Hybrid Excavator Structure & Function

Hybrid Excavator
Troubleshooting Course
Hybrid hydraulic excavator

Structure & Function
Techno Training Center

Department for Promotion of Distributor HR
Development Construction Equipment
Solution Division
Contents
◆ High voltage circuit and control signal ・・・Slide 3

◆ Swing control system ・・・Slide 7
◆ Lowered engine-pump speed
matching control ・・・Slide 17
◆ PPC Pressure sensor ・・・Slide 28
◆ Insulation and interlock circuit for
high voltage components ・・・Slide 32
◆ Hybrid cooling system ・・・Slide 38
◆ Control valve ・・・Slide 47
Hybrid Excavator Troubleshooting Course 2

High voltage circuit and
control signal

Hybrid system control unit
Starting SW ON Starting SW START
Motor Motor
① Generator Generator
⑤
④
②
⑦ ⑥
②
② Swing Electric Swing Electric

motor motor
①When Starting SW is turned ON, Power is supplied from When ③ key switch is set to START, ④ engine starts, ⑤ Motor
ACC signal line, ②and all the controllers start up. Generator is rotated by engine, ⑥ rotation signal is input4to
controller, ⑦ hybrid system starts to operate.

Power system diagram
MOTOR GENERATOR
SWING ELECTRIC MOTOR
High voltage circuit and control signals (HB205-3)

Electric Motor Internal Coil Connection
Swing Electric Motor Motor Generator
Phase
Phase
W B
C
phase
V
phase Phase
U A
phase
GM03
GM02
PM02
1. Internal connections of the Swing electric motor and the Motor Generator are different.
2. The resistance between the coil and the wiring (power cable) is small, and the standard value of the
resistance between terminals with continuity is 1.0 ohm or less.

Swing control system

Reduction of Fuel Consumption by HYB System
Electrification of Swing
In a conventional hydraulic excavator, excess kinetic energy is converted into heat and
released during swing deceleration. However, the hybrid hydraulic excavator can store
this energy in a capacitor and reuse it.
Energy storage and discharge
Energy during swing acceleration
Acceleration
(Supply from capacitor and Motor Generator)
Swing
acceleration
（Discharge）
Energy generated during Swing
０[m/s2]
Deceleration
Regene- (Power Accumulated in the Capacitor)
ration
(Charge
electricity)
Reference
STD excavator such as
Deceleration
PC200 that uses a

hydraulic motor, releases
energy during
Time[s]
deceleration as heat.

Power flow during Swing operation
(1) Levers in Neutral (2) Swing acceleration
(Capacitor full charge)
Motor Motor
Generator Generator
Engine Engine
Swing Swing
machinery machinery
Inverter Swing
Inverter Swing Electric
Electric Motor
Motor
Capacitor Capacitor
Generate & Drive
Drive
(3) Swing deceleration (4) Swing stops (Until Capacitor is
fully charged)
Motor Motor
Generator Generator
Engine Engine
Swing Swing
machinery machinery
Swing Inverter Swing

Inverter
Electric Electric
Motor Motor
Capacitor
Regeneration Charging
Capacitor

Monitoring display
Motor Generator torque (Nm）＋ Acceleration

assist
Motor Motor
＋＝
Engine Pump
Plus（＋） Minus（－） Generator absorption
Torque Torque
torque (assist) torque
Power generation
－generation
Acceleration (Driving a swing Power
Purpose
and Assist electric motor or
Pump
＋＝
charging a capacitor) Engine Motor
Generator absorption
Torque torque
torque (load)
HB205-2, -3 Swing electric motor torque (Nm)

Motor Torque Plus（＋） Minus (－)
Clockwise turn Regeneration Drive
Counterclockwise
Drive Regeneration
Turn
※HB205‐1, -8E0 (± is reversed depending on the model)

Swing control system
Input signal to the hybrid controller for Swing operation Control pressure
The left and right swing operation of the hybrid hydraulic (From self-pressure
excavator is detected by two PPC pressure sensors each. reducing valve)
The hybrid controller issues a command signal according to PPC
the amount of lever operation to accelerate, decelerate, and valve
stop the Swing Electric Motor. RH Swing PPC
Pressure sensor
Pump PPC
controller pressure
sensor
Engine
controller
Injector
Supply pump
CAN
Motor communication
Engine Gene-
rator PPC
Rotation Hybrid pressure LH Swing PPC
sensor
controller sensor Pressure sensor
Power
supply
Charging
Resolver Hybrid Pump
Controller controller
Inverter
Using CAN, PPC pressure sensors Regene Power
signals received by both Pump and ration supply
CAN
Hybrid controllers are checked to Engine
confirm that there is no abnormality Capacitor Swing communication
controller
with the pressure sensor. electric motor
Swing control system: Swing parking brake operation
Activation of Swing parking brake of Hybrid hydraulic excavator
Swing parking brake is mounted on the swing machinery. When the swing parking brake solenoid
valve is energized by the signal from the Hybrid controller, hydraulic oil is outputted to the swing
parking brake. The output hydraulic pressure pushes the piston inside the swing parking brake
and the spring is compressed to release the swing parking brake.
Swing machinery
Swing parking brake
Swing parking brake

release solenoid valve
Inverter
Swing Electric
Motor Emergency swing lock switch
(PC200-8E0、HB205-1 only)
Swing lock switch
Swing holding brake

release switch

Swing parking brake function
Swing parking brake release/Operating conditions
The hybrid controller controls the signal to the swing parking brake solenoid valve
according to the input signal of the work equipment operating lever as follows:
Swing parking
Release Actuation
brake
Work ・Work equipment lever Approximately 5 seconds
equipment operation after Work equipment
operation (Operation of all work operation lever and
equipment except Travel) attachment operation pedal
・Attachment operation Pedal are put to neutral
operation
※ The swing parking brake is not released by only operating the travel lever.
• Swing lock switch ON
A switch that fixes the upper swing body so that it does not rotate. Set the
swing lock switch to ON position when not swinging, such as during OFF
travelling.
In the ON position, the swing parking brake is always activated and does
not swing even if the swing operation is performed. At this time, the swing
lock monitor lamp lights up on the monitor panel.

Swing holding brake function
• Swing holding brake release switch
ON(Release)
Swing parking allows swing work temporarily when
the brake system is abnormal. Do not use except
in case of abnormality. When the switch is turned
on, the Swing lock monitor blinks. When the switch
is released from the released position, it OFF(Normal)
automatically returns to its normal position.
• Emergency Swing stop switch

A switch to stop the upper swing body when an abnormality occurs in the hybrid system. At the
ON position, the swing parking brake is activated to make an emergency stop of swinging. At this
time, the user code (E09) is displayed on the monitor, or the hybrid monitor lights up.
Adoption Status per model(Adopt:〇、
Not adopted:✖)
Machine model Adoption status

PC200-8E0 〇
HB205-1 〇
HB205-2 ✖
HB205-3 ✖
To turn the switch to OFF position, pull the switch head or turn it to the right with the
left and right operating levers in the neutral position. After the start key switch is
turned off, the hybrid system will restart the next time the start switch is turned on.

Reference: Swing control system (hydraulic excavator)
Reference: Overview of Swing control of hydraulic excavators
In a hydraulic excavator such as a PC200, the swing main spool of the control valve moves
due to the PPC pressure output from the PPC valve, and the oil discharged from the pump is
supplied to the swing motor to turn the upper structure.
PPC
Pump Pressure PPC
controller sensor Valve
Engine CAN
Communication
controller
Control Pressure
(From self-pressure
reducing valve)
Control valve
Injector
Supply pump
Engine

Lowered engine-pump speed
matching control

Motor Generator drive and power generation
（1） Lever neutral Motor
When the lever is neutral and the auto deceleration
Control valve
Generator
Engine function is ON, the engine speed drops to 1250 rpm,

and if this condition continues for 4 seconds, the
engine speed drops further to about 700 rpm when
Capacitor
Inverter the capacitor is fully charged.
Swing
Electric Machinery
Motor
（2）Working Motor When the work equipment lever is operated from
Control valve
Generator
neutral (700 rpm), electricity is supplied from the
Engine
capacitor to increase the engine rotation immediately,
and the Motor Generator functions as a motor to
assist engine acceleration.
Capacitor
Inverter
Acceleration assist
Swing
Electric Machinery
Motor
（3） Lever neutral (until the capacitor is fully charged)

Motor
Control valve
Generator
Engine
When the capacitor voltage drops during deceleration,
the engine speed rises to about 1150 rpm due to
charging. After charging is complete, the engine
Capacitor
Inverter
Charging speed drops to about 700 rpm.
Swing
Electric Machinery
Motor

Engine speed control of hybrid excavator
Hydraulic Variable engine-pump
excavator matching control
Hybrid excavator Lowered engine-pump
speed matching control
PC200-10 generation、PC200-11 generation
Fluctuation of Engine speed
Fluctuation of Engine
speed Heavy Heavy
load load
Engine torque
Engine torque
Light
Light Auto-decel load
load operating time
Auto-decel Fine
Fine operation
operating time
operation
Engine Rotation speed Engine Rotation speed
Fixed engine-pump In low-speed matching control, the engine speed is kept

PC200-8 generation or
speed matching control relatively low in order to reduce fuel consumption in the no-
earlier
Fluctuation of load state (※1) and the light load state (※2). Since it is
Engine speed
possible to receive engine acceleration assistance from the
Heavy load Motor Generator, engine speed control that emphasizes fuel
エンジントルク（Nm）
efficiency is established while maintaining operability.

Since the lowered engine-pump speed matching control is
performed in this way, the fluctuation of the engine speed of
torque
the hybrid hydraulic excavator becomes relatively large.

Light load
Engine
※1： No-load state means that the PPC pressure is low (approx. less
than 0.5 MPa) when the lever is in the neutral position or when the work
Auto-decel Fine operation
equipment is not moving.
operating time
※2： Light load state means a state that does not require high output,
Engine Rotation speed (rpm) such as during boom lowering operation

Fluctuations in engine speed of hybrid excavator
Torque curve：Indicates maximum
（HB205-3）
torque in each engine rotation area
800 P, ATT-P mode

E, ATT-E mode matching point Rated output
matching point 1670rpm 2000rpm
1460rpm Work equipment relief +
one touch Power-up switch ON
600
Engine torque (Nm)
400
200 Low Idle Charging

700rpm 1150rpm
Fine operation High Idle
1250rpm 1850rpm
0
600 800 1000 1200 1400 1600 1800 2000 2200
Engine rotation (rpm)
Measurement conditions：Fuel adjustment dial MAX, auto-decel switch ON, engine
coolant temperature 60 to 100°C, hydraulic oil temperature 45 to 55°C

Measurement of Engine high-idle speed
The Engine high idle is measured within the range of the Engine water temperature and
hydraulic oil temperature determined for each model, satisfying the measurement conditions
shown in the table below.
High idle measurement conditions by model

Hydraulic PC200-11 ・ Work mode: P
excavator ・ Swing lock switch：ON
・ Work Equipment lever and Travel
lever: Neutral
Hybrid HB205-1 ・ Travel speed：Hi ※
Hydraulic ・ Travel lever fine operation
excavator ・ Fuel adjustment dial: MAX
・ Auto decel switch: OFF
HB205-2 ・ Travel speed：Hi ※
・ Work mode: B
・ Travel lever fine operation
HB205-3 ・ Swing lock switch: ON

・ Work mode: B
・ Travel lever fine operation
* Not listed in the standard value table of the shop manual. Correct values cannot
be measured according to the shop manual.

Reference: Output fluctuation of hydraulic excavator
High engine output ➡ More work in each amount of time can be done (moving the work
equipment over a long distance at high power)
Example: 90 ° Swing loading work
High output for high load work Low output for low load work
Engine output
Excavating Boom up swing Dump Boom down Excavating

(hoist swing) turn
(Note) This is an image of engine output. time

Reference: Relationship between engine speed, torque, and output
Same Rated
Engine Torque（Nm）
output Output, HP
Low speed
rotation, high The output is the
torque same on these curves.
However, "fuel
consumption" and
High speed "responsiveness
rotation, low when the load
torque increases" are
different.
Engine RPM（rpm）
Reference: Calculation formula of engine output
The engine output is calculated from the "Engine torque" and “Engine Rotation speed (Engine
speed)" of the engine output shaft. The "engine torque" increases as the "pump discharge
amount per revolution" and "pump discharge pressure" increase.
Engine RPM(rpm) × 2π
Engine output (W) = Engine torque(Nm) ×
60

Rated
Rated
torque
Engine torque（Nm）
output
Engine rotation
Engine RPM（rpm） speed
Reference: Basic engine terms

Rated output： Maximum engine output
Rated rotation speed ： Engine speed at rated output
Rated torque ： Engine output shaft torque at rated output

P、 ATT-P Rated
Engine torque（Nm）
output
B E、 ATT-E
L
Engine RPM（rpm）
Reference: Control method at high output
• In the P, E, ATT-P, and ATT-E modes, the engine rotation is controlled to be kept near the matching
point (engine torque and rotation speed) set in each mode.
• In B mode and L mode, the engine output is controlled to be kept constant.

Reference: Classification of engine rotation control for
medium-sized hydraulic excavators
Low-speed matching
Variable matching control
control
（ With pump angle sensor ） With pump No pump angle
angle sensor sensor
PC200-10 HB205-2 PC200-8E0
PC200-11 HB205-3 HB205-1
Hybrid excavator
Fixed
matching
PC200-8世代以前
control
* "Fixed matching control", "variable matching control", and "low-speed matching control" are hardly
explained in the shop manual, and the names are not described. It is mainly described in sales manuals and
product catalogs.

Reference: Engine speed control system diagram
Hybrid controller Engine
Inverter
Injector Ne Sensor
Supply pump Bkup Sensor

Lever operation pattern
PPC pressure sensor
(Lever operation pattern &
Pump absorption torque setting

Lever stroke
operation amount)
Rotation sensor
Actual engine speed
Engine Motor Generator

controller
R・PC-PEC
Target engine speed
F Servo
valve
F angle
sensor
CAN Communication
Monitor
Lo Hi
F Pump pressure
Control
sensor valve
Fuel Dial
F・PC-PEC
Pump
R Servo
valve
R angle
Sensor
controller
R Pump pressure
Pump discharge amount (per rotation) sensor
Pump discharge pressure
The target engine speed under normal operation (no error occurs, or SCR is not active) is calculated according to the
following conditions:
Fuel control of the engine and power generation (or drive) of the Motor Generator are performed and engine speed
fluctuates.
・ Values related to engine speed control
Work mode, fuel adjustment dial, actual engine speed, control lever operation amount, operation pattern, F/R pump
pressure sensor, F/R pump angle sensor, capacitor voltage, running speed (Lo, Mi, Hi), swing lock switch

PPC pressure sensor

Adoption status of PPC pressure
sensor Usage Guide
PPC pressure sensor comparison table ◎：Sensor △：Switch ー：None
Hydraulic Hybrid excavator
excavator
Model
PC200-8 PC20 PC200-8E0 HB205-2 Purpose
0-11 HB205-1 HB205-3
Controller Pump Pump Pump HYB Pump HYB
Swing (right)
◎ ◎ ◎ ◎ ◎ ◎ Safety reasons
Always compare the two sensor
◎ ◎ ◎ ◎ ◎ ◎
Swing (left) signals to prevent inoperability.
◎ ◎ ◎ ◎ ◎
Arm in To improve reaction speed
ー (Too late via CAN)
Arm dump
△ ◎ △ ◎ ◎ ー For lowered engine-pump speed
matching control, ON / OFF
△ ◎ △ ◎ ◎
signal to proportional signal
Boom down
ー
Boom up
◎ ◎ ◎ ー ◎ ー CAN communication
(Sensor → Pump controller ~
◎ ◎ ◎ ◎
CAN communication-HYB
Bucket curl
ーー controller)
Bucket dump
◎ ◎ ◎ ー ◎ ー

Reference: An example of an error code
➢ HB205-3 Shop manual （40-765） Reference
Swing right PPC pressure sensor signal mismatch for HYB
（ When there is a difference between the signals of the two PPC pressure sensors ）
Fault code (DHVAL8)

Action
Fault code Swing right PPC pressure sensor signal mismatch for HYB
Level Failure
phenomenon (Hybrid controller System)
L03 DHVAL8
There is a difference of 0.49MPa {{5.0} kgf / cm2 or more} between the detection value of the swing right PPC pressure
Failure content sensor for hybrid and the swing right PPC pressure sensor for pump controller while the Motor Generator is rotating.
• Select and control the minimum swing right PPC pressure for the pump and hybrid controllers.
Action of the
• Limit swing speed, etc.
controller • Even if the cause of the failure is resolved naturally, it will not return to normal unless the start switch is turned off once.
Phenomenon that
appears in the Turning speed etc. are limited
machine
➢ HB205-1 ～ HB205-3
When there is a difference of 0.49MPa or more between the signals of the two swing PPC pressure
sensors for swing, it is judged that one of the sensors has failed and the swing speed is limited.

Reference: An example of an error code
➢ PC200-8E0 Shop manual （40-305） Reference
• Open or short circuit in HYB swing RIGHT PPC pressure sensor
（ When there is a difference between the signals of the two PPC pressure sensors ）
Fault code[DHVAKZ]
User code Failure code Open or short circuit in HYB swing RIGHT PPC pressure
Failure sensor
(Hybrid controller system)
● When control lock lever is shifted down, swing RIGHT PPC hydraulic pressure sensor is 0.5 Mpa
Detail of failure {5 kg/cm2} or swing RIGH PPC pressure sensor for hybrid system is 0.5 Mpa {kg/cm2} and generator speed
is 500 rpm or more.
Action of ● Controls system by setting swing RIGHT PPC pressure at 0 MPa {0 kg/cm2}.
Controller ●Even if cause of failure disappears, system does not reset itself until starting switch is turned to OFF position.
Problem in ● Swinging stops suddenly during right swinging motion. Continues swinging during left swinging motion. After stopping, machine cannot swing to the
right.
Machine ● Operator cannot control the swinging motion.
★ If pressure sensor 5 V circuit (3) and ground circuit (1) are connected reversely, sensor will be broken.
Accordingly, take extreme care when checking.
● Voltage of swing right PPC pressure sensor can be checked with monitoring function.
Related (Code: 09007 Swing right PPC pressure sensor 2 voltage)
Information ● Method of reproducing failure code: Turn starting switch to ON position or start engine.
● This failure code may be displayed when communication with pump controller has abnormality.
Accordingly, if [DA2RMC] or [GA14KR] is also displayed, perform troubleshooting for it first.
➢ PC200-8E0
When there is a difference of 0.5 MPa or more in the signal of the two turning PPC pressure sensors, it is not available to turn.
Insulation and interlock circuit for
high voltage components

Insulation of High Voltage Components
In the figure below, the high-voltage components (orange) are surrounded by insulation (black). The low
voltage parts that are 24V or lower are grounded to the machine body through flexible electric wires (gray).
The structure is such that an electric shock accident does not occur except when multiple failures overlap.
Generator
housing
motor
voltage part
motor High
Power gen
Capacitor
Engine
housing
Flexible electric wire Flexible electric wire

Flexible electric wire (inverter)
(Motor Generator) (capacitor)

Interlock circuit
The power cable (orange) is connected by seven connectors. The connection between the Motor
Generator and the swing motor is monitored by interlock circuit (green). When a disconnection of
the interlock switch or a looseness of the connector is detected due to a trouble in the wiring
harness, etc., the hybrid system will stop and display an error code.
Motor Generator
Swing
Electric
motor
:Interlock
switch

Position and Orientation of Power Cable Connector
Inverter-Motor Generator (inverter side) Capacitor-inverter (capacitor side)
Power cable and connector (HC04 &HC03 male side) Power cable and connector (HB01 female side)
No interlock
The one-touch connector has a structure in which the

electrodes are protected by a waterproof seal and an
Interlock (male) insulator, making it difficult to touch the electrodes.
Inverter side connector (HC04 & HC03 female side)
1:Core conductor 3:Electromagnetic seal

2:Waterproof seal 4:Insulator
Interlock (female)
Position and Orientation of Power Cable Connector
Motor Generator Swing electric motor
As for the swing electric motor, there is no mark on
the main body side, so it is good to check by looking
at the position of interlock.
Inverter
The power cable connector has a vertical orientation.

Align the marks I, II, III, and IIII on the power cable side
and the main unit side on the same surface.

Hybrid System Stop Switch
The hybrid system stop switch temporarily stops the hybrid system when there is an abnormality in
the machine, and stops the operation of the Motor Generator, the Swing electric motor, and the
inverter.
Even when the hybrid system is stopped, the engine and hydraulic system are still operating, so
work equipment and travel operations are possible. Once the hybrid system is stopped, the it
remains stopped until the start switch is turned “OFF”.
When the switch is set to be at “(a)” position, the hybrid system stop monitor will light up on the
machine monitor.
Adoption status by model type Hybrid System
Adopted:〇、Not adopted:✖ Stop switch
Model Status
PC200-8E0 ✖
HB205-1 ✖
a: emergency（in case
HB205-2 〇 of abnormality)
b: normal（normal time)
HB205-3 〇
Hybrid System
Stop monitor Hybrid
controller
Battery
relayE
CN-F01①
Fusible Fuse
Battery B M
link (5A)

Hybrid cooling system

Hybrid Cooling System
Swing Electric Motor Cooling & lubricating oil flow
Stator coil temperature
Cooling water flow
Temperature sensor
Motor Generator
Radiator
Coil
Hybrid temperature
radiator Engine
Main pump
Inverter
Inside the booster Tandem
pump
Water pump
Capacitor cell
Capacitor Capacitor cell, busbar temperature
（1）Cooling and Lubrication pump is mounted to the Motor Generator, and it pumps oil that cools & lubricates the
Motor Generator & Swing Electric Motor. The lubrication circuit of the Motor Generator is equipped with an oil cooler that
uses the same coolant from the engine. There is no oil cooler in the swing motor line.
（2）Hybrid water pump is mounted in front of the inverter capacitor. The cooling water circulates through the inverter
capacitor and the swing motor, and then it is cooled by the hybrid radiator. The cooling water sub-tank is shared with that
of the engine. (not shared for -2 & -3)
（3）Hybrid components are equipped with temperature sensors to monitor internal temperatures. When an abnormally
high temperature is detected, an overheat warning alarm sounds and an error code is displayed.

The hybrid water pump is driven by supplying 24V power when the start switch is turned on. Even if an
electrical failure occurs between the hybrid water pump and the capacitor (CN-HP01 2 pin, 11 pin) to the
hybrid water pump (CN-HK01 1 pin, 2 pin), the controller cannot recognize it, and there will be no fault
code for the electrical system.
CN-F01②
M B
fuse Fusible
Battery
(30A) link
E BR
Battery relay
Capacitor
Hybrid water pump HB205-3

HB335 class
In the HB335 class, two hybrid water

pumps of the same part number are
Hybrid attached in series. The cooling /
Water pump lubrication pump is mounted on the
main pump. The flow of cooling water
cooling・lubricating pump and oil is the same as that of the
（Tandem pump for
lubrication）
HB205 class.

Relief valve
Swing Electric Motor

Swing Electric Motor cooling oil delivery filter
Perform periodic
inspections every 2000
hours to clean or
replace filters as
needed.
Pressure test port

（HB205-3 new model standard value）
Swing Electric Motor 0.3MPa or
Case lubricating oil
pressure
lower

filter Perform periodic
inspections every 1000
Motor Generator hours, clean if dirty, and
install in the original
position after cleaning.
Pressure
detection
port
Oil Cooler

Reference: Hybrid cooling system (HB335 class)
In the HB335 class, two hybrid water pumps of the same part number are attached in
series. The cooling/lubrication pump is mounted on the main pump. The flow of cooling
water and oil is the same as that of the HB205 class.
Hybrid
Water pump
Cooling/lubrication pump
(Tandem pump for
lubrication)

Hybrid temperature warning and system outage
Temperature sensors are attached to each the hybrid components, and the hybrid system stops when
even one of them reaches the system stop temperature. In addition, the operator is warned by the
monitor display, buzzer, and swing output derate before the system stop temperature is reached, in
order to prompt for action.
Detailed table of hybrid heat load (HB205-3)
Equipment Part Name Monitoring item name A2 Temp. A1 System
Name Temp. Stop temp
Swing Electric Stator coil Swing Electric Motor coil 120℃ 140℃ 160℃
Motor temperature
Motor Generator Generator coil Motor Generator 170℃ 180℃ 190℃
temperature
Inverter Booster transistor Boost inductor temperature 120℃ 125℃ 130℃
BoosterIGBT 125℃ 130℃ 135℃
ー
Junction(※１)
Booster IGBT base Boosted air IGBT temperature 78℃ 80℃ 100℃
IGBT for PM Swing Inverter 125℃ 130℃ 135℃
Junction(※１) JCT Temperature
IGBT for SR Generator driver IGBT 85℃ 95℃ 100℃
Junction(※１) Base Temperature
Capacitor ー Capacitor cell temperature 60℃ 63℃ 65℃
※１：Estimated value by calculation, not direct measurement
Key Impact of Overheating Hybrid Components

・Capacitor life is shortened
・Parts inside the inverter melt and break down
・The insulation of the hybrid component deteriorates, and electric leakage occurs.

Hybrid temperature warning and system outage
A1 temperature
In the hybrid temperature gauge, the
A2 temperature A2 temperature is set as the right-
most end of the green gauge, and
the temperature of the part closest to
overheating is displayed as a
Hybrid
representative. Individual
Hybrid temperature
temperature gauge temperatures are measured by
warning light monitoring.
Display when normal Display at the time of abnormality
Pointer at green A2 temperature A1 temperature System down temp.

range (Pointer at left end of red (Pointer at the right end of (Pointer at the right end of
range) red range) red range)
Hybrid temperature
warning light is in blue Hybrid temperature warning light turns red
Derate swing output (torque & speed) Failure code”GA00NS”

is displayed & hybrid
system is stopped
Alarm buzzer sounds continuously

Shows action level L02

Control Valve

Control Valve
• HB205-2 and prior hybrid excavator
Uses a control valve with the same valve arrangement as the PC200 class control valve except
for swing. Since the swing is not needed, it is not used and is left blank.
• HB205-3
By attaching the bucket valve in a blank space that has not been used until now, the
hydraulic loss due to pressure compensation is reduced.
Service Service
Bucket Bucket Service
LH Travel LH Travel LH Travel
Merge-divider
合
Merge-divider
R
Merge-divider
R
R
Boom 分
valve
Boom Boom 分
valve
valve
流流
F
弁
F
F
弁
Turning （blank） Bucket
RH Travel RH Travel RH Travel
Arm Arm Arm
PC200 class HB205-2 HB205-3

HB205-1
PC200-8E0
Control Valve
• Improvement of the combined flow control system ①（HB205-3）
In digging work, the pressure on the arm and bucket cylinders tends to be high. In HB205-3,
高圧高圧
pressure compensation loss is reduced by operating the arm and bucket with one pump (F
pump) during high load operation. If the flow rate cannot be supplied by one pump, it operates
アーム弁
by merging.
高圧動作
右走行弁高圧高圧
Working pressure （ブランク）

during excavation
アーム弁
Working pressure
合分流弁
高圧動作
during excavation
アーム弁
(Load pressure) ブーム弁
右走行弁高圧動作
低圧動作 (Load pressure) 右走行弁
Service 左走行弁
（ブランク）アーム弁
High
高圧高圧
高圧動作
合分流弁（ブランク）
Bucket
バケット弁
P ブーム弁右走行弁
Service
高圧動作
低圧動作アーム弁
（サービス1弁）ブーム弁
高圧動作 Drive left 左走行弁 Merge-divider 低圧動作（ブランク）
アーム弁
Drive left
Merge-divider
R
左走行弁
Low 右走行弁高圧動作
R
Boom
バケット弁ブーム弁
Low
valve
右走行弁
P
valve
Boom
高圧動作（ブランク）低圧動作バケット弁
（サービス1弁） F P高圧動作左走行弁
（ブランク）
（Blank）
合分流弁
F
（サービス1弁）
ブーム弁
低圧動作 High Bucket
バケット弁
ブーム弁
Travel right 左走行弁 P
高圧動作
低圧動作
High
Travel right 左走行弁
Arm
バケット弁
P High
Arm
高圧動作バケット弁
（サービス1弁） P
高圧動作
HB205-2
HB205-1 HB205-3
PC200-8E0
Control Valve
• Improvement of combined flow control system ②（HB205-3）
HB205-3 is more accurate due to the adoption of a sensor that detects the working
pressure of the work equipment cylinder. It has become possible to control merging
and dividing during combined operations more accurately.
HB205-2 HB205-3
・ Addition of arm and bucket pressure sensors
・ Change work machine piping
・ Boom pressure
sensor added
・ Piping change
Judge the "merging or dividing" of In addition to the signal from the

the merge-divider valve from the conventional sensor, the operating
operator's input such as PPC pressure of the work equipment cylinder
pressure and work mode. is sensed to determine the "merging or
dividing" of the merge-divider valve.

END

Hybrid Excavator Structure &amp; Function

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Hybrid Excavator

Hybrid hydraulic excavator

Techno Training Center

◆ High voltage circuit and control signal ・・・Slide 3

Hybrid Excavator Troubleshooting Course 2

Hybrid Excavator Troubleshooting Course 3

② Swing Electric Swing Electric

Hybrid Excavator Troubleshooting Course 4

SWING ELECTRIC MOTOR

High voltage circuit and control signals (HB205-3)

Hybrid Excavator Troubleshooting Course 5

Hybrid Excavator Troubleshooting Course 6

Hybrid Excavator Troubleshooting Course 7

(Supply from capacitor and Motor Generator)

PC200 that uses a

Hybrid Excavator Troubleshooting Course 8

Swing Inverter Swing

Hybrid Excavator Troubleshooting Course 9

Motor Generator torque (Nm） ＋ Acceleration

HB205-2, -3 Swing electric motor torque (Nm)

Clockwise turn Regeneration Drive

Hybrid Excavator Troubleshooting Course 10

Swing parking brake

Swing parking brake

Swing lock switch

Swing holding brake

Hybrid Excavator Troubleshooting Course 12

Hybrid Excavator Troubleshooting Course 13

• Emergency Swing stop switch

Machine model Adoption status

Hybrid Excavator Troubleshooting Course 14

Hybrid Excavator Troubleshooting Course 15

Hybrid Excavator Troubleshooting Course 16

Engine function is ON, the engine speed drops to 1250 rpm,

（2）Working Motor When the work equipment lever is operated from

（3） Lever neutral (until the capacitor is fully charged)

Hybrid Excavator Troubleshooting Course 17

Fixed engine-pump In low-speed matching control, the engine speed is kept

efficiency is established while maintaining operability.

the hybrid hydraulic excavator becomes relatively large.

Hybrid Excavator Troubleshooting Course 18

800 P, ATT-P mode

200 Low Idle Charging

Hybrid Excavator Troubleshooting Course 19

High idle measurement conditions by model

HB205-3 ・ Swing lock switch: ON

Hybrid Excavator Troubleshooting Course 20

Example: 90 ° Swing loading work

Excavating Boom up swing Dump Boom down Excavating

(Note) This is an image of engine output. time

Hybrid Excavator Troubleshooting Course 22

Reference: Basic engine terms

Hybrid Excavator Troubleshooting Course 23

• In B mode and L mode, the engine output is controlled to be kept constant.

Hybrid Excavator Troubleshooting Course 24

Hybrid Excavator Troubleshooting Course 25

Supply pump Bkup Sensor

Pump absorption torque setting

Hybrid Excavator Structure & Function

Hybrid Excavator Structure & Function

Hybrid Excavator Structure & Function

Motor Generator torque (Nm）＋ Acceleration