. 40-618 E-42 Swing brake does not operate while
E-16 Hybrid temperature monitor lights up in swing parking brake cancel switch is set to
red while engine is running......................... 40-619 NORMAL position ..................................... 40-653
E-17 Engine oil pressure monitor lights up in E-43 One-touch power maximizing function
red while engine is running......................... 40-621 does not operate, or indicator is not displayed
E-18 Fuel gauge display does not move from on monitor ................................................ 40-655
minimum or maximum ............................... 40-622 E-44 One-touch power maximizing function
E-19 Fuel gauge indicates incorrect amount cannot be canceled ................................... 40-657
(indicates neither full nor empty) ................. 40-623 E-45 Alarm does not sound during travel....... 40-658
E-20 Engine coolant temperature gauge E-46 Alarm does not stop sounding while
display does not move from minimum or machine is stopped ................................... 40-659
maximum ................................................. 40-624 E-47 Horn does not sound ........................... 40-660
E-21 Engine coolant temperature gauge E-48 Horn does not stop sounding ............... 40-662
indicates incorrect temperature (indicates E-49 Wiper monitor does not light up, or does
neither full nor empty) ................................ 40-625 not go out, while wiper switch is operated .... 40-663
E-22 Hydraulic oil temperature gauge does not E-50 Wiper does not operate while wiper
move from minimum or maximum ............... 40-626 switch is operated ..................................... 40-664
E-23 Hydraulic oil temperature gauge indicates E-51 Window washer does not operate while
incorrect temperature (indicates neither full window washer switch is operated .............. 40-666
nor empty) ................................................ 40-628 E-52 Boom LOWER is not displayed correctly
E-24 Hybrid temperature gauge does not move with monitoring function ............................. 40-667
from minimum or maximum ........................ 40-629 E-53 Arm OUT is not displayed correctly with
E-25 Hybrid temperature gauge indicates monitoring function.................................... 40-668
incorrect temperature (indicates neither full E-54 Arm IN is not displayed correctly with
nor empty) ................................................ 40-630 monitoring function.................................... 40-669
E-26 Contents of display on machine monitor E-55 Boom RAISE is not displayed correctly
is different from actual machine condition .... 40-632 with monitoring function ............................. 40-670
E-27 Some areas of machine monitor screen E-56 Bucket CURL is not displayed correctly
are not displayed....................................... 40-633 with monitoring function ............................. 40-671
E-28 Function switch does not work ............. 40-634 E-57 Bucket DUMP is not displayed correctly
E-29 Automatic warm-up system does not with monitoring function ............................. 40-672
operate (in cold season) ............................ 40-635 E-58 Swing is not displayed correctly with
E-30 Auto-deceleration monitor does not light monitoring function.................................... 40-673
up, or does not go out, while auto- E-59 Travel is not displayed correctly with
deceleration switch is operated .................. 40-636 monitoring function.................................... 40-674
E-31 Auto-deceleration function does not E-60 Service is not displayed correctly with
operate or is not canceled while lever is monitoring function.................................... 40-675
operated................................................... 40-637 E-61 Attachment hydraulic circuit cannot be
E-32 Working mode selection screen is not changed ................................................... 40-678
displayed while working mode selector switch E-62 KOMTRAX system does not operate
is operated ............................................... 40-639 normally ................................................... 40-679
E-33 Setting of engine and hydraulic pump is EGR cooler .................................................. 10-14
not changed while working mode is changed .....40- EGR system piping drawing............................. 10-9
640 EGR valve ................................................... 10-12
E-34 Travel speed monitor does not change Electric circuit diagram .................................. 90-17
when travel speed switch is operated.......... 40-641 Electric control unit ....................................... 10-36
2 HB215LC-2
INDEX
Electric swing motor...................................... 10-34 Failure code [CA1896] EGR Valve Stuck Error ....40-
Electrical circuit diagram of air conditioner unit 90-47 239
Electrical control system.............................. 10-196 Failure code [CA1942] Crankcase Press Sens
Engine controller......................................... 10-236 In Range Error .......................................... 40-240
Engine mount ................................................. 60-3 Failure code [CA1961] EGR_Motor Driver IC
Engine related parts ........................................ 10-3 Over Temp Error ....................................... 40-241
Explanation of terms for maintenance standard ...00- Failure code [CA2185] Throt Sensor Sup Volt
25 High Error................................................. 40-242
Failure code [CA2186] Throt Sensor Sup Volt
Low Error ................................................. 40-244
F Failure code [CA221] Ambient Press Sens
Failure code [879FMC] Air Mix Damper High Error................................................. 40-165
Abnormality .............................................. 40-128 Failure code [CA222] Ambient Press Sens Low
Failure code [A900FR] Abrupt Engine Stop by Error ........................................................ 40-167
Auto Idle Stop 3 ........................................ 40-133 Failure code [CA2249] Rail Press Very Low
Failure code [A900N6] Abrupt Engine Stop by Error 2...................................................... 40-246
Auto Idle Stop 1 ........................................ 40-134 Failure code [CA227] Sensor 2 Supply Volt
Failure code [A900NY] Abrupt Engine Stop by High Error................................................. 40-169
Auto Idle Stop 2 ........................................ 40-135 Failure code [CA2272] EGR Valve Pos Sens
Failure code [AA10NX] Air Cleaner Clogging. 40-136 Low Error ................................................. 40-247
Failure code [AB00KE] Charge Voltage Low . 40-138 Failure code [CA2311] IMV Solenoid Error .... 40-249
Failure code [B@BAZG] Eng Oil Press Low .. 40-140 Failure code [CA234] Eng Overspeed........... 40-170
Failure code [B@BAZK] Eng Oil Level Low ... 40-141 Failure code [CA2349] EGR Valve Solenoid
Failure code [B@BCNS] Eng Water Overheat .....40- Open Error ............................................... 40-250
142 Failure code [CA2353] EGR Valve Solenoid
Failure code [B@BCZK] Eng Water Level Low ....40- Short Error................................................ 40-252
143 Failure code [CA2357] EGR Valve Servo Error ....40-
Failure code [B@HANS] Hyd Oil Overheat.... 40-145 254
Failure code [CA1117] Persistent Data Lost Failure code [CA2373] Exhaust Manifold Press
Error ........................................................ 40-232 Sens High Error ........................................ 40-255
Failure code [CA115] Eng Ne and Bkup Speed Failure code [CA2374] Exhaust Manifold Press
Sens Error ................................................ 40-146 Sens Low Error ......................................... 40-257
Failure code [CA122] Chg Air Press Sensor Failure code [CA2375] EGR Orifice Temp Sens
High Error................................................. 40-147 High Error................................................. 40-259
Failure code [CA123] Chg Air Press Sensor Failure code [CA2376] EGR Orifice Temp Sens
Low Error ................................................. 40-149 Low Error ................................................. 40-261
Failure code [CA131] Throttle Sensor High Failure code [CA238] Ne Speed Sensor
Error ........................................................ 40-151 Supply Volt Error ....................................... 40-171
Failure code [CA132] Throttle Sensor Low Failure code [CA2387] KVGT Servo Error ..... 40-263
Error ........................................................ 40-153 Failure code [CA239] Ne Speed Sens Supply
Failure code [CA144] Coolant Temp Sens High Volt High Error .......................................... 40-172
Error ........................................................ 40-155 Failure code [CA2554] Exh Manifold Press
Failure code [CA145] Coolant Temp Sens Low Sens In Range Error.................................. 40-264
Error ........................................................ 40-157 Failure code [CA2555] Grid Htr Relay Volt Low
Failure code [CA153] Chg Air Temp Sensor Error ........................................................ 40-265
High Error................................................. 40-159 Failure code [CA2556] Grid Htr Relay Volt High
Failure code [CA154] Chg Air Temp Sensor Error ........................................................ 40-267
Low Error ................................................. 40-161 Failure code [CA271] IMV/PCV1 Short Error . 40-173
Failure code [CA1695] Sensor 5 Supply Volt Failure code [CA272] IMV/PCV1 Open Error . 40-175
High Error................................................. 40-233 Failure code [CA295] Ambient Press Sens In
Failure code [CA1696] Sensor 5 Supply Volt Range Error.............................................. 40-177
Low Error ................................................. 40-234 Failure code [CA2961] EGR Orifice Temp High
Failure code [CA1843] Crankcase Press Sens Error 1...................................................... 40-269
High Error................................................. 40-235 Failure code [CA2973] Chg Air Press Sensor
Failure code [CA1844] Crankcase Press Sens In Range Error .......................................... 40-270
Low Error ................................................. 40-237 Failure code [CA322] Inj #1(L#1) Open/Short
Failure code [CA187] Sensor 2 Supply Volt Error ........................................................ 40-178
Low Error ................................................. 40-163 Failure code [CA324] Inj #3(L#3) Open/Short
Error ........................................................ 40-180
HB215LC-2 3
INDEX
Failure code [CA331] Inj #2(L#2) Open/Short Failure code [CA556] Crankcase Press High
Error ........................................................ 40-182 Error 2...................................................... 40-217
Failure code [CA332] Inj #4(L#4) Open/Short Failure code [CA559] Rail Press Low Error ... 40-218
Error ........................................................ 40-184 Failure code [CA689] Eng Ne Speed Sensor
Failure code [CA3419] Mass Air Flow Sensor Error ........................................................ 40-220
Sup Volt High Error.................................... 40-271 Failure code [CA691] Intake Air Temp Sens
Failure code [CA3421] Mass Air Flow Sensor High Error................................................. 40-222
Sup Volt Low Error .................................... 40-273 Failure code [CA692] Intake Air Temp Sens
Failure code [CA343] ECM Critical Internal Low Error ................................................. 40-224
Failure ..................................................... 40-186 Failure code [CA697] ECM Internal Temp
Failure code [CA351] Injectors Drive Circuit Sensor High Error ..................................... 40-226
Error ........................................................ 40-187 Failure code [CA698] ECM Int Temp Sensor
Failure code [CA352] Sensor 1 Supply Volt Low Error ................................................. 40-227
Low Error ................................................. 40-188 Failure code [CA731] Eng Bkup Speed Sens
Failure code [CA356] Mass Air Flow Sensor Phase Error .............................................. 40-228
High Error................................................. 40-190 Failure code [CA778] Eng Bkup Speed Sensor
Failure code [CA357] Mass Air Flow Sensor Error ........................................................ 40-229
Low Error ................................................. 40-192 Failure code [D110KB] Battery Relay Drive
Failure code [CA3724] EGR/KVGT Motor Short Circuit ............................................. 40-285
Driver Power Low Error ............................. 40-275 Failure code [D19JKZ] Personal Code Relay
Failure code [CA3741] Rail Press Valve Trip Abnormality .............................................. 40-287
Error ........................................................ 40-277 Failure code [D811MC] KOMTRAX Error ...... 40-290
Failure code [CA386] Sensor 1 Supply Volt Failure code [D862KA] GPS Antenna Open
High Error................................................. 40-194 Circuit ...................................................... 40-291
Failure code [CA3918] KVGT Stuck Error ..... 40-278 Failure code [D8ALKA] Operating Lamp Open
Failure code [CA3919] KVGT Motor Driver IC Circuit (KOMTRAX) ................................... 40-292
Over Temp Error ....................................... 40-279 Failure code [D8ALKB] Operating Lamp Short
Failure code [CA3921] KVGT Servo Error 2 .. 40-280 Circuit (KOMTRAX) ................................... 40-294
Failure code [CA3922] KVGT Motor Driver Failure code [D8AQKR] CAN2 Discon
Open Error ............................................... 40-281 (KOMTRAX) ............................................. 40-295
Failure code [CA3923] KVGT Motor Driver Failure code [DA20MC] Pump Controller
Short Error................................................ 40-283 Malfunction............................................... 40-296
Failure code [CA428] Water in Fuel Sensor Failure code [DA22KK] Pump Solenoid Power
High Error................................................. 40-195 Low Error ................................................. 40-297
Failure code [CA429] Water in Fuel Sensor Failure code [DA25KP] 5V Sensor 1 Power
Low Error ................................................. 40-197 Abnormality .............................................. 40-299
Failure code [CA435] Eng Oil Press Sw Error......40- Failure code [DA26KP] 5V Sensor 2 Power
199 Abnormality .............................................. 40-301
Failure code [CA441] Battery Voltage Low Failure code [DA29KQ] Model Selection
Error ........................................................ 40-200 Abnormality .............................................. 40-303
Failure code [CA442] Battery Voltage High Failure code [DA2LKA] Operating Lamp Open
Error ........................................................ 40-202 Circuit (Pump Con).................................... 40-305
Failure code [CA449] Rail Press Very High Failure code [DA2LKB] Operating Lamp Short
Error ........................................................ 40-203 Circuit (Pump Con).................................... 40-307
Failure code [CA451] Rail Press Sensor High Failure code [DA2QKR] CAN2 Discon (Pump
Error ........................................................ 40-204 Con) ........................................................ 40-308
Failure code [CA452] Rail Press Sensor Low Failure code [DA2RKR] CAN1 Discon (Pump
Error ........................................................ 40-206 Con) ........................................................ 40-311
Failure code [CA466] KVGT Motor Driver Failure code [DAF0MB] Monitor ROM
Position Error............................................ 40-208 Abnormality .............................................. 40-312
Failure code [CA488] Chg Air Temp High Failure code [DAF0MC] Monitor Error ........... 40-313
Torque Derate........................................... 40-210 Failure code [DAF9KQ] Model Selection
Failure code [CA515] Rail Press Sens Sup Volt Abnormality .............................................. 40-316
High Error................................................. 40-211 Failure code [DAFGMC] GPS Module Error .. 40-317
Failure code [CA516] Rail Press Sens Sup Volt Failure code [DAFLKA] Operating Lamp Open
Low Error ................................................. 40-213 Circuit (Monitor) ........................................ 40-318
Failure code [CA553] Rail Press High Error 1 40-215 Failure code [DAFLKB] Operating Lamp Short
Failure code [CA555] Crankcase Press High Circuit (Monitor) ........................................ 40-320
Error 1...................................................... 40-216
4 HB215LC-2
INDEX
Failure code [DAFQKR] CAN2 Discon Failure code [DV20KB] Travel Alarm Short
(Monitor) .................................................. 40-321 Circuit ...................................................... 40-392
Failure code [DAZ9KQ] A/C Model Selection Failure code [DW43KA] Travel Speed Sol
Abnormality .............................................. 40-322 Open Circuit ............................................. 40-394
Failure code [DAZQKR] CAN2 Discon (Aircon Failure code [DW43KB] Travel Speed Sol
ECU) ....................................................... 40-323 Short Circuit ............................................. 40-396
Failure code [DB2QKR] CAN2 Discon (Engine Failure code [DW45KA] Swing Brake Sol Open
Con) ........................................................ 40-327 Circuit ...................................................... 40-398
Failure code [DB2RKR] CAN1 Discon (Engine Failure code [DW45KB] Swing Brake Sol Short
Con) ........................................................ 40-332 Circuit ...................................................... 40-401
Failure code [DGH2KB] Hyd Oil Sensor Short Failure code [DW45KK] Swing Brake Sol.
Circuit ...................................................... 40-338 Valve Low Sup. Voltage ............................. 40-404
Failure code [DHA4KA] Air Cleaner Clog Failure code [DW45KY] Swing Brake Sol. Val.
Sensor Open Circuit .................................. 40-340 Pow. Short Cir. .......................................... 40-406
Failure code [DHPAMA] F Pump Press Sensor Failure code [DW91KA] Travel Junction Sol
Abnormality .............................................. 40-341 Open Circuit ............................................. 40-408
Failure code [DHPBMA] R Pump Press Sensor Failure code [DW91KB] Travel Junction
Abnormality .............................................. 40-344 Solenoid Short Circuit................................ 40-410
Failure code [DHS3MA] Arm Curl PPC Press Failure code [DWA2KA] Attachment Solenoid
Sensor Abnormality................................... 40-347 Open Circuit ............................................. 40-412
Failure code [DHS4MA] Bucket Curl PPC Failure code [DWA2KB] Attachment Solenoid
Press Sensor Abnormality ......................... 40-349 Short Circuit ............................................. 40-414
Failure code [DHS8MA] Boom Raise PPC Failure code [DWK0KA] 2-Stage Relief Sol
Press Sensor Abnormality ......................... 40-351 Open Circuit ............................................. 40-416
Failure code [DHS9MA] Boom Lower PPC Failure code [DWK0KB] 2-Stage Relief Sol
Press Sensor Abnormality ......................... 40-353 Short Circuit ............................................. 40-418
Failure code [DHSAKZ] Swing RH PPC Press Failure code [DWK2KA] Variable Back Press
Sensor Abnormality................................... 40-355 Sol Open Circuit........................................ 40-420
Failure code [DHSBKZ] Swing LH PPC Press Failure code [DWK2KB] Variable Back Press
Sensor Abnormality................................... 40-357 Sol Short Circuit ........................................ 40-422
Failure code [DHSCMA] Arm Dump PPC Failure code [DXA8KA] PC-EPC (F) Sol Open
Press Sensor Abnormality ......................... 40-359 Circuit ...................................................... 40-424
Failure code [DHSDMA] Bucket Dump PPC Failure code [DXA8KB] PC-EPC (F) Sol Short
Failure code [DHSFMA] Travel Fwd LH PPC Failure code [DXA9KA] PC-EPC (R) Solenoid
Press Sensor Abnormality ......................... 40-363 Open Circuit ............................................. 40-428
Failure code [DHSGMA] Travel Fwd RH PPC Failure code [DXA9KB] PC-EPC (R) Sol Short
Failure code [DHSHMA] Travel Rev LH PPC Failure code [DXE0KA] LS-EPC Sol Open
Failure code [DHSJMA] Travel Rev RH PPC Failure code [DXE0KB] LS-EPC Sol Short
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Failure code [DXE4KA] Attachment Flow EPC
Sen. Opn/Short Cirt. .................................. 40-371 Open Circuit ............................................. 40-436
Failure code [DHVAL8] HYB Swing-R PPC Pr. Failure code [DXE4KB] Attachment Flow EPC
Sen. Signal Mismatch................................ 40-374 Short Circuit ............................................. 40-438
Failure code [DHVAMA] HYB Swing-R PPC Failure code [DXE5KA] Merge-divide Main Sol
Sensor Malfunction ................................... 40-375 Open Circuit ............................................. 40-440
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Failure code [DXE5KB] Merge-divide Main Sol
Sen. Opn/Short Cir. ................................... 40-377 Short Circuit ............................................. 40-442
Failure code [DHVBL8] HYB Swing-L PPC Pr. Failure code [DXE6KA] Merge-divide LS Sol
Sen. Signal Mismatch................................ 40-379 Open Circuit ............................................. 40-444
Failure code [DHVBMA] HYB Swing-L PPC Failure code [DXE6KB] Merge-divide LS Sol
Sensor Malfunction ................................... 40-380 Short Circuit ............................................. 40-446
Failure code [DKR0MA] F Pump Swash Plate Failure code [DY20KA] Wiper Working
Sensor Abnormality................................... 40-382 Abnormality .............................................. 40-448
Failure code [DKR1MA] R Pump Swash Plate Failure code [DY20MA] Wiper Parking
Sensor Abnormality................................... 40-385 Abnormality .............................................. 40-450
HB215LC-2 5
INDEX
Failure code [DY2CKB] Washer Drive Short Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt.
Circuit ...................................................... 40-452 Sens. Malfunction ..................................... 40-518
Failure code [DY2DKB] Wiper Drive (Forward) Failure code [GA1FKR] Swing Mot. Drv.
Short Circuit ............................................. 40-454 Communication Failure.............................. 40-519
Failure code [DY2EKB] Wiper Drive (Rev) Failure code [GA1FMA] Abnormal Swing Motor
Short Circuit ............................................. 40-456 Driver....................................................... 40-520
Failure code [GA——] Table and check sheet Failure code [GA1GKR] Swg Mot. Driver Sub-
of monitoring items on hybrid components... 40-487 CPU Comm. Failure .................................. 40-521
Failure code [GA****] Precautions for hybrid Failure code [GA1GKT] Swing Mot. Drv. Sub-
components and troubleshooting of high CPU Cont. Abnormal ................................. 40-522
voltage parts............................................. 40-458 Failure code [GA1GMB] Swing Mot. Drv. Sub-
Failure code [GA00NS] HYB Equipment CPU Funct. Degraded ............................... 40-523
Overheat .................................................. 40-492 Failure code [GA1HKZ] Swg Mot. Dr. Ph-U
Failure code [GA01KA] Power Cable Interlock Tem. Sens Opn/Shrt Cir ............................. 40-524
Open Circuit ............................................. 40-493 Failure code [GA1JKZ] Swg Mot. Dr. Ph-V
Failure code [GA01KB] Power Cable Interlock Tem. Sens Opn/Shrt Cir ............................. 40-525
Short Circuit ............................................. 40-495 Failure code [GA1KKZ] Swg Mot. Dr. Ph-W
Failure code [GA02KZ] DC Line Open & Short Tem. Sens Opn/Shrt Cir ............................. 40-526
Circuit ...................................................... 40-497 Failure code [GA1LKZ] Swg Mot. Dr. Current.
Failure code [GA04KG] Abnormal DC HW Volt. Sens. Opn/Shrt Cir .................................... 40-527
Before Booster.......................................... 40-498 Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt.
Failure code [GA05KG] Abnormal DC SW Volt. Sen. Opn/Shrt Cir. ..................................... 40-528
Before Booster.......................................... 40-499 Failure code [GA1NNS] Swing Motor Driver
Failure code [GA05KP] Low DC SW Output IGBT Overheat ......................................... 40-529
Volt. Bef. Booster ...................................... 40-500 Failure code [GA1SFS] Contactor Locked..... 40-530
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Failure code [GA1SMC] Contactor Failure .... 40-531
Cir. Bef. Booster........................................ 40-501 Failure code [GA1TKP] Capacitor Low Output
Failure code [GA08KG] Abnorm. DC HW Volt. Voltage..................................................... 40-532
After Booster ............................................ 40-502 Failure code [GA1TNS] Capacitor Overheat.. 40-533
Failure code [GA09KG] Abnorm. DC SW Volt. Failure code [GA1UKZ] Capacitor Temp.
After Booster ............................................ 40-503 Sensor Opn/short Cir. ................................ 40-535
Failure code [GA09KP] Low DC SW Output Failure code [GA1VFS] Capacitor Contactor
Volt. After Booster ..................................... 40-504 Locked ..................................................... 40-537
Failure code [GA0AKZ] DC Vlt. Sen. Op./Shrt Failure code [GA1VMC] Capacitor Contactor
Cir. Aft. Booster......................................... 40-505 Failure ..................................................... 40-539
Failure code [GA0BKZ] AC Line Open & Short Failure code [GA1XKZ] Boost. Ind. Temp.
Circuit ...................................................... 40-506 Sens. Open/Shrt. Circ................................ 40-540
Failure code [GA10MA] HYB Controller Failure code [GA1YNS] Booster Inductor
Malfunction............................................... 40-507 Overheat .................................................. 40-541
Failure code [GA10MC] HYB Controller Error 40-508 Failure code [GA1ZKZ] Booster IGBT Temp.
Failure code [GA12NK] High-Voltage Line Sens. Opn/Shrt. Circ.................................. 40-542
Start-up Failure ......................................... 40-509 Failure code [GA1ZNS] Booster IGBT Temp.
Failure code [GA13KP] Low HYB Control. Sen. Sens. Overheat......................................... 40-543
Power Sup................................................ 40-510 Failure code [GA22NS] Booster IGBT Junction
Failure code [GA13KY] HYB Control. Sen. Overheat .................................................. 40-544
Power Short Cir ........................................ 40-511 Failure code [GA23KZ] Gen. Mot. Dr. Temp.
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen.0 Opn/Short Cir. ................................. 40-545
Sen. Opn/Short. Cir ................................... 40-512 Failure code [GA24KZ] Gen. Mot. Dr. Temp.
Failure code [GA17KR] Gen. Mot. Drv. Sen.1 Opn/Short Cir. ................................. 40-546
Communication Failure.............................. 40-513 Failure code [GA25MA] Gen. Motor Driver
Failure code [GA17MB] Gen. Mot. Drv. IGBT 0 Abnormality ................................... 40-547
Function Degraded.................................... 40-514 Failure code [GA25NS] Gen. Motor Driver
Failure code [GA18MC] Gen. Mo.Dr. Excite. IGBT 0 Overheat....................................... 40-548
Pow. Sup. Failure...................................... 40-515 Failure code [GA26MA] Gen. Motor Driver
Failure code [GA19KR] Gen. Motor Driver Sub- IGBT 1 Abnormality ................................... 40-549
CPU Comm. Failure .................................. 40-516 Failure code [GA26NS] Gen. Motor Driver
Failure code [GA19KT] Int. Abnorm. Gen. Mot. IGBT 1 Overheat....................................... 40-550
Drv. Sub-CPU Con. ................................... 40-517 Failure code [GA27KZ] DC Cur. Sens. Bef.
Booster Opn/Short Cir ............................... 40-551
6 HB215LC-2
INDEX
Failure code [GA2QKR] CAN2 Discon (Hyb Failure code [GAA6KY] HYB Control. Sen.
Con) ........................................................ 40-552 Power 2 Short Cir...................................... 40-588
Failure code [GA2RKR] CAN1 Discon (Hyb Failure code [GACLKA] Operating Lamp Open
Con) ........................................................ 40-554 Circuit (HYB Con) ..................................... 40-589
Failure code [GA60KZ] Generator Motor Open/ Failure code [GACLKB] Operating Lamp Short
Short Circuit ............................................. 40-555 Circuit (HYB Con) ..................................... 40-591
Failure code [GA60MC] Generator Motor Failure code [879AKA] A/C Inner Sensor Open
Failure ..................................................... 40-556 Circuit ............................................ 40-120, 80-53
Failure code [GA60N1] Generator Motor Failure code [879AKB] A/C Inner Sensor Short
Overrun.................................................... 40-558 Circuit ............................................ 40-121, 80-54
Failure code [GA61KZ] Gen. Motor Temp. Failure code [879BKA] A/C Outer sensor Open
Sens. Opn/Short Cir. ................................. 40-559 Circuit ........................................................ 80-55
Failure code [GA61NS] Generator Motor Failure code [879BKA] A/C Outer Sensor
Temp. Sensor Overheat............................. 40-561 Open Circuit ............................................. 40-122
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Failure code [879BKB] A/C Outer sensor Short
Sen. Power Short Cir................................. 40-562 Circuit ........................................................ 80-57
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Failure code [879BKB] A/C Outer Sensor Short
Sen. Open/Short Cir .................................. 40-563 Circuit ...................................................... 40-123
Failure code [GA62MA] Gen. Mot. Ph-A Failure code [879CKA] Ventilating Sensor
Current Sen. Malfunction ........................... 40-564 Open Circuit ................................... 40-124, 80-59
Failure code [GA62MC] Gen. Mot. Ph-A Cur. Failure code [879CKB] Ventilating Sensor
Sen. Defect Op. ........................................ 40-565 Short Circuit ................................... 40-125, 80-60
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Failure code [879DKZ] Sunlight sensor Open
Sen. Power Short Cir................................. 40-566 or Short Circuit............................................ 80-61
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Failure code [879DKZ] Sunlight Sensor Open
Sen. Open/Short Cir .................................. 40-567 or Short Circuit.......................................... 40-126
Failure code [GA63MA] Gen. Mot. Ph-B Failure code [879EMC] Ventilation Damper
Current Sen. Malfunction ........................... 40-568 Abnormality .................................... 40-127, 80-63
Failure code [GA63MC] Gen. Mot. Ph-B Cur. Failure code [879FMC] Air Mix Damper
Sen. Defect Op. ........................................ 40-569 Abnormality ................................................ 80-64
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Failure code [879GKX] Refrigerant
Sen. Power Short Cir................................. 40-570 Abnormality .................................... 40-129, 80-65
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Failure code [989L00] Engine Controller Lock
Sen. Open/Short Cir .................................. 40-571 Caution1 .................................................. 40-130
Failure code [GA64MA] Gen. Mot. Ph-C Failure code [989M00] Engine Controller Lock
Current Sen. Malfunction ........................... 40-572 Caution2 .................................................. 40-131
Failure code [GA64MC] Gen. Mot. Ph-C Cur. Failure code [989N00] Engine Controller Lock
Sen. Defect Op. ........................................ 40-573 Caution3 .................................................. 40-132
Failure code [GA70KB] HYB Swing Motor Failure code [DAF8KB] Camera Power Supply
Short Circuit ............................................. 40-574 Short Circuit ............................................. 40-314
Failure code [GA70MD] HYB Swing Motor Failure code [DR21KX] Camera 2 Picture Rev.
Defective Stirr. Motion ............................... 40-575 Drive Abnormality...................................... 40-388
Failure code [GA70NS] HYB Swing Motor Failure code [DR31KX] Camera 3 Picture Rev.
Overheat .................................................. 40-576 Drive Abnormality...................................... 40-390
Failure code [GA71KZ] HYB Swing Mot. Temp. Failure code list related to air conditioner ........ 80-52
Sens. Opn/Shrt Cir. ................................... 40-577 Failure mode and cause table ...................... 40-683
Failure code [GA72MA] HYB Swing Motor Final drive ............................................10-44, 60-8
Resolver Malfunction................................. 40-579 Fuse location table...................................... 40-107
Failure code [GA72MC] HYB Swing Motor
Resolver Defect Op. .................................. 40-581
Failure code [GA81KZ] Swing Motor Power
H
Cable Opn/Shrt Circ. ................................. 40-582 H-1 All of work equipments and travel
Failure code [GAA0KB] HYB Con. Battery operations lack speed or power .................. 40-689
Relay Drive Short Cir. ................................ 40-583 H-2 Engine speed lowers significantly or
Failure code [GAA2KB] Swing Brake Sol. engine stalls ............................................. 40-692
Supply Line Short Cir................................. 40-585 H-3 None of work equipment or travel works . 40-695
Failure code [GAA6KP] Low HYB Control. H-4 Unusual sound is heard from around
Sen. Power 2 Sup. .................................... 40-587 hydraulic pump ......................................... 40-696
HB215LC-2 7
INDEX
H-5 Fine control performance or response is High voltage wiring harness (power cable) ...... 10-37
poor ......................................................... 40-697 How to open the electrical system abnormality
H-6 Speed or power of boom is low .............. 40-699 record screen in service mode of the machine
H-7 Speed or power of arm is low................. 40-703 monitor....................................................... 80-38
H-8 Speed or power of bucket is low............. 40-708 How to read electric wire code (Hybrid)........... 00-42
H-9 Work equipment does not move in single How to read the shop manual ........................ 00-23
operation.................................................. 40-711 How to read this manual .................................. 50-4
H-10 Hydraulic drift of boom is large ............. 40-712 Hydraulic circuit diagram ................................. 90-7
H-11 Hydraulic drift of arm is large ................ 40-713 Hydraulic component layout........................... 10-48
H-12 Hydraulic drift of bucket is large............ 40-714 Hydraulic tank .................................... 10-52, 60-24
H-13 Time lag of work equipment is large...... 40-715
H-14 When part of work equipment is relieved
singly, other parts of work equipment move . 40-717
I
H-15 One-touch power maximizing function Idler ............................................................. 60-14
does not operate ....................................... 40-718 Important safety notice (Hybrid) ..................... 00-16
H-16 In combined operation of work Information described in troubleshooting table
equipment, equipment having heavier load (H-mode).................................................. 40-680
moves slower ........................................... 40-719 Information in troubleshooting table ...... 40-49, 80-51
H-17 Machine does not travel straight........... 40-720 Information mentioned in troubleshooting table
H-18 Travel speed is slow............................ 40-723 (S mode) .................................................. 40-745
H-19 Machine is hard to steer or travel power Inspection procedure before troubleshooting... 40-16
is low ....................................................... 40-726 Interlock function .......................................... 10-31
H-20 Travel speed does not change, or travel Isolating the parts causing hydraulic drift in
speed is too slow or fast ............................ 40-730 work equipment .......................................... 30-74
H-21 One of tracks does not run................... 40-731
H-22 Upper structure does not swing to the
right or left ................................................ 40-733
K
H-23 Upper structure swings only to the right or KCCV layout drawing .................................... 10-16
left ........................................................... 40-734 KCCV ventilator............................................ 10-18
H-24 Swing acceleration or swing speed is low KDOC muffler............................................... 10-20
in both directions (right and left).................. 40-735 KOMTRAX Settings (GPS & Communication
H-25 Swing acceleration performance is poor Status) ..................................................... 30-153
or swing speed is slow in only one direction. 40-736 KOMTRAX Settings (terminal setting status) . 30-153
H-26 Upper structure overruns excessively KOMTRAX Settings screen (Modem Status) . 30-154
when it stops swinging (both right and left) .. 40-737 KOMTRAX system ..................................... 10-277
H-27 Upper structure overruns excessively KOMTRAX terminal start-up procedure......... 30-156
when it stops swinging (either right or left) ... 40-738
H-28 Shock is large when upper structure
stops swinging .......................................... 40-739
L
H-29 Large unusual noise is heard when upper List of abbreviation........................................ 00-62
structure stops swinging ............................ 40-740
H-30 Swing drift on a slope is large while swing
parking brake is applied ............................. 40-741
M
H-31 Swing drift on a slope is large while swing Main pump ......................................... 10-59, 60-25
parking brake is released ........................... 40-742 Method of disconnecting and connecting of
H-32 Attachment hydraulic circuit cannot be push-pull type coupler ................................. 00-31
changed while attachment is installed ......... 40-743 Motor-generator............................................ 10-32
H-33 Oil flow in attachment circuit cannot be
controlled ................................................. 40-744
Handling cylinder cutout mode operation ........ 30-33
N
Handling equipment of fuel system devices..... 00-27 No-Injection................................................ 30-152
Handling hybrid components and high voltage
wiring harness ............................................ 00-53
Handling no injection cranking operation......... 30-34 O
Handling of compressor oil ............................ 80-82 Outer temperature sensor.............................. 80-23
Handling of electrical equipment .................... 00-34 Outline of hybrid system ................................ 10-24
Handling of hydraulic equipment .................... 00-29 Outline of refrigeration cycle ............................ 80-8
Handling of intake system parts ..................... 00-28
Handling voltage circuit of engine controller .. 30-161
8 HB215LC-2
INDEX
P Removal and installation of front wiper

Parts and connectors layout .......................... 80-31 assembly........................................................ 50-255
Power train system ....................................... 10-39 Removal and installation of fuel cooler
PPC valve........................................ 10-157, 60-39 assembly.......................................................... 50-82
Practical use of KOMTRAX............................ 00-52 Removal and installation of fuel tank assembly....50-
Precautions for disconnecting and connecting 84
air conditioner piping ................................... 80-80 Removal and installation of hybrid radiator
Precautions for refrigerant ............................... 80-3 assembly....................................................... 50-106
Precautions related items to hybrid................. 30-37 Removal and installation of hybrid water
Precautions related to hybrid equipment .40-771, 50- pump assembly............................................. 50-109
6 Removal and installation of hydraulic oil cooler
Precautions when performing operation.......... 00-47 assembly.......................................................... 50-54
Preparation for troubleshooting of electrical Removal and installation of hydraulic tank
system ....................................................... 40-37 assembly........................................................ 50-189
Procedure for draining and refilling generator Removal and installation of idler and idler
lubricating oil ................................................ 50-119 cushion assembly .......................................... 50-169
Procedure for testing and troubleshooting ....... 80-24 Removal and installation of injector assembly ...50-27
Protection function for workers when Removal and installation of inverter and
disassembling hybrid component.................. 10-28 capacitor assembly ....................................... 50-114
Protective function of hybrid component ......... 10-26 Removal and installation of inverter assembly .....50-
111
R Removal and installation of KCCV assembly .... 50-90
Releasing remaining pressure from hydraulic Removal and installation of KDOC assembly ... 50-89
circuit ......................................................... 30-46 Removal and installation of KOMTRAX
Removal and installation of aftercooler terminal assembly .......................................... 50-275
assembly......................................................... 50-57 Removal and installation of machine monitor
Removal and installation of air cleaner assembly........................................................ 50-271
assembly......................................................... 50-96 Removal and installation of main pump
Removal and installation of air conditioner assembly........................................................ 50-192
compressor assembly .................................. 50-262 Removal and installation of mass air flow and
Removal and installation of air conditioner temperature sensor ....................................... 50-274
condenser assembly .................................... 50-264 Removal and installation of motor-generator
Removal and installation of air conditioner and housing assembly.................................. 50-124
unit assembly ............................................... 50-247 Removal and installation of operator cab glass
Removal and installation of center swivel joint (adhered glass)............................................. 50-225
assembly.......................................... 50-184, 50-187 Removal and installation of operator's cab
Removal and installation of control valve assembly....................................................... 50-220
assembly....................................................... 50-196
Removal and installation of FRXQWHUZHLJKW Removal and installation of operator's seat.....50-251
assembly....................................................... 50-181 Removal and installation of pump controller
Removal and installation of cylinder head assembly....................................................... 50-268
assembly......................................................... 50-33 Removal and installation of pump swash plate
Removal and installation of EGR (Exhaust Gas sensor............................................................ 50-273
Recirculation) cooler assembly....................... 50-99 Removal and installation of radiator assembly . 50-51
Removal and installation of EGR (Exhaust Gas Removal and installation of revolving frame
Recirculation) valve assembly......................... 50-97 assembly........................................................ 50-179
Removal and installation of engine controller Removal and installation of seat belt............... 50-253
assembly....................................................... 50-266 Removal and installation of sprocket .............. 50-168
Removal and installation of engine front oil Removal and installation of starting motor ........ 50-74
seal ................................................................. 50-76 Removal and installation of supply pump
Removal and installation of engine hood assembly.......................................................... 50-23
assembly......................................................... 50-86 Removal and installation of swing circle
Removal and installation of engine rear oil seal ...50- assembly....................................................... 50-164
79 Removal and installation of electric swing
Removal and installation of engine, motor- motor assembly ............................................ 50-131
generator, and main pump assembly ............. 50-59 Removal and installation of swing motor and
Removal and installation of fan belt .................. 50-71 swing machinery assembly .......................... 50-146
Removal and installation of floor frame Removal and installation of tandem pump
assembly........................................................ 50-241 assembly....................................................... 50-121
Removal and installation of ffront window Removal and installation of travel motor and
assembly........................................................ 50-235 final drive assembly....................................... 50-136
HB215LC-2 9
INDEX
Removal and installation of work equipment T

assembly....................................................... 50-210
Removal and installation of work equipment T-branch box and T-branch adapter table...... 40-102
control lever assembly ............................. 50-254-1 Testing air leakage (duct)............................... 80-35
Testing and adjusting oil pressure in pump LS
ROPS cab.................................................. 10-195
control........................................................ 30-58
Testing and adjusting oil pressure in pump PC
S control circuit .............................................. 30-54
S-1 Engine does not crank when starting Testing and adjusting oil pressure in work
switch is turned to START position.............. 40-746 equipment and travel circuits........................ 30-51
S-2 Engine cranks but no exhaust smoke Testing and adjusting track tension................. 30-45
comes out ................................................ 40-747 Testing and adjusting valve clearance ............ 30-14
S-3 Fuel is being injected but engine does not Testing blowby pressure ................................ 30-21
start (misfiring: engine cranks but does not Testing boost pressure .................................. 30-10
start) ........................................................ 40-748 Testing diodes ............................................ 30-163
S-4 Engine startability is poor....................... 40-749 Testing (dual) pressure switch for refrigerant ... 80-45
S-5 Engine does not pick up smoothly .......... 40-751 Testing engine oil pressure ............................ 30-22
S-6 Engine stops during operation................ 40-753 Testing engine speed ...................................... 30-8
S-7 Engine runs rough or is unstable ............ 40-755 Testing FRESH/RECIRC air changeover ........ 80-43
S-8 Engine lacks power............................... 40-756 Testing fuel circuit for leakage ........................ 30-32
S-9 Exhaust smoke is black ......................... 40-758 Testing fuel discharge, return and leakage ...... 30-28
S-10 Engine oil consumption is excessive..... 40-760 Testing fuel pressure ..................................... 30-23
S-11 Oil becomes contaminated early........... 40-761 Testing oil leakage ........................................ 30-76
S-12 Fuel consumption is excessive............. 40-762 Testing oil pressure of control circuit ............... 30-50
S-13 Oil is in coolant (or coolant spurts or Testing outlet pressure of solenoid valve......... 30-66
coolant level goes down) ........................... 40-763 Testing PPC valve outlet pressure .................. 30-70
S-14 Oil pressure drops............................... 40-764 Testing relays ............................................... 80-46
S-15 Fuel mixes into engine oil .................... 40-765 Testing sunlight sensor.................................. 80-44
S-16 Water mixes into engine oil (milky)........ 40-766 Testing swing circle bearing clearance............ 30-44
S-17 Coolant temperature rises too high Testing swing parking brake........................... 30-42
(overheating) ............................................ 40-767 Testing vent (mode) changeover .................... 80-41
S-18 Unusual noise is heard ........................ 40-768 Testing water pressure of hybrid coolant ......... 30-40
S-19 Vibration is excessive.......................... 40-769 Testing with self-diagnosis function................. 80-38
S-20 Air cannot be bled from fuel circuit ........ 40-770 Track frame and idler cushion .............. 10-46, 60-12
Sensor....................................................... 10-280 Track roller ................................................... 60-16
Separation and connection of track shoe Travel motor ..................................... 10-144, 60-36
assembly........................................................ 50-165 Travel PPC valve ........................................ 10-164
Sequence of events in troubleshooting ........... 40-12 Troubleshooting chart 1................................. 80-47
Service Message ........................................ 30-155 Troubleshooting chart 2................................. 80-48
Sketch of tools for testing and adjusting ............ 30-6 Troubleshooting points .................................. 40-10
Solenoid valve.................................. 10-180, 60-49 Troubleshooting with gauge pressure ............. 80-75
Special functions of machine monitor.............. 30-84 Truck shoe ................................................... 60-18
Special tools list..................................... 50-11, 50-16
Specification drawing ...................................... 01-3
Specifications .........................................01-3, 01-5
V
Sprocket ...................................................... 60-10 Valve control ................................................ 10-50
Standard tightening torque table .................... 00-56 VFT ............................................................... 10-5
Standard value table for electrical system ....... 20-20
Sunlight sensor............................................. 80-22
W
Swing circle..........................................10-41, 60-5
Swing machinery with swing brake .........10-42, 60-6 Water pump ................................................. 10-38
Symbols in electric circuit diagram.................. 90-13 Weight table ................................................... 01-9
Symbols in hydraulic circuit diagram................. 90-3 Work equipment ............................... 10-191, 60-53
Symptom and troubleshooting numbers.......... 40-46 Work equipment and swing PPC valve ...10-157, 60-
System chart of hydraulic and mechanical 39
systems ................................................... 40-681 Work equipment cylinder ............................... 60-62
System component parts............................. 10-236 Work equipment shim ................................. 10-192
System diagram ........................................... 80-28 Working range drawings.................................. 01-4
10 HB215LC-2
INDEX
Y
Y-1 Hybrid monitor does not go out............... 40-772
Y-2 Machine does not swing ........................ 40-773
Y-3 Swing acceleration or swing speed is low......40-
776
Y-4 Upper structure overruns excessively
when it stops swinging............................... 40-777
Y-5 Shock is large when upper structure stops
swinging................................................... 40-778
Y-6 Large unusual noise is heard when upper
structure stops swinging ............................ 40-779
Y-7 Swing drift on a slope is large ................. 40-780
Y-8 Electric swing motor overheats............... 40-781
Y-9 Motor-generator temperature increases
abnormally ............................................... 40-782
Y-10 Inverter temperature increases
abnormally ............................................... 40-783
Y-11 Capacitor overheats ............................ 40-784
HB215LC-2 11
HB215LC-2 HYDRAULIC EXCAVATOR
Form No. SEN06488-09
© 2022 KOMATSU
All Rights Reserved
Printed in Japan 08-22 (01)

HB215LC 2

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SEN06488-09

HB215LC-2 50001 and up

00 Index and foreword

Hydraulic system ...................................................................................................................... 10-48

Power train............................................................................................................................... 30-44

Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-132

Failure code [DAFGMC] GPS Module Error........................................................................ 40-317

Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ................................................... 40-444

Information described in troubleshooting table (H-mode) ..................................................... 40-680

S-17 Coolant temperature rises too high (overheating) ........................................................ 40-767

Disassembly and assembly of swing machinery assembly........................................................ 50-150

Hydraulic system ...................................................................................................................... 60-24

Foreword, safety and general information (ALL-0370-001-A-00-A)

Important safety notice (Hybrid) (HB380-1120-012-A-00-A)

General precautions • Before starting work, lower the work equipment

• When lifting down a load, stop it temporarily at

Precautions for using mobile crane

a Ask a qualified person for collecting, adding and

• When loosening the nuts of the air conditioner

Precautions to prevent fire (ALL-0000-17B-K-03-A)

Action if fire occurs (ALL-0000-17A-K-01-A)

• Turn the starting switch to OFF position to stop

To prevent pollution, pay full attention to the way to

Some kinds of rubber and plastics may produce

How to read the shop manual (ALL-0320-010-A-01-A)

Composition of shop manual

Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)

the parts can not be used any longer. This value

Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)

Use care for working environment

How to clean parts when dirt is stuck

Precautions for replacing fuel filter cartridge

Handling of intake system parts (PC220-A900-2A4-K-00-A)

Be careful of working environment

Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)

Be careful of working environment

Disassembly and maintenance work in the field

Plugging of opening (prevention of flowing out

Method of disconnecting and connecting of push-pull type coupler (ALL-

Handling of electrical equipment (ALL-E000-2A4-P-01-A)

Precautions for handling electric equipment

Handling wiring harnesses and connectors

Main failures occurring in wiring harness

blow it with compressed air and spray it with

High-pressure water entering connector

Entry of water, mud or dirt when disconnecting a

• Check that there is no oil, dirt or water stick

3. Action to take after removing connectors

• If the connector clamp is removed, be sure to Drying wiring harness

2. Dry the inside of the connector with a dryer.

3. Perform a continuity test on the connector.

2. While pressing lock (L2), pull out connector (1).

Slide, lock type

a If the lock is located on the underside, use

temperature even for a short period of time.

• Precautions when performing arc welding

Precautions for troubleshooting electrical

How to read electric wire code (Hybrid) (HB380-E500-030-P-00-A)

Type, symbol, and material

CAVS Standard - 1.6 - 1.8 - 2.1

a "f" of nominal No. denotes "flexible".

Color codes table

Types of circuits and color codes