Komatsu HB205-1, HB215LC-1 Hybrid Excavator Service Manual

Table of Contents

00 Index and Foreword
01 Specifications
10 Structure and function
20 Standard value table
30 Testing and adjusting
40 Troubleshooting
50 Disassembly and assembly
60 Maintenance standard
80 Appendix
90 Diagrams and drawings

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

00. Index and foreword
This section contains the index, foreword, safety and basic information.

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

10. Structure and function
This section explains the structure and function of each component. It 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
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.

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

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

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

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

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

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